SECTION 3 - FRONT SUSPENSION

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to Section

00 CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL DESCRIPTION

2. WHEEL ALIGNMENT

2.1 STEERING GEOMETRY

CASTER

CAMBER

WHEEL TOE

STEERING AXIS INCLINATION

SCRUB RADIUS

INCLUDED ANGLE

TOE-OUT ON TURNS

2.2 WHEEL ALIGNMENT CHECKING AND

ADJUSTMENT

PRELIMINARY INSPECTION

CASTER ADJUSTMENT

CAMBER ADJUSTMENT

TOE ADJUSTMENT

2.3 JACKING PRECAUTIONS

2.4 FRONT WHEEL HUB ASSEMBLY - END

FLOAT CHECKING PROCEDURE

3. SERVICE OPERATIONS

3.1 SERVICE NOTES AND CAUTIONS

3.2 SUSPENSION AND TRIM HEIGHT, CHECK

3.3 FRONT WHEEL HUB ASSEMBLY, BRAKE

ROTOR AND/OR BRAKE SHIELD

REMOVE

INSPECT

REINSTALL

3.4 FRONT WHEEL HUB STUDS

REPLACE

3.5 FRONT STRUT ASSEM BLY

REMOVE

REINSTALL

3.6 UPPER STRUT SUPPORT BEARING

AND MOUNT

REMOVE

REINSTALL

3.7 FRONT SPRING

REMOVE

REINSTALL

3.8 FRONT STRUT UNIT

REPLACE

3.9 STEERING KNUCKLE

REMOVE

REINSTALL

3.10 FRONT LOWER CONTROL ARM

REMOVE

REINSTALL

3.11 FRONT LOWER CONTROL ARM SOCKET

INSPECT

3.12 FRONT LOWER CONTROL ARM

PIVOT BUSHING

REPLACE

3.13 FRONT LOWER CONTROL ARM ROD

BUSHING

REPLACE

3.14 FRONT LOWER CONTROL ARM ROD

REMOVE

REINSTALL

3.15 FRONT LOWER CONTROL ARM ROD

INSULATING BUSHING

REPLACE

3.16 FRONT SUSPENSION CROSSMEMBER

REMOVE

REINSTALL

3.17 STABILIZER SHAFT LINK

REPLACE

3.18 STABILIZER SHAFT

REMOVE

REINSTALL

4. DIAGNOSIS

4.1 DIAGNOSIS GUIDE

5. SPECIFICATIONS

SUSPENSION TRAVEL

FRONT SPRING DETAILS

FRONT STABILIZER SHAFT DETAILS

FRONT STRUT DETAILS

FRONT LOWER CONTROL ARM DETAILS

FRONT WHEEL BEARINGS

SUSPENSION AND TRIM HEIGHT

SPECIFICATIONS

FRONT WHEEL ALIGNMENT

SPECIFICATIONS

6. TORQUE WRENCH SPECIFICATIONS

7. SPECIAL TOOLS

Techline

1. GENERAL DESCRI PTI O N

The front suspension fitted to all MY 2003 VY and V2 Series Models operates on the MacPherson strut principle.

The assembly consists of the front crossmember, front lower control arms, front lower control arm rods, stabilizer

shaft and light weight strut assemblies (Refer to Figure 3-1).

The crossmember is bolted to both longitudinal frame side members. The front crossmember to side member

attaching bolts incorporate a tapered boss near the head of the bolt to aid in f ront crossm ember to body alignm ent

during assembly while the pivots of the front lower control arms are rubber bushed and are attached to the

crossmem ber by bolts and nuts. The outer end of each front lower control arm is connected to the k nuckle on the

strut assembly through a front lower control arm socket assembly.

The strut assem bly incorporates a hydraulic wet sleeve type dam per inside the strut tube, a rubber front strut dust

shield assembly with air filter and compression rubber, a coil type suspension spring mounted between the strut

housing and upper spring seat collar, a bearing assembly and an upper strut support.

The strut assembly is located at the upper end to the body structure by an upper strut support and secured by a

self-locking nut and locating disc. The lower end of the strut tube is fastened to the steering knuckle by two bolts

and nuts.

Positioning of the front lower control arm assembly is controlled by a front lower control arm rod, which connects the

front lower control arm to the front suspension crossmember. The front lower control arm rod is mounted in a

rubber bushing at the front lower control arm end and a fluid filled insulator at the other.

A stabilizer shaf t is m ounted to the side m embers of the cros sm ember by two brackets and insulating rubbers, and

attached to eac h st rut tube by a spacer stud, ins ulator s, r etainer s and attac hing nuts . T he lower end of the s tabilizer

shaft spacer stud is connected to the stabilizer shaft with a socket stud and nut.

For identification information and specification details for the STANDARD or FE2 suspension types, refer to

5. SPECIFICATIONS in this Section.

NOTE: There are three suspension options available f or MY 2003 VY Series Models; Standard (Production Option

FE1), Sports (Production Option FE2) and Country Pack (FR1). There are also numerous configurations for each

suspension option, depending on body type and powertrain combination. For further information regarding the

identification of which suspension option is fitted to a particular vehicle, refer to 9.3 BODY AND OPTION PLATE in

Section 0A, GENERAL INFORMATION. For all other information regarding the suspension application fitted to a

particular vehicle, refer to 5. SPECIFICATIONS in this Section.

