SECTION 3 - FRONT SUSPENSION

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air b ags or seat belt pre- tensioners, driv er’s and front passenger’s air bag and left and right

hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M, Supplemental Restraint System of

this Service Information CD before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of safety, the LPG

fuel system should be isolated by turning ‘OFF’ the manual service valve and then draining the LPG

service lin es, b efo re any serv ice work is carried o ut on th e v ehi cle. Refer t o t he L PG leaf let in clud ed with

the Owner's Handbook for details or the appropriate Section of this Service Information CD for more

specific servicing information.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service

Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as

detailed in 4. DIAGNOSIS, ABS or ABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC (V6

Engine) or (GEN III V8 Engine) of this Service Information CD.

1. GENERAL DESCRIPTI ON

Changes to the front suspension for VT Series II

vehicles are minor and are as follows:

a. Re-introduction of V5W Country Pack

suspension to VT series Sedan and Station

Wagon vehicles.

b. Revisions to some wheel alignment angles

and changes to suspension specifications to

reflect the introduction of the GEN III V8

engine and optimise vehicle ride

characteristics.

c. Apart f rom the notes contained in this Section,

all service operations remain unchanged from

those published Section 3 FRONT

SUSPENSION of the VT Series I Information.

For identification information and specification

details for the different suspension components

available for VT Series II vehicles, refer to

4. SPECIFICATIONS in this Section.

To identify the suspension fitted to an individual

vehicle, refer to “SUSP” (1) on the Body, Option

and Identification Plate.

For the location of this plate, refer to Section 0A

GENERAL INFORMATION, of this Service

Information CD.

Figure 3-1

Techline

2. WHEEL ALIGNMENT

2.1 WHE EL ALIGNMENT CHECKING AND ADJUSTMENT

PRELIMINARY INSPECTION

Before any attempt is made to check camber,

caster or toe-in, these preliminary checks should

be carried out.

1. Check tyre and tyre mountings. Always check

camber and toe-in at the mean run-out

position on the tyre or rim.

2. Check and adjust tyre pressures to

recommended values.

3. Front wheel bearing end float is to be chec k ed

to ensure it is within specification, as detailed

in 2.4 FRONT WHEEL BEARING HUB - END

FLOAT CHECKING PROCEDURE, FRONT

SUSPENSION, of this Service Information

CD.

4. Lower control arm ball joints and inner bushes

should be checked for wear.

5. Check steering gear mounting bolts for

tightness and tie rod ball joints for wear.

6. The vehicle should be at curb weight, fuel

tank full, without driver, passengers or

luggage etc.

7. Check for improperly operating front struts or

rear shock absorbers.

8. Check for loose or missing stabiliser bar or

tension rod attachments.

9. Before checking the front wheel alignment,

refer to 4A REAR SUSPENSION of this

Service Information CD for rear wheel

alignment details.

CASTER ADJUSTMENT

Only a nominal change in caster angle is

achievable and is limited to the addition (or

deletion) of a spacer washer (1) to one of the

tension rods (2). The sole purpose of fitting this

spacer is to equalis e c ast er angle f r om side to s ide,

to within 0° 30'. Only one spacer washer is to be

fitted and is to be added to the s ide with the higher

caster reading.

Figure 3-2

CAMBER ADJUSTMENT

1. Raise front of vehicle and support on safety

stands under f ront side members. Refer to 0A

GENERAL INFORMATION of this Service

Information CD for location of jacking and

support points.

2. Remove wheel cover (steel wheels) or centre

cap (alloy wheels) and mark relationship of

wheel to hub stud, using a felt tipped pen or

similar.

3. Remove wheel attaching nuts and remove

wheel.

4. Loosen, remove and discard the two lower

strut attaching bolts and nuts (1).

Reinstall NEW lower strut attaching bolts and

nuts (1) but do not tighten fully to

specification until after the camber has been

adjusted to the recommended specification.

5. Reinstall road wheel, aligning previously made

marks. Install wheel nuts and tighten to the

correct torque specification. Do not over-

tighten!

ROAD WHEEL A T T A CHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

6 Bounce vehicle several times to settle

supsension, then check the camber angle.

7. If required, adjust camber by turning the

camber adjusting screw (2) in the required

direction. Clockwise to reduce negative

camber, anti-clockwise to reduce positive

camber.

NOTE: The camber adjusting screw has thread

sealant applied in the form of micro-encapsulation

and does not require a lock nut.

Figure 3-3

8. Raise vehicle once again, support on safety

stands and remove the front road wheels.

