E5AQ01F1 - 607

SETTING UP ENGINE SUB-FRAME CHECKING EQUIPMENT

1 - SPECIAL TOOLS

1 - 1 - CHECKING GAUGE FOR FRONT MOUNTINGS OF THE FRONT WISHBONE ON THE SUB-FRAME (-).1107

Including :

• [1] : 1 frame
• [2] : 2 checking yokes (left and right) with each 1 drift [2a] and 2 adjusting shims of 1 mm [2b]
• [3] : 2 special bolts (with nuts) for mounting the steering rack housing
• [4] : 2 bolt (with nuts) for rear mounting of the gauge
• [5] : 4 yoke mounting bolts
• 1 operating instructions
• 1 side diagram for autocheck of the sub-frame
• 1 small case for storage (of yokes and bolts)

The purpose of this tooling is to determine accurately, without dismantling, whether the sub-frame needs to be replaced .

It is possible to use it to check the angles of slope of the yokes (caster 1°, camber 5°) for mounting the front wishbones on the sub-frame, first one side then the other, (or both sides at the same time) which are liable to be twisted following an impact .

1 - 2 - TOOLS FOR CHECKING THE SUB-FRAME AFTER FRONT IMPACT (ADDITION TO TOOLING (-).1107)

The complete sub-frame checking kit (-).1107-ZZ, Including :

• [6] : 2 extensions (left and right)
• [7] : 4 bolts for mounting extension on gauge
• [8] : 2 centralising devices
• [9] : 1 mounting plate
• [10] : 1 threaded bush for fitting plate [9] on sub-frame
• [11] : 1 checking pin

The purpose of this tooling is to determine, without dismantling, whether it is advisable to replace the sub-frame after a front impact .

It enables a check to be made as to whether there is twisting of the sub-frame at the end of the chassis leg after an impact .

2 - CHECKING OF FRONT WISHBONE MOUNTINGS ON ENGINE SUB-FRAME

WARNING : this gauge is to be used after a front suspension check .

2 - 1 - REPAIR ON VEHICLE

Remove :

• the front wishbone(s), depending on the side (or side) to be checked
• the 2 rear bolts (1) fitting the sub-frame to the body
• the 2 nuts (2) securing the steering rack housing

2 - 2 - CHECK

Position the 2 centralising pins [8] on the frame [1] .

Hook the gauge on using the small chain (3) :

• for the 6 cylinders on the exhaust pipe
• for the 4 cylinders on the front right-hand drive shaft arm

Pivot and position the gauge, ensuring that the centralising pins are inside the perforations of the sub-frame, and fit the sub-frame with the [4] bolts and the 2 nuts for fitting the steering rack housing (4), tightening them a moderate amount (The bolts [4] are supplied in the kit) .

Position the checking yoke [2], pin with bolts [5], fasten with bolts 1 mm [2b], insert a shim [5] (nominal setting), tighten the bolts [2a] and pin them with the drift .

If pinning is impossible :

• add the second shim (set to + 1 mm), or remove the first one (set to - 1 mm),

After making these three checks, if pinning proves impossible: replace the sub-frame .

2 - 3 - OPERATION ON SUB-FRAME WHICH HAS BEEN REMOVED

These checks can also be carried out by offering up the sub-frame on its own, on the gauge which has previously been laid flat .

3 - SUB-FRAME CHECK AFTER FRONT IMPACT

3 - 1 - OPERATION ON GAUGE

Bend the ring 90 to (A) °, in order to avoid any contact with the sub-frame .

3 - 2 - REPAIR ON VEHICLE

Remove :

• the shields under the engine
• the 2 rear bolts (1) fitting the sub-frame to the body
• the mounting stud and nut (2) for the right side of the steering rack housing
• the front mounting bolt for the front sub-frame (side to be checked)

3 - 3 - CHECK

Position the 2 centralising pins [8] on the frame [1] .

Hook the gauge on using the small chain (3) .

Pivot and position the gauge, ensuring that the centralising pins are inside the perforations of the sub-frame and mount the sub-frame using bolts [4], tightening them a moderate amount (The bolts [4] are supplied in the kit (-).1107) .

Position the mounting plate [9] on the gauge and secure it using the mounting ring [10] supplied .

Position the extension [6] on the gauge and secure it using the 2 bolts [7] supplied, on the side to be checked .

Using the checking pin[11], place it in the sub-frame mounting hole, supported by the sub-frame .

Check the conformity of .

NOTE : the check only takes place with the sub-frame in place and fitted at 3 points (never remove the 2 sub-frame front mounting bolts at the same time) .

3 - 4 - CHECKING THE CORRECTNESS OF THE SUB-FRAME

[6] : Extension .

[11] : Checking pin .

(5) : Sub-frame .

(A), (B) : Negative check, Part outside tolerance, sub-frame to be replaced following impact .

(X) : Reference interval .

(Y) : Reference surface .

(C), (D), (E) : Check correct, Part within the tolerances, sub-frame not twisted .

4 - TIGHTENING TORQUE(S)

Rear bolts mounting the sub-frame on the body : 6.5 da.Nm .

Mounting nut for the steering rack housing : 8 da.Nm .

Front bolts mounting the sub-frame on the body : 10 da.Nm .

5 - COMMENT(S)

After use, store in the small case (-).1107 already in your possession :

• the extension mounting bolts [7]
• the threaded bush [10]
• the 2 centralising pins [8]
• the checking pin [11]