belltech 61 007 Performance Coilover Kits Instruction Manual

belltech 61 007 Performance Coilover Kits

Product Information

• Product Name: KW Coilovers
• Part Number: 61 007
• Vehicle Model: Chevrolet Colorado Type 285
• Front Axle Load: Maximum permissible load: 610 kg / 1344 lbs
• Coilover Strut / Shock Absorber Signature: KW 20-60-80 / KW 140-200

Approximate Adjustment Range:

• A: Minimum – 30 mm / 1.2 inch, Maximum – 80 mm / 3.1 inch
• B: Minimum – 420 mm / 16.5 inches, Maximum – 485 mm / 19.1 inch

Rear Axle:

• Coilover part number: 610 1105
• Approximate adjustment range: Not specified

Product Usage Instructions

Before starting the installation work, please ensure the following:

1. Check that the TUEV certificate matches the vehicle specifications, including front and rear axle weights, vehicle identification number (VIN), etc.
2. Ensure that the suspension components match the specifications for the application, including springs and shock/struts identification numbers.
3. Strictly observe the instructions provided.

KW Coilovers are designed for easy installation. Unless specified otherwise in these instructions, all suspension components should be installed and removed according to the manufacturer’s specifications for standard springs and damper components.

Important Note: The allowable measurement between the wheel hub center and fender edge should not exceed the specified measurement when using standard fenders.

Danger:

1. Always follow the latest accident prevention regulations for each step to prevent serious bodily harm or injury (not applicable for North America).
2. We recommend using a vehicle hoist or lift for installation. If not available, ensure the vehicle is secured with commercial wheelblocks and jack stand to ensure safety.
3. The suspension components should only be installed by trained technical personnel using the proper tools.
4. Read the General Installation instructions and Technical Inspectorate documents before attempting installation.
5. Never use impact wrenches or guns to install or remove shock absorber piston hardware.
6. Never disassemble or cut open shock absorbers and/or shock absorber inserts as they contain oil under pressure, posing a risk of explosion.
7. After installation, carry out the work steps on page 7, items 11 through 14 before driving on public highways.
8. If available, disable the suspension regulation through an authorized dealer.
9. Take care to ensure fittings, such as fittings of shock absorber housings or fittings of the lower… (remaining text is cut-off)

Installation Instructions|
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Instruction No.| 686 61 007|  | Date| 05.10.2006

INSTALLATION INSTRUCTIONS

Before you start installation work, please read the following carefully:

• Ensure that the TUEV certificate matches the vehicle specifications (front and rear axle weights vehicle identification number (VIN) etc.
• The suspension components must match the suspension application specifications (springs and shock/struts identification numbers).
• The instructions must be strictly observed.

KW Coilovers for automobile suspensions are designed for easy installation. If not otherwise stipulated in these instructions, all suspension components are installed and removed in accordance with the manufacturer’s specifications for installing and removing standard springs and damper components. At the time of printing all instructions and specifications are correct.

Technical data

Technical data| Coilover part number … 61 007
---|---
Vehicle Model| Chevrolet Colorado Type 285| max. permissible front axle load:
 | f r o n t     a x l e| r e a r a x l e
Spring signature| KW 20-60-80 / KW 140-200*| –
Coilover strut / Shock absorber signature| 610 1005| 610 1105
Approximate adjustment *range A in mm/inch| min:| max:| min:| max:
30 mm / 1,2 inch| 80 mm / 3,1 inch| –| –
Approximate wheel hub center to fender edge measurement B in mm/inch| min:| max:| min:| max:
420 mm / 16,5 inch| 485 mm / 19,1 inch| 440 mm / 17,3 inch| –

Calculating the adjustment range: (Photos are examples only)

Please enter the adjusted height of the modified car into the list:

Coilover part no

| ****

Vehicle type

| ****

Measurement A

| Wheel hub center to wheel arch Measurement B
---|---|---|---
Front| Rear| Front| Rear
 |  |  |  |  |

• The remaining thread measurement is approximate and is only intended as a general guide. Actual results may vary due to various axle weights.
• IMPORTANT: The allowable measurement between wheel hub center and fender edge as indicated above, may not exceed this measurement when using standard fenders.

