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Installing KW Coilovers

 
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harleyrider86
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PostPosted: Thu Mar 20, 2008 8:19 pm    Post subject: Installing KW Coilovers Reply with quote

Installing KW Coilovers :
This article will outline my install of a set of KW Variant 1 Coilovers :
http://www.kw-suspension.com/en/30_Products/20_KW_Coilovers/40_Application_List/index.php?modell_1=PT%20Cruiser&level=3&hersteller_1=CHRYSLER&gruppe=Coilover&zeile=1
I passed this article to Apex & RallyD for an accuracy check

As some of you already know, I am a former car stereo installer with no previous suspension experiance. I have good hand skills.

I'm going to break this article into pieces........this first piece is only the measurement chart the manufacturer supplies with the package :

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04 Dream 3 #0531/AutoStick(DS Predator-Stage1 plus)


Last edited by harleyrider86 on Fri Mar 21, 2008 2:27 am; edited 3 times in total
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harleyrider86
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PostPosted: Thu Mar 20, 2008 8:21 pm    Post subject: Reply with quote

REAR COILOVER INSTALLATION : (both must be done at same time since the rear is a one piece axle)
(READ : instructions to conclusion before beginning project)

1) lift the car and put it on jackstands
2) take off rear wheels
3) undo sway bar to link bolts and let hang
4) undo bottom strut bolt (at this point the axle will just hang)
5) undo top strut bolt and remove the rear strut
6) remove springs
7) prepare the KW Rear Springs & Adjuster. The adjuster goes on top (or can be left out of the install for an additional 10mm of drop)
8 use your jack and lift the axle up so the new springs can be installed (they are a lot shorter then the stock springs so the jack makes up for the difference). Clock the springs until the bottom spring ends are pointing towards the left side of the car
9) install new strut by attaching top strut bolt – do not tighten yet
10) use your jack to lift the axle until the bottom strut bolt aligns with it’s mounting hole.
11) cut the bumpstop to 65mm in length (55mm if you do not use the rear adjuster)
12) tighten all bolts (BE SURE TO TORQUE 3 TIMES!!!).
13) reattach the rear sway bar using the original dogbones and torque
14) install the wheels and torque

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04 Dream 3 #0531/AutoStick(DS Predator-Stage1 plus)


Last edited by harleyrider86 on Fri Mar 21, 2008 2:29 am; edited 3 times in total
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harleyrider86
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PostPosted: Thu Mar 20, 2008 8:25 pm    Post subject: Reply with quote

FRONT COILOVER INSTALLATION : (should be done one side at a time)
(READ : instructions to conclusion before beginning project)

1) open hood
2) remove solenoid/cruise control bracket (see note ^^)
3) lift the car and put it on jackstands
4) take off front wheels
5) remove sway bar endlinks, loosen sway bar clamp bolts and rotate sway bar down
6) remove two strut to knuckle nuts at the bottom of the strut
7) unhook abs sensor wire and brake line attached to the strut body
8 ) tap strut to knuckle bolts out with hammer
9) while holding the strut assembly up, remove three strut tower nuts and remove assembly
10) at his point the strut/spring assembly should be off the car
11) you'll have to remove the top hat and transfer it onto the new assembly. Rent strut spring compressors^ for this. The strut spring compressor is a pair of hooks attached to each other by a long threaded bolt. By threading the 2 hooks towards each other you compress the spring and take the pressure off the tophat. Once the pressure is gone, remove the tophat by gripping the shaft of the shock with a pair of vice grips and loosen the top nut^^. Release the pressure of the old springs carefully by loosening the 2 long threaded bolts until the hooks fall away.
12) mount the tophats on the KW Coilovers by lowering the spring perch all the way to allow zero spring pressure on the tophat. Use an open end wrench on the top nut AND a torx driver thru the center of the top nut into the strut piston top. Torque the top nut to specs.
13) prepare the KW Front Springs & Adjuster. Relocate hose brackets from OEM to KW. The adjuster goes approximately 1 3/8” from the bottom as a starting point (this is KW recommended lowest front height).
14) while holding the strut assembly up, install three strut tower bolts
15) tap strut to knuckle bolts into place with hammer
16) install two strut to knuckle nuts at the bottom of the strut (make a note that the top is slotted to allow for camber adjustment – YOU WILL NEED AN ALIGNMENT – adjust it so you have as much negative camber as possible as this is safer than positive camber)
17) reattach the abs and brake lines to the strut body
18 rotate sway bar up and install sway bar endlink bolts
19) tighten all bolts TORQUE EVERYTHING 3 TIMES
20) install the wheels and torque
21) lower the car to the ground off the jackstands
22) install solenoid/cruise control bracket
23) close hood
24) get an alignment^^^
25) drive home aggressively, and once there grab a beer and look at car

(^) Rent Strut Spring Compressors for this job. Take note that Coil Spring Compressors compress a spring inside the middle of the coil……..this can not be done with the PT. You must use the 2 piece Strut Spring Compressor that attaches to the outside of the coil springs.
(^^) As an alternative to using vise grips to remove the tophat restraining nut. When still at step 2, try an impact wrench to break the nut loose while the car is still on the ground.
(^^^) actually wait 2 weeks to get the alignment done. The car needs to settle, so drive it and have fun.

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