SECTION C - SUSPENSION
CAUTION:
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS
consists of seat belt pre-tensioners (fitted to all front seats), and a driver’s-side air
bag or a driver’s-side air bag AND a passenger’s-side air bag. Refer to CAUTIONS,
Section 12M, before performing any service operation on or around SRS
components, the steering mechanism or wiring. Failure to follow the CAUTIONS
could result in personal injury or unnecessary SRS system repairs.
PURPOSE
The purpos e of this sect ion is to provide inform ation on the front and rear suspension assem blies fitted to HSV VT
models. The information is designed to supplement the information contained in the Holden VT Series Service
Information CD-ROM, and details are given where differences occur between the HSV models and standard Holden
models. A series of instruction drawings describe the design changes and indicate specific part numbers, fitting
instructions and relevant notes for vehicle servicing.
NOTE:
If specific technical data on a HSV model is not contained in this supplement, obtain data for that model from the
Holden VT Series Service Information CD . References are made throughout this section to the Holden VT Series
Service Information CD, to assist in providing information for specific service operations.
CAUTION:
W hen hois ting (or j acking) HSV models , ensure that the lifting head of the hoist lifts on the chas sis before the arm
of the hoist contacts the side-skirt
FRONT SUSPENSION
1. GENERAL
The f r ont su spens ion as s embly fitted to all HSV VT models is bas ed on the Holden ‘Mac Phers on Str ut’ des ign. T his
basic assembly (and the rear assembly) is then modified by HSV to provide a suspension system more suited to the
requirements of the owner and the HSV vehicle. That is, Performance and Sport suspension systems are fitted to
sport and perf ormanc e type vehicles, and Luxury or Boulevard suspension s ystems satisfy the requirem ents of the
luxury sedans. A summary of these suspension systems and their Standard (S) and Optional (O) applications is
contained in the following paragraphs:
TABLE-1 - HSV SUSPENSION SYSTEMS
MODEL SPORT PERFORMANCE LUXURY VS
BOULEVARD
SENATOR SEDAN O S
SENATOR ESTATE O S
GTS S
CLUBSPORT S O
MANTA S O
GRANGE S
MALOO S
2. FRONT SUSPENSION COMPONENTS
The following components are fitted to front suspension assemblies as indicated:
SPORT SUSPENSION
03C-970301 Spring - Frt Susp (Sports)
03F-970301 Strut Asm - Front - RH
03F-970302 Strut Asm - Front - LH
03G-970301 Bar - Front Stabiliser
03G-133502 Insulator - Stabiliser Bar
LUXURY SUSPENSION
03C-970301 Spring - Frt Susp(Luxury)
03F-970803 Strut Asm - Frt Susp - RH (Luxury)
03F-970804 Strut Asm - Frt Susp - LH (Luxury)
03G-970801 Bar Front Stabiliser
03G-133502 Insulator - Stabiliser Bar
PERFORMANCE SUSPENSION
03C-970701 Spring Frt Susp (Perform)
03F-970701 Strut Asm Frt RH (Perform)
03F-970702 Strut Asm Frt LH (Perform)
03G-970701 Bar Front Stabiliser
03G-133502 Insulator Stabiliser Bar
BOULEVARD SUSPENSION
03C-671902 Spring - Font Suspension
03F-741903 Strut Asm Frt RH
03F-741904 Strut Asm Frt LH
03G-728001 Bar - Front Stabiliser
03G-191902 Insulator - Stabiliser Bar
3. SERVICE OPERATIONS
Service front suspension assemblies fitted to HSV models in accordance with the relevant sections in the Holden
VT Series Service Information CD, refer Section 3 - FRONT SUSPENSION. Additional service requirements for
specific HSV suspension assemblies are detailed in succeeding paragraphs.
CAUTION:
SAFETY AND CAUTIONARY NOTE FOR VEHICLES EQUIPPED WITH ABS
Whenever any component that forms a part of the ABS is disturbed, it is vital that the complete ABS system is
checked. Refer to the Holden VT Series Service Information CD Section 12L ABS & ABS/ETC for details
The tyre life of high performance low-profile tyres fitted to HSV VT vehicles is very sensitive to the toe-in setting of
the front suspension. It is crucial therefore, that care is taken to set the toe-in accurately to the correct specification.