Legend for Figure 3-1

1. Nut (2 Plac es) 11. Insulator (2 Places) 19. Front Lower Control Arm Rod (2 P l aces)

2. Washer (2 Pl aces) 12. Shaft – S tabilizer 20. Washer – Cupped (2 Places)

3. Insulat or (2 Places) 13. Bolt – Front , Fl anged (2 Places) 21. Control Arm (2 Places)

4. Seat (2 Pl aces) 13a. Bolt – Rear, Plain (2 Places) 22. Washer (2 Places)

5. Insulator (2 Places) 14. Nut (8 Places) 23. Nut – Stepped (2 Places)

6. Washer (2 Pl aces) 15. Nut (2 Places) 24. Bolt (2 Places)

7. Stabilizer Shaft Stud (2 Places) 16. Insulator Bushing – Front Lower Control 25. Cover – Dust (2 Places)

8. Nut (2 Plac es) Arm Rod (2 Places ) 26. Nut (2 Places)

9. Nut (4 Plac es) 17. Washer (1 On Driver’s Side Only) 27. Loc ating Disc (2 Places)

10. Bracket (2 Places) 18. Nut (2 Plac es) 28. Front Sus pension Cross mem ber

‘A-A’ - Assemble washer ‘20’ as shown.

Stud to be hel d while nut s are torqued to s pecific ation.

Fastener must be new and ass embled dry.

Figure 3-1

2. WHEEL ALIGNMENT

IMPORTANT

All front suspension fasteners are important attaching parts as they affect the performance of vital

components and/or could result in major repair expense. Where specified in this Section, fasteners

MUST be replaced with parts of the same part number or a GM approved equivalent. Do not use

fasteners of an inferior quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all front

suspension components.

Throughout this Section, fastener torque wrench specifications may be accompanied with the following

identification marks:

+ Fasteners must be replaced after loosening.

& Vehicle must be at curb height before final tightening.

6 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock

and should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

2.1 STEERING GEOMETRY

To achieve the desired handling characteristics of a vehicle under various operating conditions, modern steering

geometry relates to both front and rear suspension systems. It m ust also be realised that the various, measurable

angles that can be checked while the vehicle is stationary, are no real indication of the changes that occur in a

dynamic situation, when the vehicle is required to have directional stability, during normal manoeuvres, such as

straight ahead driving, cornering or braking.

Even though some of the following descriptions of front wheel alignment angles are not normally measurable and

(in some instances) not adjustable, each is an inherent part of the vehicle's dynamic suspension tuning that has

been developed over an extended testing program.

CASTER

It is usual to describe this front wheel alignment

angle as the tilting of the steering axis either

forward or backward (1) from the vertical (2) when

viewed from the s ide of the vehicle. A back ward tilt

at the top steering axis point is said be positive (+)

and a forward tilt is said to be negative (-).

Measurement is usually expressed as an angle in

degrees and minutes. Figure 3-2 shows the usual

practice where the vertical and steering axis

centrelines both pass through the wheel centre (3).

This results in a caster distance (4), which can be

described as being the distance in side view,

between the point where the steering axis contacts

the ground and the centre of the tyre’s footprint

contact.

Figure 3-2

The amount of caster angle (1) will determine the

ability of the steering to retur n to the straight ahead

position after a cornering manoeuvre. Too high an

angle though, can result in an excessive steering

effort with associated ‘wheel fight' and ‘kickback'.

To optimise vehicle handling and control during

cornering and to maintain the benefits of positive

caster , MY 2003 VY or V2 Series Models have a 12

mm caster offset (2) incorporated into the

suspension design.

This is achieved by moving the wheel spindle

centreline (3) forward (in this instance, by 12 mm),

which will effectively reduce the caster distance by

that amount (Refer to Figure 3-3). This action

reduces the undesirable effects of a high caster

angle but maintains the directional stability,

increased front axle lateral grip and steering feel

that a high caster angle normally provides.

Figure 3-3

CAMBER

This angle is the tilting of the wheels from the

vertical (1) when viewed from the front of the

vehicle. When the wheels tilt outward at the top, the

camber (2) is said to be positive (+). When the

wheels tilt inward at the top, camber is said to be

negative (-). The amount of tilt is measured in

degrees from vertical and this measurement is

called the camber angle.

While unequal camber may result in unstable

steering or wander, unequal and/or excessive

camber can also cause rapid tyre wear.

Figure 3-4

WHEEL TOE

Wheel Toe (Refer to Figure 3-5), is the turning in

(or out) of the wheels when viewed from the

overhead position. The actual amount of toe is

normally only a few minutes of a degree. The

purpose of a static toe specification is to ensure

parallel rolling of the wheels, once the vehicle is in

a dynamic state.

Excess ive toe-in or toe-out m ay increase tyre wear.

With rear wheel drive vehicles, a slight amount of

toe-in, measured statically with the vehicle at rest,

is required to off-set the small deflections due to

rolling resis tanc e and brake applications which tend

to turn the wheels outward.

Figure 3-5

STEERING AXIS INCLINATION

When viewed from the vehicle front, Steering Axis

Inclination (1) can be described as being the angle

formed between the steering axis (2) and the true

vertical ( 3), where the steer ing ax is is the imaginar y

centreline through the upper strut support bearing

and the front lower control arm socket assembly,

both components being the pivot points of the strut

assembly.

The Steering Axis Inclination angle is an important

factor in determining steering effort and directional

stability of the vehicle, by assisting caster in

keeping the front wheels in a central position.

Steering Axis Inclination also provides a self-

centring effect after cornering.

Figure 3-6

SCRUB RADIUS

This term refers to the distance that two imaginary

points ar e apart, at the road surf ace (1). T hese two

imaginary points are;

a. The inters ection of the steering ax is (2) and the

road surface.

b. The centreline of the tyre (3) at the road

surface.

As road wheel offset will affect scrub radius (4), in

the interests of vehicle handling and safety, non-

standard road wheels ar e not to be fitted to any MY

2003 VY or V2 Series vehicle.

With rear wheel drive vehicles, it is usual practice

to maintain a positive scrub radius (as shown in

Figure 3-7) to make the steering more responsive

and direc t, thereby providing the driver with a more

positive sense of the tyre and road surface

interaction.

