Front Suspension Page 3–1

Page 3–1

Section 3

Front Suspension

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information............................................................................................................................... 2

2 Service Operations................................................................................................................................3

2.1 Suspension Height Check.....................................................................................................................................3

Preliminary Inspection...........................................................................................................................................3

Front Suspension Height Check...........................................................................................................................4

Rear Suspension Height Check............................................................................................................................4

Front and Rear Suspension Height Comparison.................................................................................................5

3 Specifications......................................................................................................................................... 6

Suspension Travel .................................................................................................................................................6

Front Spring details ...............................................................................................................................................6

Front Strut Details..................................................................................................................................................6

Suspension Height Specifications........................................................................................................................7

Techline

Front Suspension Page 3–2

Page 3–2

1 General Information

With the following exceptions, MY 2004 VY and V2 Series front suspension information carries over from MY 2003 VY

Series vehicles. For information not contained within this Section, refer to Section 3, Front Suspension in the MY 2003

VY and V2 Series Service Information.

• The front spring on right-hand drive Domestic Level 3 vehicles has been revised.

• Front suspension strut brace fitted.

A front suspension strut brace is attached to the front suspension towers and provides additional torsional stiffness to the

body structure. Refer to Section 1A1 Body for further information.

Front Suspension Page 3–3

Page 3–3

2 Service Operations

2.1 Suspension Height Check

The suspension height specification determines the vehicle ride height. Incorrect suspension height can cause:

• Bottoming out over bumps

• Damage to the suspension components

• Symptoms similar to those produced when there is a problem with the wheel alignment.

NOTE

Measure the suspension height when diagnosing

suspension complaints and before measuring the

wheel alignment.

NOTE

Good judgement must be exercised before

replacing a spring or springs. Even if a vehicle's

suspension height should prove to be slightly

outside the specifications, the vehicle could well

be in a serviceable condition. Spring replacement

under conditions of excessive weight due to non-

standard fittings such as LPG etc. will assist very

little in restoring the vehicle to its specified height.

Preliminary Inspection

Before carrying out the suspension height inspection procedure, check that the:

• Tyre pressures are within specifications.

• Fuel tank is full – add additional weight in order to simulate a full fuel tank if necessary.

• Rear compartment is empty except for the spare wheel and the weight simulating a full fuel tank, if required.

• Vehicle is on a level surface.

• Hood, all doors and rear compartment lid are closed.

• Vehicle is not damaged from a collision.

NOTE

On average, all MY 2004 VY and V2 Series right-

hand drive vehicles will sit approximately 4 mm

lower at the right hand side front, because of the

vehicle's battery weight.

Front Suspension Page 3–4

Page 3–4

Front Suspension Height Check

1 Using a steel rule or tape measure, measure the

vertical distance (1) from the lower edge of the front

fender (2) to the centre of the wheel rim (3).

2 Compare this measurement to the front suspension

height specification, refer to 3 Specifications.

NOTE

The specification provided is for a standard

vehicle with base equipment only.

Figure 3 – 1

NOTE

If difficulty is experienced in determining the

centre of the wheel rim, perform the following:

a. Measure the diameter (1) of the wheel rim.

b. Divide the wheel rim diameter by two to get the

wheel rim radius (2).

c. Add the wheel rim radius measurement to the

front suspension height specification.

d. Measure the vertical distance (3) from the lower

edge of the front fender to the bottom edge of

the wheel rim. Compare this to the measurement

calculated previously in Step c.

Figure 3 – 2

3 If the measurement is not within the specification, replace the front springs. Refer to Section 3, 3.7 Front Spring in

the MY 2003 VY and V2 Series Service Information.

Rear Suspension Height Check

1 Using a steel rule or tape measure, measure the

vertical distance (1) from the lower edge of the rear

fender (2) to the centre of the wheel rim (3).

2 Compare this measurement to the rear suspension

height specification, refer to 3 Specific atio ns.

NOTE

The specification provided is for a standard

vehicle with base equipment only.

Figure 3 – 3

Front Suspension Page 3–5

Page 3–5

NOTE

If difficulty is experienced in determining the

centre of the wheel rim, perform the following:

a. Measure the diameter (1) of the wheel rim.

b. Divide the wheel rim diameter by two to get the

wheel rim radius (2).

c. Add the wheel rim radius measurement to the

rear suspension hei ght spe cif i cati on.

d. Measure the vertical distance (3) from the lower

edge of the rear fender to the bottom edge of the

wheel rim. Compare this to the measurement

calculated previously in Step c.

Figure 3 – 4

3 If the measurement is not within the specification, replace the rear springs. Refer to Section 4A, 2.8 Rear Spring

and Insulators in the MY 2003 VY and V2 Series Service Information.

Front and Rear Suspension Height Comparison

1 When checking a vehicle's suspension height, the following tolerances must also be taken into account before any

spring is replaced. Compare the front and rear suspension height measurements between:

• Front to rear

• Side to side

Suspension Height Variation from Specifications

Front to rear ± 20 mm

Side to side ± 10 mm

Suspension height ± 5 mm

NOTE

Suspension height variation may also be due to

any one or a combination of the following:

• Spring seat location on the suspension/body.

• Incorrect springs; check spring identification

against the table shown in 3. Specifications.

• Non-standard, additional vehicle weight, such

as a tow bar and/or after-market LPG fitment.

• Any combination of the above.

Front Suspension Page 3–6

Page 3–6

3 Specifications

Suspension Travel

Suspension Configuration Compression - 2/3 Compression of

Bumper (mm) Rebound (mm)

RHD Level 3 & FE1 67 127

Front Spring details

Identification of the front spring fitted to a particular vehicle

can be achieved by cross-referencing the two digit code

provided on the production identification tag (1) with the

table below.

Figure 3 – 5

Suspension

Configuration Number of Coils Free Length

(mm) Inside Diameter

(mm) Spring Type and

Rate Production ID

Code

Level 3 & FE1 5.25 355 136 ± 1.5 Variable

24 - 31 N/mm

(3660 ± 110N @

200 mm)

Front Strut Details

Type..............................................................................................Wet strut – non-serviceable

Piston Diameter............................................................................................................. 30 mm

Identification of the front strut assembly fitted to a particular

vehicle can be achieved by cross-referencing the two digit

code provided on the production identification tag (1) with

the table below.

Figure 3 – 6

Suspension

Configuration Right-hand ID

Code Left-hand ID Code

Level 3 & FE1 MD MC

Front Suspension Page 3–7

Page 3–7

Suspension Height Specifications

Figure 3 – 7

Legend

A Front Suspension Height B Rear Suspension Height C Wheelbase

MY 2004 VY Vehicles Suspension Height (mm)

Vehicle

Description Transmission Suspension Wheelbase

(mm) Front Rear

Level 3 Manual/Automatic FE1 2788 375 373

Suspension Height Variation from Specifications

Front to rear ± 20 mm

Side to side ± 10 mm

Suspension height ± 5 mm