The front wheel alignment specification for HSV VT vehicles is:
VT VS
Toe-in Degrees Total 0°20' ± 0°10' 0°40' ± 0°10'
Degrees Per Wheel 0°10' ± 0°5' 0°20' ± 0°05'
Camber -0°48' ± 0°30' -0°25' ± 0°05'
Caster 7°45' ± 1°15' 4°45' ± 1°15
The toe-in specification is deliberately quoted as an angle because wherever possible toe-in should be
measured in degrees.
If toe-in is to be measured in millimetres refer to Holden Service Bulletins April 1992 and November 1993 to
ensure accurate results (4mm ± 1mm). A summary of the November 93 Bulletin follows.
Techline
WHEEL ALIGNMENT MACHINE CALIBRATION
(From Holden Service Bulletin November 1993)
Investigation of front wheel alignment complaints has revealed a number of dealers with alignment machines
incorrectly calibrated for the vehicle/s being checked. This situation arises because of two basic conventions for
measuring toe-in;
Measured across a 14"rim as if tyre is not fitted, and
Measured across 28" tyre. In reality, few modern tyres have a 28"outside diameter, but this standard was
developed when larger tyres were used.
The 28"s tandard is a c arr yover from the days when toe-in was measur ed by jack ing the f r ont wheels of f the gr ound,
spinning them , and scribing a r eference line on eac h tread. After s ettling the vehicle down, the toe-in could then be
measured directly from the tyres with a ‘trammel bar’. However, some manufacturers specify toe-in as if the
tram mel bar was placed at the wheel rim diameter , nominally 14" Setting toe-in using the wrong c onvention for the
wheel alignment machine will cause the actual toe-in to be either TWICE or HALF as much as the specification.
IF IN DOUBT , SET TOE- IN USING DEGREES, AS THE ANGLE IS UNAFFECTED BY THE DIAMETER OF T HE
WHEELS USED.
HOW TO CHECK YOUR MACHINE
Check with the m anufacturer of your equipment if unsure of which s tandard your mac hine uses to display toe-in. If
unable to establish this, or if your machine appears to be inaccurate, check the machine as follows:
Fit properly inflated 15"wheels and tyres to the f ront of a VP or VR Com m odore. J ack the car, spin the wheels
and scribe a line at the m iddle of each tyre Set the vehicle on the alignment m achine and set toe-in to 10mm
(5mm per wheel).
Measure toe-in at rear of tyres and then at front of tyres with a ‘tramm el bar’. If the front distance is less than
the rear distance, you are measuring the toe-in correctly. Compare the measured toe-in to the following table to
assess your machines calibration.
MEASURED TOE-IN RESULT
7 to 11 mm Machine reads @28"
16 to 22 mm Machine reads @ 14"
OTHER CALIBRATE MACHINE
NOTE: The above figures are correct for a 205/65/15 tyre, being a 25"diameter.
2. REAR SUSPENSION COMPONENTS
The following components are fitted to rear suspension assemblies as indicated:
SPORT SUSPENSION
04E-970701 Spring - RR Susp (Sport)
04E-970301 Shock Abs - RR (Sport)
04F-970301 Bar - RR Stabiliser (Sport)
04F-251902 Insulator - Rear Stabiliser Bar
LUXURY SUSPENSION
04B-970801 Spring - RR Susp (Sedan)
04B-970201 Spring RR Susp (Estate)
04E-970801 Shock Abs - RR (Luxury Sedan)
04E-971001 Shock ABS-RR (Estate)
04F-251902 Insulator - Rear Stabiliser Bar
04F-971001 Bar RR Stabiliser
PERFORMANCE SUSPENSION
04B-970801 Spring RR Susp (Sport )
04E-970701 Shock ABS-RR (Perform)
04F-970701 Bar-RR Stabiliser(Perform)
04F-251902 Insulator Rear Stabiliser bar
04E-970702 Shock ABS RR (Perform, Lvl ride)
BOULEVARD SUSPENSION
04B-251908 Spring Rear Suspension
04E-711901 Shock Absorber - Rear Suspension (Lvl ride)
04F-401901 Bar - Rear Stabiliser
04F-401902 Insulator - Rear Suspension
2.1 REAR SUSPENSION – LUXURY (INCORPORATING AUTOMATIC LEVEL RIDE)
2.1.1 GENERAL DESCRIPTION
The "Luxury" rear suspension system fitted to HSV VT models consists of HSV gas shock absorbers incorporating
Monroe Sensatrac, rear springs, and an Automatic Level Ride System. Automatic Level Ride is an electronically
controlled self levelling system that maintains the vehicle at a constant trim height, independent of load. This feature
uses a specifically designed electronic sensor, fixed to the rear crossmember on the right hand side (see Figure C-1
below), which controls an electric motor driving a single cylinder air compressor, and an exhaust air solenoid valve.