Figure 3-7

INCLUDED ANGLE

When both the Steering Axis Inclination angle (1)

and Camber angle (2) are combined, the resulting

angle is referred to as the Included Angle (3). This

information can be effectively used to determine if a

component is damaged or whether an adjustment

is responsible for an out-of-specification condition

occurring.

While Figure 3-8 shows a positive camber angle,

this has only been used to clarify the term ‘Included

Angle'.

Figure 3-8

TOE-OUT ON TURNS

During cornering operations, a vehicle's road

wheels all turn about a common turning point,

causing the outer wheels to try and turn through a

greater radius than the inner. To overcome the

tendency for wheel slip under these conditions, the

outer wheel is commonly caused to toe-out, to

compensate for this increased turning circle.

The amount of toe-out during cornering, is

governed by the angle of the steering arms, which

are an inherent part of the steering knuckle.

Figure 3-9

2.2 WHE EL ALIGNMENT CHECKING AND ADJUSTMENT

LT Section No. – 06-212

NOTE: The following fastener MUST be replaced

when performing this operation:

Steering knuckle to strut attaching nuts and

bolts.

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 checked to ensure it is within specification, as detailed in

2.4 FRONT WHEEL HUB ASSEMBLY END FLOAT CHECKING PROCEDURE in this Section.

4. Front lower control arm socket assembly and pivot bushing should be checked for wear, refer to

3.11 FRONT LOWER CONTROL ARM SOCKET ASSEMBLY in this Section.

5. Check steering gear mounting bolts for tightness and steering linkage outer tie rod sockets for wear, refer to

3.6 RIGHT-HAND DRIVE POWER STEERING GEAR or 3.7 LEFT-HAND DRIVE POWER STEERING GEAR

in Section 9, STEERING as applicable.

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 stabilizer shaft or front lower control arm rod attachments.

9. Before checking the front wheel alignment, refer to 2.12 REAR WHEEL ALIGNMENT CHECKING in Section

4A, REAR SUSPENSION for rear wheel alignment details.

CASTER ADJUSTMENT

W hile one bright f inished spaced washer (1) will be

fitted to the driver’s s ide front lower contr ol arm r od

(2), the fitment of an additional was her is permitted

to correct minor caster adjustments

NOTE: Only one additional spacer washer is to be

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

caster reading.

Figure 3-10

CAMBER ADJUSTMENT

1. Raise the front of the vehicle and support on

safety stands under the front side members.

Refer to 2.3 JACKING PRECAUTIONS in this

Section.

2. Remove the wheel cover (steel wheels) or

centre cap and decorative wheel nut caps (alloy

wheels) and mark the relationship of the wheel

to the hub stud, using a felt tipped pen or

similar.

3. Remove the wheel attaching nuts and remove

the wheel.

4. Loosen, r emove and discar d the two lower strut

attaching bolts and nuts (1).

Install NEW lower s trut attac hing bolts and nuts

but do not tighten fully to specification until

after the camber has been adjusted to the

recommended specification.

5. Install the road wheel, aligning the

previously made mark s . Tighten the road wheel

attaching nuts to correct torque specification,

working in a ‘star’ pattern. Ref er to Section 10,

WHEELS AND TYRES f or detailed inform ation

regarding the installation procedure for the road

wheels.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................110 – 140 Nm

Figure 3-11

6. Lower the vehicle to the ground and bounce several times to settle the suspension.

7. Check the camber angle.

8. If required, adjust the 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.9. Raise vehicle once again, support on safety stands and remove the front road wheels.

10. Tighten both steering knuckle bolts and nuts to the correct torque specification.

( + ) STEERING KNUCKLE TO STRUT

ATTACHING BOLTS AND NUTS

TORQUE SPECIFICATION ................ Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 Turn

through 90°

11. Install the road wheels, aligning the marks made prior to removal.

12. Remove the jack stands and lower the vehicle.

13. Tighten the road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern. Refer to

Section 10, WHEELS AND TYRES for detailed information regarding installation procedure for the road

wheels.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 - 140 Nm

14. Install the wheel cover/centre cap.

15. Check the camber angle again to ensure that it is still within specification.

TOE ADJUSTMENT

Toe of both front wheels, is checked with the

wheels in the straight ahead position.

Adjustment is achieved by winding the steering

linkage outer tie rods in or out of the steering

linkage outer tie rod sockets, thus increasing or

decreasing their length and thereby altering the toe-

in setting.

1. Set steering gear and wheels in straight ahead

position.

2. To check if steering gear is in straight ahead

position (on-centre), the pinion (input) shaft (1)

should be aligned as shown.

NOTE: While the one-piece steering rack housing

is shown in Figure 3-12, the on-centre position is

the same for all steering racks.

Figure 3-12

3. Before adjusting the steering linkage outer tie

rods (1), disconnect the steering gear outer

boot clips (2).

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

steering linkage outer tie rod.

5. Turn each steering linkage outer tie rod as

required, until the correct toe is obtained.

NOTE: During the toe adjustment, ensure that the

steering wheel is held in the straight ahead

position.

6. Tighten the lock nuts to the correct torque

specification, ensuring that the steering linkage

outer tie rod soc kets are in alignm ent with their

ball studs.

STEERING LINKAGE OUTER TIE ROD TO

STEERING LINKAGE OUTER TIE ROD SOCKET

ASSEMBLY LOCK NUT

TORQUE SPECIFICATION ...................... 58 – 71 Nm

7. Tighten the outer boot clips securely, making

sure that the convolutions of the boots are not

distorted.

8. With the steering gear in the straight ahead

position, ensure that the steering wheel is

centralised. If not, remove and reposition the

steering wheel, refer to 2.4 STEERING

WHEEL ASSEMBLY in Section 9, STEERING.