9. Tighten both steering knuckle bolts and nuts

to the correct torque specification.

NOTE: New bolts and nuts MUST be used!

STEERING KNUCKLE TO STRUT Stage 1 85 Nm

ATTACHING BOLTS & NUTS Stage 2 100 Nm

TORQUE SPE CI F ICATION Stage 3 Turn through 90 °

10. Reinstall road wheels, aligning the marks

made prior to removal.

11. Remove jack stands and lower vehicle.

12. Tighten road wheel attaching nuts to correct

torque specifications. Do not over-tighten!

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

13. Refit wheel cover/centre cap.

14. Check the camber angle again to ensure that

it is still within specification (refer to

Figure 3-6).

TOE ADJUSTMENT

Toe of both front wheels, is checked with the

wheels in the straight ahead position.

Adjustm ent is achieved by winding the tie rods in or

out of the tie rod ends, thus increasing or

decreasing their length and thereby altering the

toe-in setting.

1. Set steer ing gear and wheels in straight ahead

position.

2. To check if steering gear is in straight ahead

position ( on-centre) , the pinion (input) s haft (1)

should be aligned as shown.

NOTE: While the one-piece steering rack housing

is shown, the on-centre position is the same for all

steering racks.

Figure 3-4

3. Before adjusting tie rods (2), disconnect

steering gear outer bellows clips (1).

4. Loosen lock nut (3) at end of each tie rod.

5. Turn each tie rod as required, until the correct

toe is obtained.

NOTE: During toe adj ustment, ensur e that steering

wheel is held in the straight ahead position.

6. Tighten lock nuts (3), to the correct torque

specification, ensuring that tie rod ends are in

alignment with their ball studs.

TIE ROD TO TIE ROD BALL

JOINT LOCK NUT 40 – 60 Nm

TORQUE SPECIFICATION

7. Tighten outer bellows clips securely, making

sure that convolutions of the boots are not

distorted.

8. With steering gear in straight ahead position,

ensure that steering wheel is centralised. If

not, rem ove steering wheel (refer to Section 9

STEERING of this Service Information CD)

and reposition.

Figure 3-5

FRONT WHEEL ALIGNMENT AT KERB WEIGHT

Wheel Alignment Angle Specification - All

Camber -0° 12' ± 0° 18'

Caster 7° 45' ± 1° 15'

Toe-in Degrees Total 0° 10’ ± 0° 10'

Degrees per Wheel 0° 5’ ± 0° 5’

Toe-out on Turns 1° 42’ @ 20 ° turn angle ± 1°

30'

Steering Axis Inclination

Angle 12° 52’ ± 1° 30'

Included Angle 12° 40’ ± 1° 30'

SERVICE INFORMATION

• The adjusting values for camber, caster and toe-in must remain

within the tolerances specified. The difference between left and

right must not exceed the following:

CASTER............. 0° 36'

CAMBER............ 0° 48'

TOE-IN ............... 0° 10'

• The specifications listed are the nominal value, with acceptable

variance from this central point. Where possible, an attempt

should always be made to achieve the nominal settings when

changing.

• Front wheel camber alters as a function of front suspension height.

• Camber adjusting bolt: After loosening both lower strut to steering

knuc kle bolts and nuts, adjus t camber by turning the adjusting bolt

clockwise to decrease negative camber and anti-clockwise to

increase negative camber. After adjustment, both bolts and nuts

MUST be replaced with new parts and tightened to the

recommended torque setting.

• The rear wheel alignment should be checked and corrected if

necess ary (refer to Sec tion 4. REAR SUSPENSION of this Service

Information CD) before checking front wheel alignment.

Fuel Mass with Full Tank - All Models 56 kg

Figure 3-6

3. SERVICE OPERATIONS

3.1 GENERAL

IMPORTANT SERVICE REQUIREMENTS

NOTE 1: Whenever a road wheel and/or brake

disc is removed from the vehicle, the

relationship of the road wheel to the hub and

the disc to the hub MUST be marked with a felt

tipped pen or similar, in order for those parts to

be reinstalled in their original positions. This is

critical to maintain the brake disc and road

wheel runout dimension to a minimum.

NOTE 2: When reinstalling road wheels, do not

use an impact gun to tighten wheel nuts,

unless it is fitted with a torque limiter bar

(commercially available). Failure to correctly

tighten wheel nuts to the correct torque

specification and in the correct order, may

result in a distorted brake disc, that may lead to

the development of brake shudder.