The compressor supplies the necessary pressure to operate the Air Shock Absorbers via "snap on" air lines. The
Air Shock Absorbers assist the rear springs in supporting the vehicle body under all loads.
The sensor has an integrated electronic controller that is programmed to adjust ride height only when necessary,
ignoring sudden changes, as experienced on bumpy roads. The design of the system maintains trim at all times
provided the battery is connected. As a safeguard to prevent the battery being flattened, an electronic timer
switches off the compressor if it runs for a prolonged period (i.e. due to an air leak in the system).
The compressor assembly includes a maximum pressure release valve and an air drier. All air entering or
exhausting the system flows through the dryer, which has an internal minimum pressure retention valve preventing
the Air Bag, surrounding each Shock Absorber, from completely exhausting independent of the sensor controlled
exhaust valve.
A number of benefits result from the level ride feature. These include headlamp aim and rear view mirror
adjustment being maintained independent of load, as well as ensuring the rear wheel camber and toe-in are held at
the optimum positions to minimise tyre wear. An additional major benefit is obtained from supplementary design
changes that can be made to spring and damper rates for improved ride quality at all loading conditions with
minimum compromise to handling. These changes are possible since the suspension does not have to be
sufficiently stiff to absorb road impacts, while supporting maximum vehicle load.
Minor variations exist between the VT and VS Level Ride System, and these differences relate mainly to electrical
wiring, and the positioning and mounting of hardware. Operating principles and Service Operations are the same
except where advised in the following paragraphs.
Electrical power to operate the Level Ride system is supplied by a separate harness except the Senator Signature
model which uses the main integrated wiring harness and a short ‘patch harness.’
Figure C-1 - HSV Level Ride - Height Sensor
2.1.2 SYSTEM OPERATION
Activation
The sensor's actuating arm is attached to the lower control arm via a connecting link (See Figure C-1). Before any
activation can occur the actuating arm must remain in either the intake or exhaust zone for a continuous 17 to 20
seconds.
The time delay prevents the compressor or exhaust valve from activating when the vehicle encounters sudden
bumps. Another stability feature is a designed "Deadband". The Deadband helps to minimise hunting by
deactivating the compressor and solenoid when the vehicle trims into or onto one of the Deadband edges. Refer to
Figure C-2 for details on rear suspension trim heights and Deadband.
Loaded Vehicle
When the vehicle is loaded, the vehicle body moves downward into the intake zone, causing the actuating arm to
move upwards. After 17 to 20 seconds, the sensor relieves compressor head pressure by briefly activating the
compressor relay. The compressor starts and pressurises the air shock absorbers until the vehicle body aligns with
the bottom edge of the Deadband, at which point the compressor stops.
Unloaded Vehicle
When the vehicle is unloaded, the vehicle body moves upward into the exhaust zone, causing the actuating arm to
move downwards. After 17 to 20 seconds, the sensor activates the exhaust relay. The exhaust solenoid activates
and vents pressure from the air shock absorbers until the vehicle body aligns with the top edge of the Deadband, at
which point the solenoid deactivates.
Deactivation
The compressor and exhaust solenoid operations are monitored and controlled by individual but interconnected
timers. The timers deactivate specific trimming operations under the following conditions:
a. If the compressor runs for a cumulative time of more than four-and-a-half minutes, the compressor timer
deactivates all system operations.
b. If the exhaust solenoid is active for a cumulative time of more than four-and-a-half minutes, the solenoid timer
deactivates the solenoid.
NOTE:
The sensor timers must be reset before any further operation can take place. The VT system is reset after each
ignition cycle ON, OFF for one minute, ON. The Boulevard system is reset by using one of the following methods:
Momentarily run engine,
Remove fuse 4 and replace after 1 minute (fuse located in passenger fuse compartment), or
Disconnect Sensor harness connector and replace after 1 minute.
2.1.3 MAINTENANCE
Service
CAUTION:
DO NOT LOWER CAR WITH EMPTY AIR BAGS AS DAMAGE MAY RESULT.