Figure 3-13

2.3 JACKING PRECAUTIONS

When rais ing the f ront of the vehicle with a jack (1),

the jack should be placed under the centre of the

front crossmember (2). THE WEIGHT OF THE

VEHICLE MUST NOT BE LIFTED UNDER THE

CONTROL ARMS.

When the vehicle is raised on the jack, it must be

firm ly supported on safety stands located under the

fram e s ide m embers before any work is attem pted.

If a vehicle is not correctly supported by safety

stands, serious injury can result if the vehicle

should slip off the jack.

For further information relating to the location

of jacking and support points, refer to

Section 0A, GENERAL INFORMATION.

Figure 3-14

2.4 FRONT WHEEL HUB ASSEMBLY - END FLOAT CHECKING PROCEDURE

LT Section No. – 06-212

1. Raise the front of the vehicle and place on safety stands. Observe the jacking precautions as detailed in

2.3 JACKING PRECAUTIONS in this Section.

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the relationship of the wheel hub assembly to the brake rotor to preserve on-vehicle wheel balancing.

Remove the wheel attaching nuts and remove road wheel.

4. Temporarily install three, reversed wheel nuts

with a flat washer under each nut, to prevent

damage to the nut thread.

5. Mount a dial indicator on to a suitable m agnetic

stand and attach to the f ront str ut tube. Position

the dial indicator pointer at the outer diameter

of the rotor, as shown.

IMPORTANT: The dial indicator guage MUST be

mounted at right-angles (90°) to the brake rotor

friction surface.

6. Apply an outward, 10 kg force to the outer

brake rotor diameter, in an opposite position

(180°) to the dial indicator. To maintain

consistency, a spring balance capable of

measuring this force, MUST be used. W ith the

force applied, zero the dial indicator.

7. Apply an inward, 10 k g forc e to the outer brak e

rotor diameter and note the dial indicator

reading.

8. The reading obtained is the angular movem ent

(NOT end float) and to determine the bearing’s

serviceability, compare the measured result

with the following specifications.

WHEE L BEARING ANGULAR ‘F LOAT’

SPECIFICATION

NEW BEARING 0.106 mm Maximum

USED BEARING 0.213 mm Maximum

9. Should this inspection show that the wheel

bearing assembly is outside the specified,

angular ‘float’ dim ension, then the hub m ust be

replaced. Refer to 3.3 FRONT WHEEL HUB

ASSEMBLY BRAKE ROTOR OR BRAKE

SHIELD in this Section.

10. Remove the dial indicator and stand, and the

three wheel nuts and flat washers.

11. Install the r oad wheel, aligning the mar ks m ade

prior to removal and secure with attaching nuts.

12. Raise the vehicle, remove the safety stands

and lower vehicle to the ground. Tighten road

wheel attaching nuts to correct torque

specification, working in a ‘star’ pattern. Refer

to Section 10, WHEELS AND TYRES for

detailed information regarding the installation

procedure for the road wheels.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

13. Install the wheel cover/centre cap.

Figure 3-15

3. SERVICE OPERATIONS

IMPORTANT

All front suspension fasteners are important attaching parts as they affect the performance of vital

components and/or could result in major repair expense. Where specified in this Section, fasteners

MUST be replaced with parts of the same part number or a GM approved equivalent. Do not use

fasteners of an inferior quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all front

suspension components.

Throughout this Section, fastener torque wrench specifications may be accompanied with the following

identification marks:

+ Fasteners must be replaced after loosening.

& Vehicle must be at curb height before final tightening.

6 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock

and should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 SERV ICE NOTES AND CAUTIONS

NOTE: Whenever a road wheel and/or brake rotor is removed from or installed to a MY 2003 VY or

V2 Series vehicle, it MUST be done in accordance with the procedure provided in

2.3 WHEEL REMOVAL AND INSTALLATION in Section 10, WHEELS AND TYRES.

CAUTION: Whenever any component that forms part of the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS system be checked, using the procedure as detailed in

4.4 ABS & T CS FUNCTION CHECK (V6 engin es) o r 5.4 ABS & TCS FUNCTION CHECK (GEN III V8 engines),

in Section 5B, ABS & TCS.

3.2 SUSPENSION AND TRIM HEIGHT, CHECK

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

5. SPECIFICATIONS in this Section.

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

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

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

passengers . Ac c umulated dir t, dis tanc e travelled, etc ., must als o be taken into cons ideration when chec king vehicle

heights.

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

1. All c hec ks must be c ar ried out on a LEVEL s urface, af ter the vehicle's tyre pressures have been c hec k ed and it

has been confirmed that the vehicle has not been subjected to accident damage.

2. On average, all MY 2003 VY and V2 Series Models will sit approximately 4 mm lower at the right hand side

front, because of the vehicle's battery weight.

3. Push the 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 the 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 5. SPECIFICATIONS in this Section), there are two different

dimens ions that must be chec ked and the location f or the measur ements to be taken is c ritic al to c orr ec tly establish

a standard vehicle condition. When checking a vehicle's ride height, the following tolerances must also be taken into

account, before any spring is replaced.

RIDE HEIGHT VARIATIONS FROM SPECIFICATION

FRO NT 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 5. 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 w ithin the limits quoted. Even if a v ehicle's dimensions should 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.

3.3 FRONT WHEEL HUB ASSEMBLY, BRAKE ROTOR AND/OR BRAKE SHIELD

LT Section No. – 06-212

NOTE 1: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Front wheel hub assembly to steering knuckle

attaching bolt.

NOTE 2: The following fasteners MUST be replaced

when performing this operation:

Front strut to steering knuckle attaching nuts

and bolts.

Brake caliper retaining bolts.

