Automotive Manual PDF

BMW has manufactured thousands of these cars and they are not all the same. This is called manufacturers tolerance. With age the chassis strut towers migrate/change location after years of use. In some cases this can cause assembly problems for the front strut installers. The 3 piece adjustable strut bars are easier to install but not as rigid or structurally sound.
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FRonT SySTem InSTALLATIon
1. Park vehicle on clean, flat, and level surface. Block the rear wheels for safety.
2. Lift front of vehicle with hydraulic jack. Secure frame rails with jack stands. If installing optional long radius arms, make sure there will be clearance for brackets.
3. Remove wheels
4. Disconnect the anti-sway bar (if equipped) from the frame, retain hardware. (Fig 1)
5. Disconnect steering linkage from pitman arm, retain nut. (Fig 2)
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1. Park the vehicle on a clean, level surface and block the rear wheels for safety.
2. Safely raise the front of vehicle and support with jack stands for safety.
3. Remove the wheels.
4. Measure and record the length of the exposed thread on the torsion bar adjusting bolts for later reference.
DRV__________ PASS__________
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FRONT INSTALLATION
1. Park the vehicle on a clean, level surface and block the rear wheels for safety.
2. Safely raise the front of vehicle and support with jack stands for safety.
3. Remove the wheels.
4. Measure and record the length of the exposed thread on the torsion bar adjusting bolts for later reference.
DRV__________ PASS__________
5. Remove the torsion bar assembly.
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This kit includes new braided stainless steel brake lines. Installation of these lines requires the entire brake system to be bled following the completed installation and prior to operating the vehicle. Consult your owner’s manual for the proper brake fluid to use for your vehicle. Fluid is not included in this kit.
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The factory service manual specifically states that striking the knuckle to loosen the ball joints or tie rod ends is prohibited. Striking the aluminum knuckle can damage it. A special puller tool #8677 (or equivalent ball joint tool) is recommended to be used to separate these components from the knuckle.
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FRONT INSTALLATION
1. Park the vehicle on a clean, level surface and block the rear wheels for safety.
2. Safely raise the front of vehicle and support with jack stands for safety.
3. Remove the wheels.
4. Measure and record the length of the exposed thread on the torsion bar adjusting bolts for later reference.
DRV__________ PASS__________
5. Remove the torsion bar assembly.
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Measure from the center of the wheel up to the bottom edge of the wheel opening
LF______ RF______ LR______ RR______2.
NOTE: The factory service manual specifically states that striking the knuckle to loosen the ball joints or tie rod ends is prohibited. Striking the aluminum knuckle can damage it. A special puller tool #8677 (or equivalent ball joint tool) is recommended to be used to separate these components from the knuckle.
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Call NRMA Technical Advice on 1300 655 443, should you require additional information on this vehicle, on other makes, or for general advice on automotive matters.
ROAD TEST REPORT
August
VOLVO S60
AWD 2.4 litre sedan
FEATURES
BEST WORST
Confident handling
Comprehensive level of safety equipment Build quality Restricted rear leg room PULP required for optimum performance
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Fairly easy, suitable for beginner with some experience, Fairly difficult, suitable for competent DIY mechanic 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 Specifications Brake system Type Hydraulic, dual circuit, split diagonally, pressure regulator on some models. Disc front brakes. Drum or disc rear brakes. Cable-operated handbrake on rear wheels. Front brakes Disc thickness: New: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Pad thickness: New - excluding backplate: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum - including backplate: All models 10.0 mm 12.0 mm 20.0 mm 8.0 mm 10.0 mm 18.0 mm 12.0 mm 14.0 mm 10.0 mm 7.0 mm
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