This system is designed to run with the minimum of maintenance. At ever y service the following components s hould
be checked:
a. Air Lines: Inspect lines and replace if sleeving or line is worn. Refer to AIR LINE for service instructions.
b. Harness Ties: Check harness ties and replace if broken or loose, refer to FIGURE C-1 and FIGURE C-3.
c. Compressor Mounts: Check compressor mounts and replace if broken. Check security of mounts.
d. Air Filter: Inspect and replace air filter if contaminated or at the 30,000km, 70,000km and subsequent
40,000km service intervals, whichever comes first. Follow instructions in A IR FILTER for replacement details.
NOTE:
The Air Filter is the only regular service item.
Figure C-2 - HSV Level Ride - Trim Height
CONTENTS OF LEVEL RIDE SYSTEM
VT Level Ride System
Part No Description
04E-211906 HEIGHT SENSOR-ASM
04E-970802 BRACKET HEIGHT SENSOR
70B-050001 NUT NYLOC
73A-082088 BOLT (HT SNSR BRKT TO XMBR)
70G-080002 NUTSERT
04E-970803 BRACKET BALL STUD
04E-970804 LINK HEIGHT SENSOR SED, LUX 70mm
04E-971002 LINK HEIGHT SENSOR WAG, LUX 77mm
04E-211917 COMPRESSOR
04E-970805 BRACKET COMP TO BODY
73A-053088 BOLT (COMPRESSOR TO BRKT)
72H-970801 BOLT (COMP BRKT TO BODY)
04E-211913 T PIECE
04E-211914 AIR FILTER
75C-180501 CABLE TIE
04E-970806 AIRLINE ASM-COMP TO SHOCK ABSORBER
12H2970801 LEVEL RIDE PATCH HARNESS
Boulevard System
Part No Description
04E-211906 HEIGHT SENSOR ASM
04E-211907 MOUNTS - COMPRESSOR ISOLATION BRACKETTO BODY MOUNTING BRACKET
04E-211908 BRACKET - HEIGHT SENSOR
04E-211910 BALL PIVOT - LINK
04E-211911 MODULE ASM - RELAY
04E-211913 T-PIECE
04E-211914 FILTER - AIR COMPRESSOR
04E-211916 LINK - HEIGHT SENSOR
04E-211925 COMPRESSOR ASM
04E-211918 BRACKET - COMPRESSOR ISOLATION
04E-211921 AIR LINE ASM - LHS
04E-211922 AIR LINE ASM - RHS
04E-251901 BRACKET - BODY MOUNTING
12H-251903 FUSE (10 AMP)
12H3711901 HARNESS LEVEL RIDE (FRONT)
12H-261902 HARNESS LEVEL RIDE (REAR)
12H4251901 CLIP
70B-050001 NUT - NYLOC
70B-060001 NUT - NYLOC
70G-060001 NUTSERT
70G-080002 NUTSERT
71A-060201 WASHER - FLAT
72H-061601 SCREW - HEX HEAD
73A-053088 BOLT - COMPRESSOR TO ISOLATION BRACKET
73A-082088 BOLT - HEIGHT SENSOR BRACKET
75C-750201 CABLE TIE
75C-180501 CABLE TIE
75F-211901 CLIP - RETAIN MOUNTS TO BRACKETS
2.1.4 COMPRESSOR ASSEMBLY SERVICE
The com press or assem bly is located above the left hand r ear axle shaf t and below the floor pan. The VT system is
secured to a compres s or brac k et which then mounts to the c hass is s ubf r ame, whereas the VS s ystem is s ecur ed to
an intermediate isolation bracket and a body mounting bracket . The general arrangement for the VS and the VT
Compressor Assembly is shown in Figure C-3.
REMOVE
Although the VS compressor assembly is connected to a compressor isolation bracket, the complete assembly
must be removed from the vehicle body by following the instructions given below.
a. Disconnect the battery earth lead and the compressor harness from assembly.
b. Disconnect "snap on" air lines from compressor assem bly by rotating each air line clip 90 degrees and gently
pulling fitting from "Tee" piece, refer Figure C-3. For air line service refer AIR LINE.
c. For VS, remove the six retaining clips (75F-211901) from both body mounting bracket and compressor
isolation bracket posts. Refer to Figure C-3. Remove the compressor (complete with isolation bracket)
assembly by removing the mounts (04E-211907) from posts.
d. For VT, remove the air filter, remove the three screws securing the compressor to the compressor mounting
bracket and remove compressor assembly.
