505 09 00001111

Pages
A· FRONT SUSPENSION STRUTS
Removal - refitting :
. with integral swivel bearing A4.oo1 - 007
. with detachable swivel bearing A4.012 - 013
B - FRONT SPRINGS
-Identification, data B1.001 - 004
- Removal - refitting 84.001 - 005
C - FRONT DAMPERS
- Dismantling - re-assembly C4.001 - 003 02.87 E

505 9 A4.001
- 9

SUSPENSION

FRONT SUSPENSION STRUT REMOVAL· REFITTING

A4.002

REMOVAL

- Remove:

- the brake caliper, without disconnecting the hose (suspend the caliper under the wing),

- the track rod ball joint.

505

II

- the pivot pin (1) from the rear arm.

IV

- Support the hub on a jack.

- Remove:

- the 3 bolts from the top mounting.

- Remove the strut.

III

- the pivot bolt (2) from the anti-roll bar link,

- the nut (3) from the front arm.

- Detach the rear arm from the cross member and from the front arm.

04-86

505

I

28.2.85 C42

II

28.2.85 C37

III

28.2.85 C36

~--II ----=-505-1 1~4004J_ 9 1

11 -

28.2.85 C37

VI

505

SUSPENSION

FRONT SUSPENSION STRUT REMOVAL - REFITTING

A4 .. 005

9

REFITTING

- Offer up the strut with the safety cup (1) parallel to the vehicle centre line.

- Fit the 3 upper bolts.

Tightening torque: 1 m.daN (7 Ibf.ft).

IV

- The arm pivot pin, with the head to the rear, as far as the splines.

- Fit a nylstop nut without tightening it.

II

- Assemble to the front arm:

- the abutment washer (2) with the chamfer (a) towards the arm.

- the cup (3),

- a rubber half-bushId).

V

-Fit the caliper.

TEVES caliper

Tightening torques: 8,5 m.daN (63 Ibf.ft).

- Turn over the lock plate.

III

- Engage the front arm in the rear arm and fit, in this order:

- the 2nd rubber half-bush,

- the cup;

- a nylstop nut, without tightening it.

- Fit:

- the anti-roll bar link,

- the track rod.

04-86

VI

DBA caliper

Tightening torque 13 m.daN (96 Ibf.ftJ.

Bolts coated with Threadlock Loctite (without washers).

9

SUSPENSION

FRONT SUSPENSION STRUT REMOVAL - REFITTING

A4.006

- Fit the wheel.

- Return the vehicle to its wheels and roll it to settle the suspension.

505

II

- Push the rear arm pivot pin fully home and tighten the nut.

Tightening torque : 4,5 m.daN (33 lbf.f't).

III

- Tighten the various fixings:

Tightening torques:

(1 ) anti-roll bar link

(2) front arm

~ 4,5 m.daN ~ (33 Ibf.ft)

(3) track rod ball joint 3,5 m.daN (26Ibf.ft)

04·86

1--- 505 1--------.----

1 91 A4.0071

I

II

28.2.85 C37

III

5.3.85 e21

09 A4~ 11 (1J

09.86
SUSPENSION FRONT SUSPENSION STRUT REMOVAL - REFITTING

09

505

I

WITH DETACHABLE SWIVEL BEARING

The suspension strut can be removed without removing:

- the stub axle

- the wishbone

- the brake caliper

REMOVAL

- Unclip the ABS sensor supply lead at (1)

-Remove:

- the road wheel

- the two bolts (2)

- the three strut fixing bolts (3)

REFITTING

- Fit:

- the strut with the three upper bolts (3): tightening torque: 1 m.daN (7 Ibf ft)

- the two bolts (2} with new nuts: tightening torque: 5,5 m.da.N (41 Ibf ft)

- the ABS sensor supply lead at (1)

- the road wheel

02.87 E

[ 505 u:

9 ! A4.013!

I

29.1 .. 86 C23

1UL86 C60

505

9

81.001

SUSPENSION
Bl.002 9 FRONT SPRINGS 505
IDENTIFICATION - DATA
505 SALOONS AND ESTATES
FLEXI LlTY : 66,3 mm under load of 100 daN.
RATE : 93 Ibf/in
Number of coils: 6,6
Wire 0: 13 mm
Spring external 0: 164 mm (6.46 in).
;-. -
mm (in)
SPRING COLOUR IDENTIFICATION Height under
reference FREE
load of 344 daN height
(773Ibf)
A 2 BLUE 208,5 408
1 GR.EEN (8.21) (16.1 )
B 2 BLUE 216,5 479
1 YELLOW (8.52) (1.8.9)
C 2 BLUE 224,6 490
1 RED (8.84) (19.3)
D 3 BLUE 234,5 503
(9.23) (19.8)
E 3 GREY 245 517
(9.64) (20.4)
F 3 YELLOW 252,5 527
(9.94) (20.7)
G 2WHITE 260 538
1 BLUE (10.24) (21.21
H 2 GREY 268 548
1 BLUE (10.55) (21.6) 04-86