Danger:

1. Always follow the latest accident prevention regulations (not applicable for North America) for each step to prevent any serious bodily harm or injury.
2. We recommend the use of a vehicle hoist or lift when installing the suspension. If a lift is not available and jacking equipment is used, make sure that the vehicle is secured with commercial wheel blocks and jack stand to ensure safety.
3. The suspension components may only be installed by trained technical personnel using the proper tools.
4. The General Installation instructions, as well as the Technical Inspectorate documents, must be read BEFORE attempting installation.
5. Never use impact wrenches or guns to install or remove shock absorber piston hardware.
6. Never disassemble or cut open shock absorbers and/or shock absorber inserts. They contain oil under pressure. Dan- ger of explosion.
7. Before driving on public highways, carry out the work steps on page 7, items 11 through 14 after installation.
8. The suspension regulation (when available) needs to be disabled through an authorized dealer.
9. Please take care in any case that fittings (for example fittings of shock absorber housings or fittings of the lower control arm in the housing of the wheel bearing) are free of dust and oil. (See manufacturer guideline)

General Instructions for Use

1. When adjusting the vehicle height, make sure that the threads are clean and free of debris. After initial cleaning, move the perch by 10 mm (0.4 Inches) downwards, and then clean the area that you desire to adjust the perch (up or down).
2. During height adjustments on separate shock and spring systems, remove the perch from the vehicle to adjust the height.
3. After adjusting the vehicle height, repeat steps 11 through 14 from page 7.
4. In the area of the piston rod and the sealing package of the new and used damper, oil and grease were collected. This could either be caused by using a special black grease while assembling the washer or due to the accumulation of streak oil. Furthermore, oil is used during the assembling the cartridge and rod guide. There is no reason to worry about and damage, as in this area dust and dirt used to be collected.

General Mounting Specifications

1. We recommend the use of a vehicle hoist or lift when installing the suspension.

2. Caution: If the vehicle is equipped with ride height sensors, they should be removed before removal of struts or dampers, otherwise damage may occur.

3. The struts should be removed as specified by the manufacturer’s instructions.

4. Manufacturer-recommended tools for removal of the original struts, or a suitable spring compressor, must be used to remove most factory-mounted suspension systems.

5. Mount the complete suspension system as described on the following pages.

6. Never use impact drivers to install nuts on the piston rods as permanent damage may occur. It is imperative that you do not damage the piston rod surface, through the use of pliers etc., as the smallest damage will result in seal damage, and will not be covered under warranty.

7. Stay within the lowering range specified in the table on page 3.
   Example: With a specified range of 20-60 mm (0.8—2.3 Inches), 40 mm (1.5 Inches) is your height adjustment range.

8. Ensure that the set screw on each spring collar is tightened to prevent movement of the spring perch. On vehicles with separate shock/spring combinations, no set screw is necessary.
   Caution: Do not over-tighten the set screw. Maximum torque is 1-2 Nm (0.74-1.47 ft-lb).

9. Install the suspension components in the vehicle as specified by the vehicle manufacturers in their document.

10. Except as noted, all torque values must comply with manufacturer-recommended specifications.

11. After assembly and installation is complete, the vehicle should be rolled onto level ground. Once on level ground, measure the vehicle height and adjust to the customer’s requirements, within the prescribed lowering range.
    Caution: Wheel hub center—wheel arch maximum measurement in the table of page 3 must not be exceeded! Also, consider the minimum road clearances specified in the table on page 7 (only valid for Germany!).
    Caution: It is common for the vehicle suspensions to settle by an additional 5—10 mm (0.2—0.4 Inches)

12. Examine the clearance between the tires and the suspension over the full range of motion of the wheel. The minimum clearance between the suspension and the tire is 4 mm (0.16 Inches). If this clearance is less than 5 mm (0.2 Inches), wheel spacers may be necessary. With strut designs that are located close to the wheel, but that have no steering functions, use 100 mm (3.9 Inches) spacers on diagonally opposed wheels (e.g., front right, rear left). In this position, you must be able to achieve the minimum clearance required. You can also check the clearance between tire and the body.
    Caution: With torsion beam trailing arm axles, this method is not sufficient. The wheel must be under full load as well as test-driven to properly calculate the clearances of 5 mm (0.2 Inches) from any other components.

13. The geometry of the suspension needs to be adjusted according to the regulations of the vehicle manufacturer. If a value cannot be reached due to the difference in height, an optimal value next to the tolerance range of the vehicle manufacturer needs to be adjusted.

14. All components that are controlled by vehicle ride height (e.g., headlights, brake bias regulator etc.) must be adjusted as specified by the vehicle manufacturer’s instructions and procedures.

15. For vehicles with ESP, DSC or EPC your new suspension components may cause an engine fault code to appear. This is only temporary as the vehicle electronics adjust to the new components/height. On some models this will end after driving approximately 3-5 miles, or through turning the steering wheel from full left to full right. On other models, this must be reset through the factory diagnostic port by a qualified technician.

Front axle:

Rear axle:

After you have completed installation of the suspension, check the clearance of the tires to the front suspension strut. The minimum clearance at the narrowest point is 5 mm and must, where necessary, be provided using commercially available, Technical Inspectorate-approved spacers.

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