NOTE:
After the VS compressor assembly and isolation bracket are removed from the vehicle, the unit can be removed
from the compressor isolation bracket by removing three bolts and the air filter as shown in Figure C-3.
INSTALLATION
The VS c ompr essor as sem bly MUST be pr e-assem bled to the com pres sor isolation brac ket as illus trated in F igure
C-3 before continuing with reverse procedure documented above.
NOTE:
Due to the confined s pace, sec ure a m ount to the body mounting brack et at loc ation "A" Figure C-3 with a retaining
clip, before proceeding with installation.
Figure C-3 - HSV Level Ride - Compressor Mounting
2.1.5 AIR LINE AND AIR FILTER – SERVICE
AIR LINE
Removal
Disconnect snap-on air lines by rotating each clip 90° and gently pulling the line free. Cut or unclip air line ties.
Installation
Reverse the above procedure taking c are not to kink lines when installing to s hock abs orber . Ensur e air lines do not
contact sheetmetal raw edges.
NOTE:
ENSURE THAT AIR LINE TIES ARE CORRECTLY POSITIONED AND THAT AIR LINES ARE SECURE.
AIR FILTER – SERVICE
Removal
Remove compressor assembly as per instructions Section 2.1.4 - Compressor Assembly Service. Unclip filter
from compressor isolation bracket and twist free from air hose.
Installation
Secure new filter to bracket and connect hose. Refer Figure C-3 for correct filter location.
2.1.6 SHOCK ABSORBER – SERVICE
The shock absor bers ar e ser viced as per the standar d Holden rear s hock absor ber s. Ref er to the Holden VT Series
Service Information CD, refer Section 4A - REAR SUSPENSION.
CAUTION:
DO NOT LOWER CAR WITH EMPTY AIR BAGS AS DAMAGE MAY RESULT. WHENEVER THE SYSTEM IS
UNPRESSURISED OR WHEN THE VEHICLE REAR SITS OBVIOUSLY HIGH AFTER LOWERING FROM AN
ON-HOIST OPERATION (SUGGESTING SHOCK ABSORBER AIR BAGS MAY BE PINCHED OR JAMMED),
IMMEDIATELY RAISE VEHICLE, DISCONNECT SENSOR CONNECTING LINK, PUSH SENSOR ARM ABOVE
HORIZONTAL FOR 17 TO 20 SECONDS, AND RUN COMPRESSOR FOR ABOUT 30 SECONDS TO INFLATE
SHOCK ABSORBERS. RECONNECT SENSOR CONNECTING LINK AND LOWER VEHICLE. DRIVING THE
VEHICLE WITH PINCHED OR JAMMED SHOCK ABSORBER AIR BAGS WILL IRREPAIRABLY DAMAGE THE
SHOCK ABSORBER
2.1.7 HEIGHT SENSOR SERVICE
The height sensor assembly is bolted to the rear crossmember on the right hand side as illustrated in Figure C-1.
The sensor bracket specification is critical and essential that the bracket is not bent or distorted. Read the
installation procedure carefully before fixing the bracket to the crossmember.
REMOVAL
a. Unclip or cut cable ties as appropriate which support sensor harness to the height sensor bracket. Separate
the harness from the sensor gently squeezing and pulling away the connector retainer. Refer Figure C-1
b. Remove height sensor link by unclipping link end cover and gently prying from sensor arm. Refer Figure C-1
for link details.
c. Support sensor while removing sensor bracket bolt (73A-082088). Refer Figure C-1.
INSTALLATION
Before proceeding any further, check that the sensor bracket is within specification as detailed in
Section 2.1.10 LEVEL RIDE SPECIFICATIONS. Reverse the above procedure, taking care not to bend or distort
the bracket. Ensure link clip is refastened otherwise,system failure may occur.
2.1.8 RELAY CONTROL MODULE – SERVICE
The VS relay control module is located behind the luggage compartment trim on the right side of the rear seat
panel, VT relays are incorporated in the Relay Box in the driver’s-side lower dash panel
REMOVAL - VS RELAY CONTROL MODULE
Pull back the trim and remove the two bolts and the module harness connector to isolate the relay control module.
INSTALLATION - VS RELAY CONTROL MODULE
Reverse the above proc edure, but ensur e the earth connection is fir m ly fixed between the module and nuts ert f itted
to the body.