SUSPENSION 09 81003111
505 FRONT SPRINGS
IDENTIFICATION - DATA
I APPLICATION TABLE - SALOONS
TO = Turbo Diesel FI = Fuel Injection
SPRING EUROPE SCANDINAVIA USA-CANADA HEAVY DUTY
SUSPENSION
A ~
A ~ GL -GR-SR-GTI
B -c:> GL-GR-SR-GTI
B ~ (GR-SR-GTI) ** GL-GR-SR-GTI
C -c:> (GR-SR-GTI) ** GL -GR-SR-GTI
SR** GL
C <>-- Turbo -V6 GTI** GR
Turbo SR
SR** GL
D~ Turbo -VS GTI** GR
Turbo SR
(Turbo - V6)** STI-GLSV6 GL**
D~ GLD-GRD Turbo** STI FI-STX V6 GR**
SRDT-GTOT Turbo-STIV6 SR**
Turbo S
(Turbo -V6)** STI-GLSV6 GL**
E -c:> GLD-GRD Turbo** STI FI-STX V6 GR**
SRDT-GTOT Turbo-STIV6 SR**
Turbo S
GLFI
E ~ GRO** SFI
SRDT** GL
GLS
GLFI
F ..c> GRO** SFI
SROT** GL
GLS
GTOT** SROT STITO GLD
F~ S TO (Canada) GRO
GTDT
GTOT** SRDT STITO GLO
G~ S TO (Canada) GRD
GTOT
G~ GL TO-S TO (GLD-GRO)**
GLSTO GTOT**
GL GLO**
H -c:> S GRO**
GLSTO GTOTH
H~ 02.87 E

81004111 09 SUSPENSION
FRONT SPRINGS 505
IDENTIFICATION - DATA
I APPLICATION TABLE - ESTATES, FAMILY ESTATES
TO = Turbo Diesel FI = Fuel Injection G= Ambulance
SPRING EUROPE SCANDINAVIA USA - CANADA HEAVY DUTY
SUSPENSION
A~ GTI GTI
A -c> GTI GTI
B~ GTI GTI
GL GL
B -c> GR GR
GTI** GTI**
GL GL
C~ GR GR
GTI .. GTI**
C GRG GL
GR + GR
D~ GR** GL
GRG GR
o --c> GTDT GTOT Turbo 86 MY GL**
S FI (Canada) GR**
E~ GTOT GTDT Turbo 86 MY GL**
S-FI (Canada) GR**
GLD-GRD GLD-GRD GLFI
E~ GTO)G GToT** SR
GRO + GL-GLS
GLo-GRD GLD-GRD GLFI
F~ GTDT** GToT** SFI
GROG GL-GLS
S TO (Canada) GLO
F -c> GRo** Turbo S GRo
GToT
S TO (Canada) GLO
G~ GRD** Turbo S GRD
GTOT
GLTD GLO**
G --c> STo GRO**
Turbo 1- 87 MY GTDT**
GLSTD
GL TO GLo**
H~ STo GRo**
Turbo 1- 87 MY GToT**
GLSTo
H~ 02.87 E

505

9

84.001

9

SUSPENSION FRONT SPRINGS REMOVAL - REFITTING

84_002

REMOVE

~ Use press (~)_0910 ZY A or AZ fitted with claw B and compression plate (E)_

~ Gap between plate and claw X"" 240 mm (9_5 in)

505

II

- Position the strut assembly between the plate and the claw, with the stub axle downward,

- Secure the top mounting to the plate E using 3 bolts in the holes marked "505",

IV

- Extend the press (gap Z "" 360 mm (14 in))

V

- Remove:

- the spring,

- the top cup,

- the bump stop washer,

- the top mounting.

III

- Compress the spring (gap between plate and claw Y "" 150 mm (6 in)).

- Remove the damper nut with tools (-).0906 Sand (-).0903 T2.

- Remove the damper body.

VI

WARNI'NG - Because of the weight distribution on the front suspension, the right-hand and left-hand springs are not usually identical.

Do not interchange them.

Note the colour identification (a),

04·86

I 505

I

-_.-

28.2.85 C25

IV

I

13.3.85 C35

III

28.2.85 C16

13.3.85 C33

I

_~IV

II

282

.. 85 C6

III

28.2.85 C9

28.2.85C18

v

28 -

.2.85 C24

505

SUSPENSION FRONT SPRINGS REMOVAL ~ REFITTING

84.005

9

REFITTING

- Attach the top mounting with 3 bolts to the plate (-).0910 E.

- Gap between plate and claw

• X"", 360 mm (14 in).

II

- Fit the ball thrust race (1) in the top mounting.

- Position the bump stop washer (2) against the thrust race.

III

- Position, between the plate and the claw, the spring fitted with the top cup and the bellows the right way round as shown opposite.

IV

- Compress the spring (gap between plate and ctaw Y"" 150 mm (6 in)).

- Fit the damper, with its bump stop (3), through the bellows into the top support.

v

- Fit the rebound stop cup (4) and position it opposite the boss (a) on the top mounting.

- Tighten the top nut.

Tightening torque 4,5 m.daN (33 lbf.ft).

505 9 C4.001
J 9

SUSPENSION

FRONT DAMPERS DISMANTLING - RE-ASSEMBLY

C4.002

DISMANTLING

- Position the damper body vertically (Support (-).0906 H).

- Remove the closing nut (1) using wrench (-).0906 G.

505

II

- Withdraw the damper piston slowly to prevent fluid spray.

- Withdraw the barrel and empty the stub axle carrier.

IV

- Fit the barrel, fitted with its valve, into the damper body.

- Pour in 0,335 drn" (11.75 fl oz) of ESSO OLEO-FLUID 42 PX.

v

- Push, the piston slowly into the barrel, taking care not to damage the piston ring.

- Fit:

- the top bearing (3) (recessed approxima-

tely 3 mm (1/8 in)).

- the top seal (4), lubricated, fully into its housing.

- Push down the piston rod seal (5). previously lubrlcsted.

III

- Withdraw the piston from the new barrel.

- Fit the piston ring (2) (supplied separately) to the piston.

VI

- Tighten the closing nut (11.

Tightening torque 8 m.daN (59 lbt.ft).

04-86

505

6.12.84 ci i 612.84 C10

II V

,....:::----------.-------.-------------,

t

I

----

6.12 .. 84 C15 6.12.84 C8

III VI

.--------..,...-------.,--------,

~

2ll

.

.

6.12.84 C17