Daystar KA09100BK User Manual

TOOLS NEEDED

BILL OF MATERIALS

FLOOR JACK
JACK STANDS
METRIC TOOLS
FLATE HEAD SCEW DRIVER

M03724 X 2 FT SPACERS
M03858 X 2 REAR SPACERS
BU76116 X HARDWARE

KA09100BK

2003-05 KIA SORENTO

2WD/4WD FRONT & REAR KIT

2.5’ LIFT

www.Daystaproducts.com

Tech Support Contact Info

[e-mail]

Phone: [phone]

Fax: [phone]

841 South 71

Phoenix, AZ 85043

st

Avenue

Instruction Sheet P11415
2008 Daystar Products International Inc.

Thank you for choosing Daystar Products

Daystar recommends a certified technician install this system . In addition
to these instruction , professional knowledge of disassemble/reassembly
procedures as well as post instructions checks must be known. Attempts to
install this system without this knowledge and expertise may jeopardize the
integrity and/or operating of the vehicle.

Please read all the instructions before beginning the installation. Check the
kit hardware against the parts list. Be sure you have all the needed parts and
understand where they go. If anything is missing , do not proceed with the
installation, Call Daystar Products to obtain needed items.

Product Use Information

As a general rule, the taller a vehicle is the easier it will roll. We strongly
recommend , because of rollover possibility, that Seat belts and shoulder
harness be worn at all times. Avoid situations where a side rollover may
occur.

Braking performance and capabilities are decreased when significantly
large/heaver tires and wheels are used. Take this into consideration while
driving, Also , speedometer recalibration is necessary when larger tires are
installed.

Do no add, alter, or fabricate any factory or after-market parts which in­crease vehicle height over the intended height of the Daystar Product pur­chased. Mixing component brands, lifts, and/or combining body lift with
suspension lift voids all warranties. Daystar makes no claims regarding
lifting devices and excludes any and all implied claims. We will not be

responsible for any products that is altered

.

BEFORE

AFTER

Notice to Dealer and Vehicle Owner

Any vehicle equipped with any Daystar Product must have the “Warning to
diver” decal installed on the sun visor or dash. The decal is to act a constant
reminder for whoever is operating the vehicle of its unique handling charac­teristics. INSTALLING DEALER— Its is your responsibility to install the
warning decal and forward these instructions on too the vehicle owner for
review and to be kept in the vehicle for service life.

After installation occurs, a qualified alignment facility is required to align
the vehicle to factory specs.

40. Jack up the axle and reconnect the shocks, track bar and sway
bar end link. Be sure the coil springs are seated properly.

41. Tighten all the shock bolts, track bar bolt, and sway bar links
to factory specifications.

42. Install the rear tires.

43. Lower off the jack stands.

44. Tighten front and rear lug nuts to factory specifications.

45. Double-check all fasteners for proper clearances and torque.

Installation steps

1. Place the vehicle on level ground.

2. Open the hood and disconnect the battery. Remove the
battery from the vehicle.

3. Remove the 4 14mm battery try bolts and the one nut at
the fuse box. Push the battery tray to the side.

4. Remove the cover off the electrical plug box to the rear of
the battery tray and the remove 10mm nut from the center
of the box .

5. Pull up on the box to get to the 2 12mm bolts under the
box. Remove the bolts and move the purge valve bracket
and electrical box to the side.

6. With the battery tray, electrical box, and purge valve bracket
out of the way you should now be able to access the 3 upper
strut nuts.

7. Loosen the 1 clamp for the air intake hose at the air filter box and
unplug the electrical connector.

8. Release the 4 air filter cover clips.

9. Remove the lid and the air filter.

36. Lower the axle using the floor jack until the coil springs are
loose so that you can remove them.

37. Remove the stock spring isolator and place it in the supplied
lift spacer.

38. Position the coil spring spacer assembly on top of the coil
spring and be sure it is indexed properly. Install the coil spring
and spacer in the upper spring mount.

10. Disconnect the intake hose leading from the lower filter box to the
fender. Remove the three bolts retaining the lower air filter box,
pull up on the base, and remove from vehicle. You should now be
able to access the three upper strut nuts on the passenger side.

29. Reinstall the ABS sensor and tighten all the upper strut bolts
and lower bolts to factory specifications.

31. Repeat steps 14 through 29 on the passenger side.

29. Install the battery tray and air box assemblies in the opposite
order they were removed..

31. After both front lift spacers are installed , re-install the front
wheels and lower to the ground and re-install the sway bar
end links.

32. Jack up the rear suspension and put the jack stands under the
frame rail in front of the rear tires. Remove the rear tires.

33. Leave the floor jack under the axle.

34. Disconnect the sway bar end links and rear shocks at the
axle. Unbolt the track bar at the frame on the driver side.

11. Jack up the vehicle and place jack stands under the frame rail
behind the front tires. Lower the vehicle on to the stands.

12. Remove the two front tires.

13. Disconnect both the driver and passenger side sway bar end
links. You may have to place a floor jack under the lower
control arm and take some load off the end link.

14. Unbolt the brake line bracket from the strut.

15. Carefully remove the ABS sensor from the front
wheel.

16. Remove the 3 upper strut nuts.

17. Remove the lower strut nut.

17. Make a note of how the brake line is routed around the strut.
Remove the upper ball joint pinch bolt and ABS and brake
line brackets.

18. Push down on the upper arm to relieve the pressure on the
pinch bolt to pull out the bolt.

20. With the upper A-arm separated from the knuckle, push down
on the lower control arm to free the strut from the upper
mount.

21. Pull out the lower strut bolt and remove the strut.

22. Install three of the supplied 3 stud extenders with thread lock
over the factory studs..

24. Install the strut by pushing the upper control arm up and the
lower control arm down.

25. Make sure that the brake line is routed properly around the strut.

26. Install the factory nuts on the 3 upper strut studs but leave loose.

27. Install the lower strut bolt and nut.

28. Reattach the upper ball joint to the knuckle using the factory
pinch bolt. Be sure to attach the brake line and ABS wire on
either side of the bolt. Tighten to factory specifications.

23. Install the lift spacer on top of the strut plat with the 3 stud extend-

ers.