2.1.9 DIAGNOSTICS
GENERAL
The following procedures are guides that can help to determine the probable cause of an Automatic Levelling
System problem.
It is important that the reader is familiar with Section 2.1.2, System Operation, in order to accurately identify the
problem.
TEST EQUIPMENT REQUIRED
1. DC Voltmeter and Ohmmeter(>20 megohm/ v).
2. Jumper leads required for short circuit (cct.) tests.
2.1.10 LEVEL RIDE SPECIFICATIONS
The rear suspension height specifications are shown on Figure C-2.
To achieve this specification note the following:
1. The free length of the rear spring is as follows:
For VT - 277mm (04B-970801)
For VT Level Ride - 275 mm (P/N 04B-970201)
2. The vehicle must be at kerb weight, see Figure C-2.
3. The internal angle of the Height Sensor Bracket is 80 degrees.
2.2 REAR SUSPENSION – MARLOO 185i UTILITY
The load carrying capacity of the Maloo has been increased by the addition of HSV modifications to the rear
suspension of the vehicle. The actual payload specification is limited by the tyre load capacity and the need to limit
the maximum rear axle load to 1120 kg. A spacer is also fitted to the right hand rear suspension to compensate for
the weight of the fuel tank (and fuel) which is located to the right hand side of the vehicle.
Components used to modify the rear suspension are as follows:
04B-208001 SPRING - REAR SUSPENSION
04B-208003 SPACER - SPRING SEAT - RH
04E-970501 SHOCK ABSORBER
04D-208001 ROD ASM - PANHARD
05E-738001 ADAPTOR - RR BIAS VALVE
70A-060001 NUT - HEX (M6)
70B-060001 NUT - NYLOCK (M6)
NOTE:
To ensure correct ride height and ride quality, the spacer plate must be fitted to the right hand rear of the vehicle as
shown in Figure C-5.
Figure C-5
3. SERVICE OPERATIONS
Service operations and service intervals for HSV Rear Suspension assemblies are the same as those detailed in
the Holden VT Series Service Information CD, refer SECTION 4A - REAR SUSPENSION except when detailed
otherwise in this supplement.
The Height Sensor Link part number and length for each Level Ride application is as follows:
04E-970809 (VT SEDAN -- 70mm)
04E-971002 (VT ESTATE -- 77mm)
For rear wheel alignment specification, refer to the Holden VT Series Service Information CD, refer
Section 4A - REAR SUSPENSION. For trim height specifications refer to Figure C-2.
VS wiring connections are shown in Figure C-4. Wiring connections for the VT system are shown in the Holden
Service Manual Supplement.
Figure C-4 - Wiring And Connector End Points
4. DIAGNOSTICS
The following procedures are guides that can help determine the cause of problems with the level ride system. It is
important that the user of these procedures has a working knowledge of the level ride system.
PRELIMINARY DIAGNOSTIC PROCEDURE
Step Action Value Yes No
1. Does vehicle trim? Go to Step 2 Go to Step 3
2. Does vehicle trim to correct height? Refer to Figure
C-2
SPECIFCATIONS
System OK Check all rear
suspension
components for wear
and damage, paying
particular attention to
the height sensor
mounting and
bracket
3. Does vehicle lower after specified
time when vehicle is unloaded? 20 seconds Go to Step 4 Go to Chart, 4.3
COMPRESSOR
ASM TEST
(SOLENOID TEST)
4. Does vehicle rise after specified time
when vehicle is loaded? 20 seconds System OK Go to chart 4.4
COMPRESSOR
ASM TEST (MOTOR
TEST)
COMPRESSOR ASSEMBLY TEST (SOLENOID TEST)
Step Action Value Yes No
1. • Has a system reset been carried out by
cycling ignition, refer 2.1.9
DIAGNOSTICS in this Section?
Go to Step 2 Carry out system reset
and re-check system
2. • Is fuse 28 OK (30 amp fuse .) ?
• Is fuse 4 OK ( 10 amp fuse in fuse
panel) ?
• Is fuse 17 OK (10 amp fuse in fuse
panel) ?
Go to Step 3 Replace blown fuse/s,
check wiring for cause
of fuse/s blowing and
re-check system
3. • Disconnect the wiring harness at the
level ride sensor
• Turn ignition ON
• Short circuit pin 2 (white wire) to pin 4
(Black wire) in the level ride sensor
connector (connector YR47)
• Listen for clicking of the solenoid valve
and the air escaping from the system, or
check for voltage between pin A & C at
the compressor harness connector
(connector YR46).