ROAD WHEEL ATTACHING NUT 110 – 140

TORQUE SPECIFICATION Nm

Figure 3-7

3.2 FRONT WHEEL HUB AND STEERING KNUCKLE

The m anufacturer of the front wheel hub has changed. Coinc ident with this change is a revision to the ABS sensor

lead retension, which has also resulted in a change to the front steering knuckle.

Note that a non-ABS hub will service back to earlier ‘V’ series vehicles but the ABS version will not, unless the

revised design steering knuckle is also changed.

Apart fr om wheel stud replacem ent, ther e are no ser viceable item s in the front wheel hub assem bly. As the unit is a

‘sealed for life’ assembly, neither bearing adjustment nor lubrication maintenance is required. Should a non-

standard condition develop, then the assembly must be replaced as a complete unit.

As with the earlier design hub, this design has zero axial free play or ‘end float’ but some angular movement may

be evident when a rocking force is applied to the mounted wheel and tyre assembly. Before a hub is replaced for

an excessive free play condition, refer to the checking procedure, detailed in Operation 2.4 in 3-FRONT

SUSPENSION, of this VT Series I Service Information.

A further revision to the design of the steering knuckle has meant that the wheel hub to knuckle sealing O-ring, is

no longer required.

Techline

3.3 SUSPENSION AND TRIM HEIGHT, CHECK

The suspension and trim height dimensions for standard vehicles with base equipment only, are provided in

4. SPECIFICATIONS in this Section.

The dimensions are for a new vehicle built to standard specification and only intended as a guide when

check ing suspens ion and trim height dim ensions at norma l curb weight. Norm al curb weight is defined as a vehicle

with a full tank of fuel, all fluids at the specified levels, spare tyre included, tyre pressures as specified and no

passengers. Accumulated dirt, mileage, etc., must also be taken into consideration when checking vehicle heights.

The following procedure should be followed before checking any suspension or trim height.

1. All checks must be c arried out on a LEVEL surfac e, after the vehicle's tyre press ures have been check ed and

it has been confirmed that the vehicle has not suffered accident damage.

2. On aver age, all VT Ser ies II vehicles will sit approxim ately 4 mm lower at the right hand side fr ont, because of

the vehicle's battery weight.

3. Push vehicle up and down several times at the front bumper bar with a decreasing force and then gently

remove hands, allowing vehicle to settle on its own. Carry out vehicle front trim and suspension height check.

4. Push vehicle up and down several times at the rear bumper bar with a decreasing force and then gently

remove hands, allowing vehicle to settle on its own. Carry out vehicle rear trim and suspension height check.

As shown in the specification listing (refer to 4. SPECIFICATIONS in this Section), there are two different

dimensions that must be checked and the location for the measurements to be taken is critical to correctly

establishing a st andard vehicle condition. When check ing a vehicle's ride height, the following tolerances m ust also

be taken into account, before any spring is replaced.

RIDE HEIGHT VARIATIONS FROM SPECIFICATION

FRONT TO REAR................................ ± 20 mm

SIDE TO SIDE..................................... ± 10 mm

NORMAL SPRING SETTLING............ ± 5 mm

NOTE: Ride height variation may also be due to any one or a combination of the following:

a. Spring seat location on the suspension/body.

b. Incorrect springs; Check spring identification against the table shown in 4. SPECIFICATIONS in this Section.

c. Non-standard, additional vehicle weight, such as a tow bar and/or after-market LPG fitment.

d. Any combination of the above.

CAUTION: Good judgement must be exercised before replacing a spring or springs from a vehicle whose

height is within the limits quoted. Even should a vehicle's dimensions prove to be slightly outside these

tolerances, the vehicle could well be in a serviceable condition.

Spring replacement under conditions of excessive weight due to non standard fittings, undercoating, road

dirt, etc; will assist very little in restoring the vehicle to its specified height.

4. SPECIFICATIONS

SUSPENSION

Type MacPherson Wet Strut

Application All VT Models

Travel

Compression

(2/3compression of bumper)

Rebound

Standard and V5W

90 mm

110 mm

FE2

80 mm

120 mm

FRONT SPRING SPECIFICATIONS

MODELS Approximat

Number

COILS

Approximate

FREE

LENGTH

(mm)

INSIDE

DIAMETE

(mm)

PROD. I.D.