NOTE 3: Apart from wheel stud replacement, there are no serviceable items in the front wheel hub assembly. As

the unit is a 'sealed f or life' as sembly, neither bearing adjus tment nor lubr ication m aintenance is required. Should a

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

NOTE 4: W hile the front wheel hub assembly is designed to have zero axial free play or ‘end-float’, some angular

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

replaced, refer to checking procedure as detailed in 2.4 FRONT WHEEL HUB ASSEMBLY – END FLOAT

CHECKING PROCEDURE in this Section.

REMOVE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and support on safety stands.

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the relationship of the road wheel to hub or brake rotor. Loosen, then remove the road wheel attaching

nuts. Remove the road wheel.

4. Remove the brake caliper retaining bolts and

washers (1) and lift the caliper assembly (2)

from the brake rotor. Position caliper in such a

way that no strain is placed on the brake hose.

If necessary, tie caliper to the suspension

spring with a piece of wire. THE CALIPER IS

NOT TO HANG BY THE BRAKE HOSE.

5. The brake rotor to hub location is marked in

production. To maintain this relationship,

ensure that the rotor to hub position is car efully

marked.

NOTE 1: This is necessary to overcome the

possibility of inducing a brake shudder condition

after reassembly.

6. Remove the brake rotor from the wheel hub

assembly.

NOTE 2: For vehicles equipped with ABS,

disconnect the wheel speed sensor connector (3)

from the hub sensor connector, by lifting the

connector locking tab and pulling on the connector

to disconnect.

Figure 3-16

7. Using a commercially available 10 mm Allen key socket and a suitable socket bar, loosen each of the three

bolts (4) holding the hub to the steering knuckle.

NOTE 3: If the Allen key socket is too long to fit into the front, upper hub bolt, then the lower strut to steering

knuckle nut (and bolt) will need to be loosened and removed. Discard the removed bolt and nut, as they must be

replaced on reassembly.

NOTE 4: For the front lower hub bolt, turn wheel outwards to provide sufficient clearance.

8. If the hub is a tight fit to the knuckle, it may be necessary to loosen the three bolts and tap on the heads. DO

NOT STRIKE THE HUB.

9. Remove the three bolts and then the hub from steering knuckle.

10. W here rem oval of the brak e shield is nec essary, drill the heads from the three rivets sec uring the shield to the

steering knuckle support.

11. After removal of the shield, carefully drill out the remainder of the rivets, using a suitable sized drill.

INSPECT

1. Check wheel studs are pressed firmly into the front wheel hub assembly and ensure threads are not damaged.

If one or more of the wheel studs require replacement, refer to 3.4 FRONT WHEEL HUB STUDS in this Section

for details.

2. Examine the brake rotor for scores or damage.

If either of these conditions exist, the brake rotor should be machined. Refer to Section 5A, SERVICE AND

PARK BRAKING SYSTEM for details.

3. Check f or damage to the shield that may cause f ouling of any rotating parts and if s us pec t, the shield s hould be

replaced.

REINSTALL

Installation of the front wheel hub assembly, brake rotor and brake shield is the reverse of removal procedures,

except for the following points:

ALL MODELS:

1. If the brake shield has been removed, install

three, common pop rivets (1), using a

commercially available pop rivet gun.

NOTE: Install the first rivet in the brake shield hole

with the round hole. This will ensure that the

clearance to brake caliper is correct.

2. Before installing the hub, inspect both mating

surfaces to make sure that they are clean and

free from burrs that could prevent correct

alignment of both parts, once installed.

Figure 3-17

WITHOUT ABS:

3. Install the hub assembly on to the steering

knuckle.

4. Install the three attaching bolts (1) and tighten

to the correct torque specification.

( 6 ) FRONT WHEEL HUB ASSEMBLY TO STEERING

KNUCKLE ATTACHING BOLT

TORQUE SPECIFICATION ................ 100 – 115 Nm

NOTE: The three hub attaching bolts are micro-

encapsulated with thread sealant and are not to be

re-used more than thr ee times. If in doubt, the bolts

should be replaced.

WITH ABS:

5. Carefully align the sensor connection on the

hub, with the hole in the steering knuckle, then

install the three hub attaching bolts (1) and

tighten to the correct torque specification.

( 6 ) FRONT WHEEL HUB ASSEMBLY TO STEERING

KNUCKLE ATTACHING BOLTS

TORQUE SPECIFICATION ................ 100 – 115 Nm

6. Fit the wheel speed sensor connector (2),

ensuring that the locking tang is in place.

Figure 3-18

ALL MODELS:

7. If removal of the lower strut to steering knuckle bolt and nut (3) was necessary, the bolt and nut, must be

replaced with new parts. Tighten the bolt and nut to the correct torque specification.

( + ) FRONT STRUT TO STEERING

KNUCKLE ATTACHING NUTS AND BOLTS

TORQUE SPECIFICATION ................ Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 Turn

through 90°

8. Install brake rotor, aligning the marks made before removal.

NOTE: If the hub was replaced, then runout checks must be carried out on the installed brake rotor. Refer to

Section 5A, SERVICE AND PARK BRAKING for important information regarding these checks.

9. Install the brake caliper (4) and attaching bolts (5) and tighten to the correct torque specification.

( + ) BRAKE CALIPER ANCHOR

PLATE RETAINING BOLTS

TORQUE SPECIFICATION ............. 80 – 90 Nm

then turn through

40° - 50°

10. Install the road wheel, aligning the marks made prior to removal and secure with the attaching nuts.

11. Remove the jack stands and lower the vehicle.

12. Tighten the road wheel attaching nuts to correct torque specification, working in a ‘star’ pattern as shown in

2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

13. Install the wheel cover/centre cap.

3.4 FRONT W HE EL HUB STUDS

LT Section No. – 06-212

NOTE: The following fastener MUST be replaced

when performing this operation:

Brake caliper attaching bolts.

REPLACE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and support on safety stands..

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the relationship of the wheel to the hub and rotor. Remove the wheel attaching nuts and remove the

wheel.