• Is there a clicking sound from solenoid
valve, escaping air from the system or
voltage at the compressor harness
connector between pin A
(Orange/Black) wire & C (white wire)?
Compressor asm
solenoid OK,
proceed to Chart 4.5
HEIGHT SENSOR
TEST (SOLENOID
OPERATION) in this
Section
Go to Step 4
4. • Check system wiring for continuity
• Is wiring OK?
Replace compressor
assembly refer 2.1.4
COMPRESSOR
Assembly -Service
Test system with other
harnesses- replace as
necessary.
COMPRESSOR ASSEMBLY TEST (COMPRESSOR MOTOR TEST)
Step Action Value Yes No
1. • Has a system reset been carried out by
cycling ignition, refer 2.1.2 -
Deactivation Note in this Section?
Go to Step 2 Carry out system
reset and re-check
system
2. • Is fuse 28 OK (30 amp fuse.) ?
• Is fuse 4 OK ( 10 amp fuse in fuse
panel) ?
• Is fuse 17 OK (10 amp fuse in fuse
panel) ?
Go to Step 3 Replace blown
fuse/s, check wiring
for cause of fuse/s
blowing and re-check
system
3. • Disconnect the wiring harness at the
level ride sensor
• Turn ignition ON
• Short circuit pin 3 (yellow wire) to pin 4
(Black wire) in the level ride sensor
connector (connector YR47)
• Listen for compressor motor running,
or check for voltage between pin B
(Green wire) & D (Black wire) at the
compressor harness connector
(connector YR46).
• Does the compressor motor run or is
there a voltage at the compressor
harness connector between pin B & D?
Compressor motor
OK, proceed to
Chart 4.6 HEIGHT
SENSOR TEST
COMPRESSOR
OPERATION in this
Section
Go to Step 4
4. • Check system wiring for continuity
• Is wiring OK?
Replace
compressor
assembly refer
Compressor
Assembly - Service
Replace patch
harness and re-
check system
HEIGHT SENSOR TEST (SOLENOID OPERATION)
Step Action Value Yes No
1. • Has a system reset been carried out by
cycling ignition, refer 2.1.2. -
Deactivation?
Go to Step 2 Carry out system
reset and re-check
system
2. • Disconnect height sensor link, refer
2.1.7 Height Sensor- Service, in this
Section
• Turn ignition ON
• Lower height sensor arm 45° and wait
20 seconds
• Listen for clicking of the solenoid valve
and the air escaping from the system,
or check for voltage between pin A
(White wire) & C (Orange/Black wire)
at the compressor harness connector
(connector YR46)
• Is there a clicking sound from solenoid
valve, escaping air from the system or
voltage at the compressor harness
connector between pin A & C?
12 volts
System OK.
(re-check system
for correct
operation if
necessary)
Go to Step 3
3. • Check system wiring for continuity
• Is wiring OK?
Replace height
sensor assembly
refer 2.1.7 HEIGHT
SENSOR- Service,
in this Section and
re-check system
Replace patch
harness and re-
check system
HEIGHT SENSOR TEST (COMPRESSOR OPERATION)
Step Action Value Yes No
1. • Has a system reset been carried out by
cycling ignition, refer 2.1.2. -
Deactivation - Note in this section?
Go to Step 2 Carry out system
reset and recheck
system
2. • Disconnect height sensor link, refer
2.1.7 HEIGHT SENSOR- Service, in
this Section
• Turn ignition ON
• Raise height sensor arm 45° and wait
20 seconds
• Listen for compressor motor running of
check for voltage between pin B
(Green wire) & D (Black wire) at the
compressor harness connector
(connector YR46)
• Does the compressor motor run or is
there a voltage at the compressor
harness connector between pin B & D?
12 volts Go to Step 3 Go to Step 5
3• The compressor motor may be
operating but the compressor may
have failed
• Run the motor for two minutes and
check the shock absorber air bags are
being pressurised
• Are air bags being pressurised?
System OK (re-
check system for
correct operation if
necessary)
Go to Step 4
4. • •Check air compressor filter for
blockage, refer 2.1.5. - Air Filter, in this
Section
• •Is filter OK?
Replace
compressor
assembly and re-
check system
Replace filter and re-
check system
5. • Check system wiring for continuity.
• Is wiring OK?