CODE

(Tag on

spring)

SPRING TYPE

& RATE

V6 ENGINE -SEDAN & STATION

WAGON MODELS – S T ANDARD

SUSPENSION. 6.05 444 136 ± 1.5 HN VARIABLE

19 - 23 N/mm

(3700 ± 110 N @

210 mm)

V6 ENGINE -SEDAN & STATION

WAGON MODELS - FE 2 S P O RTS

SUSPENSION. 5.25 341 136 ± 1.5 HJ VARIABLE

24 - 31 N/mm

(3660 ± 110 N @

200 mm)

V6 ENGINE - SEDAN & STATION

WAGON MODELS - V5W

COUNTRY PACK SUSPENSION 6.12 376 136 ± 1.5 HS VARIABLE

24 - 31 N/mm

(3660 ± 110 N @

230 mm)

V6 SUPERCHARGED & GEN III V8

ENGINES -SEDAN & STATION

WAGON MODELS - STANDARD

SUSPENSION.

6.05 444 136 ± 1.5 HN VARIABLE

19 - 23 N/mm

(3700 ± 110 N @

210 mm)

V6 SUPERCHARGED & GEN III V8

ENGINES -SEDAN & STATION

WAGON MODELS – FE2 S PORTS

SUSPENSION.

5.70 348 136 ± 1.5 HT VARIABLE

25 – 35 N/mm

(3825 ± 110 N @

194 mm)

Figure 3-8

LEGEND

1. Production Identification Code Tag

STABILISER BAR (FRONT)

Type ......................................................................... Decoupled

STABILISER BAR IDENTIFICATION

Diameter I.D.

MODELS mm CODE

(2) (1)

All VT Series II Models and

Suspensions, except for

Sedan with FE2 26.0 GE

Sedan Models and FE2 Suspension 27.0 GH

Figure 3-9

LEGEND

1. Production Identification Code Tag

2. Stabiliser Bar Diameter

FRONT STRUT

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

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

Fluid Type............................................................... Hydraulic fluid to Holden Specification HN 1588

Capacity............................................................. 350 ml

FRONT STRUT ID ENTIFICATION

Suspension and Application Right Hand Side Left Hand Side

STANDARD SUSPENSION –

SEDAN AND STATION WAGON RS LS

SPORTS SUSPENSION (FE2) –

SEDAN AND STATION WAGON RT LT

COUNTRY PACK SUSPENSION –

SEDAN AND STATION WAGON RU LU

CONTROL ARM

Type........................................................................ Forged with rubber bushes for attachment to front

crossmember and tension rod. Ball joint is a press fit

into the control arm.

FRONT WHEEL BEARINGS

Type........................................................................ Double row ball bearing

Lubricant................................................................. Sealed for life: non-adjustable

SUSPENSION A ND TRIM HEIGHT SPECIFICATIONS

A Front Suspension Height

B Rear Suspension Height

C Trim Height Checking Locations

1. Wheelbas e: All VT Sedan – 2798 mm

All Station Wagon – 2935 mm

2. Referenc e P oi nt

: All Models – 584.5 mm

3. Trim Hei ght Spacing:

All Sedan – 1615 mm

All Station Wagon – 1765 mm

4. Ground Line

Figure 3-10

1. Door 2. Trim 3 Ground Line ‘A’ Trim Height 1. Wheel Rim 2. Fender Opening ‘A’ Sus pension Height

Figure 3-11 – Rear Trim Height Checking Location (Front

Similar) Figure 3-12 – Front and Rear Suspension Height

Checking Location

NOTE: The following suspension/trim height dimensions are intended for reference and are intended to be a guide

only (Refer to 3.3 SUSPENSION AND TRIM HEIGHT CHECK, in this Section).

VT SERIES II MODELS WITH V6 ENGINE AND STANDARD SUSPENSION

SUSPENSION HEIGHT

(mm) TRIM HEIGHT

(mm)

VEHICLE

DESCRIPTION TRANSMISSION MODEL FRONT REAR FRONT REAR

Executive Sedan Manual Base 593 583 192 201

Berlina Sedan Automatic Base 593 583 192 201

Calais Sedan Automatic Base 593 583 192 201

Executive Station Wagon Manual Base 603 573 192 210

Berlina Station Wagon Automatic Base 598 582 192 210

5. TORQUE SPECIFICATIONS

NOTE: Only those torque specifications that relate to service operations described in this Section, are included

here. For all other torque specification relating to the steering system, refer to either Section 9A STEERING of the

VT Series I Information or Section 9A STEERING of the VT Series II Information. Nm

Steering Knuckle to Strut Attaching Bolts and Nuts Stage 1............ 85

Stage 2............ 100

Stage 3............ Turn through 90°

Road Wheel Attaching Nut................................................................ 110 - 140

Tie Rod to Tie Rod Ball Joint Lock Nut............................................. 40 – 60