4. Remove the brake caliper retaining bolts and

washers, lift the caliper assembly from the

brake rotor. Suspend the caliper on a wire or

hook to avoid strain on the hose. DO NOT

ALLOW CALIPER TO HANG BY BRAKE

HOSE.

5. Remove the brake rotor from the hub.

6. Install a wheel nut until the nut is flush with the

end of the stud, then, using Tool No. AJ24292-

C or equivalent, press the stud/s from the front

wheel hub assembly.

NOTE 1: To avoid the unnecessary rem oval of the

micro-encapsulated studs retaining the front wheel

hub assembly to the steering knuckle, it is

recommended that wheel stud/s replacement be

carried out with the hub left undisturbed.

NOTE 2: To remove the stud/s, first drill out the

three rivets securing the brake shield to the

steering knuckle. Then rotate the shield and

remove the wheel stud by manipulating the head

under the shield and into the one recess in the

steering knuckle, at approximately the 11 o'clock

position, as shown.

Figure 3-19

7. New studs can be installed as follows;

a. Install T ool No. KM468, using two revers ed

wheel nuts.

b. Install the replacement stud by first

manipulating the s tud under the f ront brak e

shield and into the wheel hub flange. Then,

after assembling a suitable sized flat

washer and reversed wheel nut (1) onto the

replacem ent st ud (2), hold T ool No. KM468

and tighten the wheel nut to draw the stud

into place.

c. Install any remaining studs in the same

manner. Remove Tool No. KM-468.

8. Using a suitable sized drill, remove the shanks

of the three brake shield retaining rivets. Then

use common pop rivets and a commercially

available pop rivet gun to install the brake

shield.

NOTE: Install the f irst rivet in the brak e shield hole

with the round hole. This will ensure that the

clearance to brake caliper is correct.

9. Install the brake rotor and caliper, tightening

the caliper retaining bolts to the correct torque

specification.

( + ) BRAKE CALIPER ANCHOR

PLATE RETAINING BOLTS

TORQUE SPECIFICATION ................ 80 – 90 Nm

Then turn

through

40° - 50°

10. Install the r oad wheel, aligning the mar ks m ade

prior to removal and secure with the attaching

nuts.

11. Remove the jack stands and lower the vehicle.

12. Tighten the road wheel attaching nuts to

correct the torque specification, working in a

‘star’ pattern. Refer to Section 10, WHEELS

AND TYRES for detailed information regarding

the installation procedure for the road wheels.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

13. Install the wheel cover/centre cap.

Figure 3-20

3.5 FRONT STRUT ASSEMBLY

LT Section No. – 06-212

NOTE: The following fasteners MUST be replaced

when performing this operation:

Upper strut locating plate retaining nut.

Brake caliper retaining bolts.

Steering knuckle to strut attaching nuts and

bolts.

REMOVE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and support on safety stands.

2. Remove the decorative road wheel retaining nut caps, if fitted.

3. Mark the relationship of the road wheel to hub or brake rotor. Loosen, then remove the road wheel attaching

nuts. Remove the road wheel.

4. Position a suitable size open end spanner to

hold the stabilizer shaft spacer stud (1) at ‘A’,

use another spanner to loosen and remove the

upper nut ( 2), washer (3) , ins ulator ( 4) and s eat

(5).

5. Disconnect the wheel speed sensor cable and

insulator from the strut bracket.

Figure 3-21

6. Remove the brake caliper retaining bolts and

washers (1), lift the caliper assembly (2) from

the brake rotor and support in such a way that

no strain is placed on the brake hose. THE

BRAKE CALIPER IS NOT TO HANG BY THE

BRAKE HOSE.

NOTE 1: This step is necessary to provide access

to the lower strut mounting bolts and nuts (3).

7. If required, remove the brake rotor from the

wheel hub assembly. The brake rotor to hub

relationship is marked during production. To

ensure this relationship is maintained, ensure

that the rotor to hub position is carefully

marked.

NOTE 2: This is necessary to overcome the

possibility of inducing a brake shudder condition

after reassembly.

Figure 3-22

8. Remove the brake hose from the strut housing bracket by turning the plastic sleeve on the hose until the flats

on the sleeve align with the bracket opening.

9. Position a suitable floor jack fitted with a block of wood on the lift pad under the control arm, and raise it

sufficiently to support the weight.

10. Loosen, remove and DISCARD the two lower strut to knuckle attaching bolts and nuts.

Techline

11. To avoid plac ing strain on the ABS sensor lead, release the connec tor lock ing tang and pull on the sens or lead

connector (4) to remove from the sensor.

12. Pull the steering knuckle clear of the strut.

13. Rem ove the dust cover ( 1) fr om the upper str ut

support, in the engine compartment.

14. While holding the strut rod shaft (2) with a 10

mm socket, remove the self-locking nut (3),

using a

24 mm ring spanner, then remove the locating

disc (4). DISCARD THE STRUT ROD NUT.

15. Carefully lower the strut (5) from the tower,

manipulate the strut to remove the stabilizer

stud from the bracket on the strut and remove

the assembly from the vehicle.

Figure 3-23

REINSTALL

Important: The torque of the strut bearing retaining nut (‘5’ in Figure 3-23) MUST be check ed for correct tightness

BEFORE installing the strut into the vehicle!

UPPER STRUT BEARING RETAINING

NUT TORQUE SPECIFICATION.............. 70 – 85 Nm

1. Manipulate the strut assembly so that the stabilizer shaft stud is located in the strut bracket, then locate the strut

assembly into the spring strut tower.

2. After installing the locating disc, partially install a NEW upper nut to the strut rod. Do not tighten at this time.

3. Pivot the hub and steering knuckle assembly

(1), sufficiently to line up the bolt holes in the

steering knuckle and the lower end of the strut

assembly (2).