Replace height
sensor assembly
refer 2.1.7 HEIGHT
SENSOR, in this
Section and re-
check system
Replace harness and
re-check system
REAR AXLE
1. GENERAL
HSV VT Senator 220i and G TS m odels are equipped with a spec ifically designed Hydratrak (Viscous coupling type
limited slip) differential.
Manual transmission vehicles final drive ratio is 3.46:1 and the differential (Part No. 04A1711902) can be
identified by Broadcast Code BL.
Automatic transmission vehicles final drive ratio is 3.07:1 and the differential (Part No. 04A1711901) can be
identified by Broadcast Code BK.
2. SERVICE OPERATIONS
The differential oil must be changed at 1500 km and then at 45,000 km intervals. Use synthetic hypoid gear oil to
HN2040 such as 'Mobilube SHC 80W-140 ID'.
The viscous coupling cartridge assembly is a sealed unit and must be replaced as a complete assembly if required.
General service operations are the same as those described in the Holden VT Series Service Information CD, refer
SECTION 4B - FINAL DRIVE AND DRIVE SHAFTS, however, to determine if the Hydratrak coupling cartridge is
faulty, undertake the following torque check. The Hydratrak rear axle assembly is covered by the current Axle
Warranty Changeover agreement between GMHAL and Spicer Axle Australia (refer GMHA Dealer Bulletins).
TORQUE CHECK
i. Place transmission in neutral with engine turned 'OFF'.
ii. Jack up one rear wheel, then release park brake lever to fully 'OFF' position. Support vehicle body on a safety
stand.
iii. Remove centre cap (alloy wheels).
iv. Mark relationship of road wheel to axle flange. Remove road wheel attaching nuts and remove wheel.
v. Remove caliper attaching bolts and remove caliper from mounting, refer Section 5 BRAKES in the Holden VT
Series Service Information CD. Support caliper on a wire hook. Remove brake disc.
CAUTION:
DO NOT ALLOW CALIPER TO HANG BY BRAKE HOSE.
vi. Using a torque wrench in conjunction with adaptor, Tool No. 4A48, and torque wrench adaptor E6662B, rotate
axle shaft in forward direction. If the unit is operating satisfactorily, a torque reading of 35 Nm should be
obtained whilst turning the axle shaft at 20 rpm (e.g. one third of a turn per second).
If a torque reading of less than 25 Nm or more than 80 Nm (@ 20 rpm) is obtained, remove differential case
and inspect the differential components and repair or replace as necessary.
However, if the Hydratrak Coupling cartridge unit is faulty it will require replacement with a new Coupling unit,
as it is a sealed, non-serviceable fluid filled component.
CAUTION:
DO NOT ATTEMPT TO REPAIR OR WELD THE COUPLING UNIT.
vii. Install brake disc and caliper. Tighten caliper attaching bolts to the correct torque specification.
CALIPER ATTACHING BOLT
TORQUE SPECIFICATION 55 - 70
Nm
viii. Install road wheel.
NOTE:
When installing the wheel, align the marks made prior to removal.
ix. Remove safety stand and lower vehicle.
x. Tighten road wheel attaching nuts to the correct torque specification.
ROAD WHEEL ATTACHING NUT
TORQUE SPECIFICATION 110-140
Nm
xi. Refit wheel cover/centre cap.
LIMITED SLI P DI FFERENTIAL
PRECAUTIONS
CAUTION:
When servicing a vehic le fitted with a Limited Slip Dif f erential (including Hydratrack type), never r un the engine with
the transm ission in gear and one wheel raised. T he driving forc e to the wheel on the ground may cause the vehicle
to move.
NOTE:
'On Car' type wheel balancers are not recommended for use on the rear wheels of cars equipped with a Limited Slip
Differential. One rear wheel will drive if in contact with the ground when the opposite wheel is raised. This type of
balancer may be used by removing the wheel opposite to the one being balanced with the vehicle raised and
supported on safety stands. (Refit wheel nuts, reversed, to retain brake disc).
PROPELLER SHAFT AND UNIVERSAL JOINTS
1. GENERAL
The HSV Senator 220i and GTS manual transmission models are equipped with a specifically designed two-piece
propeller shaft. The propeller shaft is of a specific length using a fine spline slip yoke and incorporating a rubber
mounted mass damper inertia ring fitted as part of the transmission slip yoke. HSV 195i models are fitted with a
standard GMHA propeller shaft and universal joints.
