Field Remedy: 1563
| Subject: | Cracking noise from front section - Temporary cracking noise from front section |
|---|
| Models: | Engines: | Option: |
|---|---|---|
| Vectra-C 2002... | All | All |
| Complaint: | Temporary cracking noise from front section. |
|---|---|
| Cause: | Misfit between spring and lower spring seat. |
| Production: | None. |
Remedy:
In case of customer complaint paint front springs in the area of lower spring seat and install insulators.
Working Procedure:
1. Remove front wheels. 2. Remove wiring harness for brake wear indicator from left and right spring strut (Picture I, 3). 3. Remove wiring harness bracket for ABS wheel sensor from left and right spring strut and disconnect wiring harness (Picture I, 1). 4. Remove left and right locking plate for brake hose. 5. Remove left and right brake hose from spring strut (Picture I, 2).
6. Remove left and right pendulum (Picture II, 1).
7. Remove left and right fastening screws for brake calliper retaining frame from steering knuckle (Picture III, 1).
Note:
Push back brake piston. Remove brake calliper retaining frame with brake calliper. Hang on brake calliper retaining frame with brake calliper inside wheel housing by use of cable strap.
8. Remove left and right fastening screw for tie rod. 9. Remove left and right tie rod from steering knuckle (Picture IV).
Note:
Press out tie rod from steering knuckle by using KM-507-C (1).
10. Remove left and right control arm (2) from steering knuckle.
Important:
Lower control arm must not be bent more than 15° to avoid loosening of bolt hydro-bushing.
Note:
Do not use a spreader tool to remove control arm from steering knuckle.
11. Remove left and right dust cap from wheel hub. 12. Remove left and right axle shaft nut (Picture V, 2).
Note:
For the removal of axle shaft nut counterhold by using KM-468-B (1).
13. Remove left and right axle shaft from steering knuckle by using KM-6268. (Picture VI, 1).
Note:
Install KM-6268 with 3 wheel bolts.
14. Remove KM-6268 from wheel hub. 15. Remove left and right upper fastening screws (arrows) for spring strut and remove spring strut out of wheel housing (Picture VII, 1).
16. Remove left and right front spring from spring strut.
- see working procedure “Spring strut, Disassemble and Assemble”, groupe “E”, Service Instruction Vectra- C.
Note:
Use a dropped ring wrench (SW 21) and a torx-socket (T50) for the removal of the fastening nut of the upper stop.
17. Clean left and right lower spring seats of spring strut. 18. Prepare left and right front spring in the area of lower spring seat for painting, remove traces of rust if necessary (Picture VIII, cross-hatching).
Warning:
The primer painting and the painting procedure is allowed in well ventilated rooms only.
19. Prime left and right front spring in the area of lower spring seat twice.
Important:
It is important to apply primer twice!
20. Protect left and right front spring in the area of lower spring seat against corrosion by using body paint (black-matt). 21. Install insulator to the left and right front spring in the area of lower spring seat (Picture IX, 1).
Note: Determine the front spring diameter for the corresponding insulator. Pay attention to the installation position of the insulator. Stops (arrows) have to fit closely to the beginning of the spring.
22. Assemble left and right spring strut
– see working procedure ”Spring Strut, Disassemble and Assemble”, group ”E”, Service Instruction Vectra- C.
23. Install left and right spring strut into wheel housing and mount it with upper fastening screws.
Note:
Do not fasten upper fastening screws yet.
24. Install left and right control arm to steering knuckle - tightening torque 60 Nm.
Note:
Insert axle shaft into wheel hub. Use new fastening nuts.
25. Install left and right tie rod to steering knuckle - tightening torque 35 Nm.
Note:
Use new fastening nuts.
26. Install new left and right axle shaft nut.
Note:
For installation of axle shaft nut counter hold with KM-468-B. Tighten fastening nut – tightening torque 150 Nm. Release fastening nut by 45°. Tighten fastening nut – tightening torque 250 Nm.
27. Install new dust cap left and right. 28. Clean thread of left and right brake calliper retaining frame. 29. Install left and right brake calliper retaining frame with brake calliper to steering knuckle – tightening torque 210 Nm + 30° + 15°.
Note:
Use new fastening screws. Coat fastening screws with locking compound.
30. Install left and right pendulum to spring strut – tightening torque 65 Nm.
Note:
Use new fastening nuts.
31. Install left and right brake hose to spring strut. 32. Install left and right locking plate for brake hose. 33. Connect wiring harness plug for ABS sensor and install left and right wiring harness bracket to spring strut. 34. Install left and right wiring harness for brake wear indicator to spring strut. 35. Install Front wheels – tightening torque 110 Nm. 36. Lower vehicle. 37. Tighten left and right fastening screws for spring strut - tightening torque 20 Nm.
Spare-Parts:
Qty.: Partname: Partnumber: Cat.-Number:
2 Insulator 13178463 3 12 232 (for Spring Wire Diameter 11,8-12,9mm) 2 Insulator 13178464 3 12 233 (for Spring Wire Diameter 13,0-14,0mm) 2 Nut, Hex., M14, Front Suspension Arm to 24433051 03 44 987 Shock Absorber Strut 2 Nut, Drive Shaft to Wheel Hub 90223979 03 26 966 2 Cap, Wheel Hub 24421102 03 30 396 2 Nut, Hex., M10, Control Arm to Strut 90576769 20 66 017 2 Nut, Hex., M12, Link Rod to Shock 90538316 03 50 890 Absorber 2 Nut, Hex., M12, Tie Rod to Steering 13136972 59 05 901 Knuckle 4 Screw Torx, M14x35,6mm, Calliper to 93171511 05 43 102 Steering Knuckle
Labour Times: TC: Hours:
T8 156 30 Protect Front Springs 90 2.1 against corrosion
001 Additional work for 90 0.2 vehicles with xenon headlamps
The costs for this repair will be covered during the normal warranty. The regular warranty procedure should be used for claiming Set-up-time.
| FunctionalGroup: | E - Front wheel suspension/Wheels/Tyres |
|---|---|
| Complaint Group: | 03 - Corrosion,14 - Noises or Vibrations |
| Trouble Code: | None |