4. Install NEW retaining bolts (3) and nuts (4),

and tighten to a preliminary torque of 85 Nm.

5. Use a 10 mm socket to hold the strut rod from

turning, then tighten the upper strut rod

retaining nut (‘3’ in Figure 3-23) to the correct

torque specification, using a 24 mm ring

spanner with a torque wrench attached.

( + ) UPPER STRUT LOCATING

PLATE RETAINING NUT

TORQUE SPECIFICATION ................... 50 – 60 Nm

6. Install the brake hose to the strut bracket by

turning the plastic sleeve on the hose until the

flats on the sleeve align with the bracket

opening.

7. If removed, install the brake rotor, aligning the

marks made prior to removal.

8. Install the brake caliper, tightening the

attaching bolts to specification.

( + ) BRAKE CALIPER ANCHOR

PLATE RETAINING BOLTS

TORQUE SPECIFICATION ................... 80 – 90 Nm

Then turn

through

40° - 50°

9. Install the wheel speed sensor connector,

pushing firmly onto the sensor until the

retaining tang is secure. Then, install the

sensor lead and insulator into the strut

mounting bracket.

Figure 3-24

10. Install the stabilizer shaft spacer stud nut (1)

after ensuring that all the components are

assem bled as shown. While holding the spacer

stud (2) with a suitable open end spanner at ‘A’,

use another spanner to tighten the upper

retaining nut until the end of the thread on the

stud is contacted.

NOTE: Do not use power tools for this tightening

operation, otherwise thread damage will result.

11. Install the r oad wheel, aligning the mar ks m ade

prior to removal .

12. Remove the safety stands and lower vehicle.

13. Tighten road wheel attaching nuts to the

correct torque specification, working in a ‘star’

pattern, as shown in 2.3 WHEEL AND TYRE

REMOVAL AND INSTALLATION in Section

10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 - 140 Nm

14. Install the decorative road wheel retaining nut

caps, as required.

15. Bounce the vehicle up and down several times

to settle the suspension.

16. Check the wheel alignment, as detailed in

2.2 WHEEL ALIGNMENT CHECKING AND

ADJUSTMENT in this Section.

17. Tighten the steering knuckle to strut bolts and

nuts to the specified torque values.

Figure 3-25

( + ) STEERING KNUCKLE TO STRUT

ATTACHING NUTS AND BOLTS

TORQUE SPECIFICATION ............. Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 Turn

through 90°

3.6 UPPER STRUT SUPPORT BEARING AND MOUNT

LT Section No. – 06-210

REMOVE

1. Remove the front strut (1) as detailed in

3.5 FRONT STRUT ASSEMBLY in this

Section.

2. Fit Tool No. 180 (or a commercially available

equivalent) on to the front spring as shown.

Compr es s the spring (2) until the upper suppor t

bearing (3) has clearance at the spring seat

collar (4).

Figure 3-26

CAUTION: Do not attempt to remove the

retaining nut from the strut rod shaft before

compressing the spring.

3. W hile holding the strut rod shaft with a 10 mm

socket, remove the upper strut bearing to strut

rod retaining nut (1), using a 24 mm ring

spanner.

4. Remove the front suspension strut mount

assembly and the two washers (2) either side.

NOTE 1: The lower washer may be binding with the

lower edge of the mount.

5. Remove the strut bearing (3) from the upper

spring seat collar, taking particular note of

the bearing's orientation.

NOTE 2: The upper support bearing is self-

lubricated and no servicing requirements are

necessar y. If cons idered to be faulty, the bearing is

to be replaced as an assembly.

NOTE 3: Under no circumstances is the machined

surface of the piston rod section to be gripped

directly on its outer surface.

Figure 3-27

REINSTALL

1. Pull the strut rod through the upper spring seat to its maximum length, then remove the strut rod nut.

2. Install the upper bearing with the same orientation as noted on removal. Generally, the coloured or narrow,

outer section, faces towards the upper spring seat collar.

3. While holding the strut rod extended and, after installing the first mount washer with the dished shape facing

downward (refer to Item 2 in Figure 3-27), install the upper front suspension strut mount assembly over the

bearing and washer.

4. Install the second washer with the dished shape facing upward (refer to Item 2 in Figure 3-27) and install the

retaining nut.

5. Using a 10 m m s ocket and a 24 m m ring spanner with a torque wrench attached, tighten the nut to the correct

torque specification.

UPPER STRUT BEARING RETAINING

NUT TORQUE SPECIFICATION.............. 70 – 85 Nm

6. Release the spring compressor and remove it from the spring.

7. Install the front strut as detailed in 3.5 FRONT STRUT ASSEMBLY in this Section.

3.7 FRONT SPRING

LT Section No. – 06-210

REMOVE

1. Remove the front strut, refer to 3.5 FRONT STRUT ASSEMBLY in this Section.

2. Remove the front strut dust shield assembly, as detailed in 3.6 UPPER STRUT SUPPORT BEARING AND

MOUNT in this Section.

3. Remove the clamp (1) securing the front strut

dust shield assembly (2) and filter (3) to the

upper spring seat collar (4) and discard.

4. Remove the upper spring seat collar, spring

insulator (5) and compression bum per (6) from

the top of the spring (7).

5. Remove the spring from the strut (8) and

release the spring compressor.

REINSTALL

NOTE 1: If installing a replacement spring, ensure

that the spring is the correct type for the

suspension system fitted to the vehicle. Refer to

5. SPECIFICATIONS in this Section for details.

1. Position spring on strut with straight projecting

end of spring correctly located in spring seat.

2. Install spring compressor Tool No. 180 or a

com m erc ially available equivalent to the spring

(refer to Figure 3-26) and compress it.

3. Install the upper spring insulator, spring seat

collar and compression bumper so that the

double notch in the upper flange of the spring

seat collar is assembled, facing inward. The

spring insulator has a step which locates on to

the straight projecting end of the spring.

4. Install the upper support plate (9) as detailed in

3.6 UPPER STRUT SUPPORT BEARING

AND MOUNT in this Section.

NOTE 2: The lower washer (10) may be binding

with the lower edge of the mount.

5. Fit the upper end of the front strut dust shield

assembly over the lower flange of the spring

seat collar and secure with a retaining clamp.

Tighten the clam p until the boot rubber is firm ly

secured.

6. Install front strut as detailed in

3.5 FRONT STRUT ASSEMBLY in this

Section.

Figure 3-28

3.8 FRONT STRUT UNIT

LT Section No. – 06-212

REPLACE

NOTE 1: When replacing the front strut, ensure that the replacement unit is the correct type for the suspension

system fitted to the vehicle. Refer to 5. SPECIFICATIONS in this Section for details.

NOTE 2: As the strut assembly is a sealed component, no overhaul procedures are possible. If any strut

component is found to be unserviceable, the complete strut must be replaced.

1. Remove the front strut assembly as detailed in 3.5 FRONT STRUT ASSEMBLY in this Section.

2. Rem o ve the upper support c om ponents as detailed in 3.6 UPPER ST RUT SUPPORT BEARING AND M O UNT

in this Section.

3. Remove the spring as detailed in 3.7 FRONT SPRING in this Section.

4. Remove the lower boot retaining clamp and

discard. Slide the front strut dust shield

assembly (1) and filter (2) from the strut

assembly (3).

5. Pull the strut rod fully up and, while supporting

the rod to stop it from slipping back into the

strut, install the front str ut dust shield ass embly

over the strut tube, ensuring that the filter

remains seated inside the boot assembly.

Figure 3-29

6. Ensure that the bottom of the front strut dust

shield assembly is positioned so that distance

‘A’ is between 30 - 35 mm.

7. Install the retaining clamp and tighten until the

rubber on the f ront s tr ut dust shield assembly is

firmly secured.

8. Install the front spring as detailed in

3.7 FRONT SPRING in this Section.

9. Install the upper strut support assembly as

detailed in 3.6 UPPER STRUT SUPPORT

BEARING AND MOUNT in this Section.

10. Install the front strut assembly as detailed in

3.5 FRONT STRUT ASSEMBLY in this

Section.

Figure 3-30

3.9 STEE RING KNUCKLE

LT Section No. – 06-212

NOTE 1: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Front lower control arm socket stud nut.

NOTE 2: The following fastener MUST be replaced

when performing this operation:

Front strut to steering knuckle attaching nuts

and bolts.

REMOVE

1. Remove the front brake rotor, wheel hub

assembly and brake shield, as detailed in

3.3 FRONT WHEEL HUB ASSEMBLY,

BRAKE ROTOR OR BRAKE SHIELD in this

Section.

2. Remove the s plit pin and loosen the castellated

nut (1) until the nut is flush with the end of the

steering linkage outer tie rod socket assembly

stud.

3. Install Tool No. 7311 as shown and, using a

ring spanner (2), press the stud out from the

steering knuckle.

Figure 3-31

4. Loosen, r emove and discar d the two lower strut

attaching bolts and nuts (1).

5. If the steering knuckle is to be replaced,

remove the camber adjusting bolt (2) from the

arm.

Figure 3-32

6. Loosen the front lower control arm socket

retaining nut (1) until the nut is flush with the

end of the front lower control arm socket stud

thread.

NOTE: Because the nut has micro-encapsulated

sealant applied to the threads, it must be replaced

after removal.

7. Install release Tool No. E9332-A as shown,

then apply force to the top of the front lower

control arm socket stud by tightening the

forcing bolt on the tool, separating the front

lower control arm socket from the knuckle.

NOTE: Once load is applied by the release tool

loading bolt, a sharp tap on the nut end of the tool

will lessen the apply force required.

8. Temporarily jam the front lower control arm

socket stud taper into the knuckle to hold the

stud, before fully removing the retaining nut.

Discard the removed nut as it has micro-

encapsulation sealant applied and must be

replaced on reassembly.

9. Separate the knuckle from the front lower

control arm socket stud and remove from the

vehicle.

Figure 3-33

REINSTALL

Installation is the reverse of the removal procedures except for the following:

1. Ins tall the steer ing knuc k le over the fr ont lower control ar m sock et s tud, then install NEW lower strut to steering

knuckle, bolts and nuts but do not tighten fully at this stage.

2. Position a suitable floor jack with a block of wood fitted to the lift pad under the front lower control arm, and

raise sufficiently to support the weight and jam the front lower control arm socket stud taper into the knuckle.

3. Install a NEW self-locking nut on to the front lower control arm socket stud and tighten the nut to the correct

torque specification.

( 6 ) FRONT LOWER CONTROL ARM

SOCKET STUD NUT

TORQUE SPECIFICATION ...................... 50 – 70 Nm

4. Ins tall the steer ing steering outer steering link age outer tie r od sock et s tud into the steering k nuc kle and tighten

the castellated attaching nut to the correct torque specification. Install new split pin.

STEERING LINKAGE OUTER TIE ROD SOCKET

ASSEMBLY STUD CASTELLATED NUT

TORQUE SPECIFICATION ...................... 58 – 71 Nm

5. Install the brake shield, wheel hub assembly and front brake rotor, as detailed in 3.3 FRONT WHEEL HUB

ASSEMBLY, BRAKE ROTOR OR BRAKE SHIELD in this Section.

NOTE: The brake rotor must be installed, aligning the marks made prior to removal.

6. Temporarily install the road wheel/s and lower the vehicle to the ground.

7. Bounce the vehicle up and down several times to settle the suspension.

8. Check the wheel alignment, as detailed in 2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

9. Following the wheel alignment, it will be neces sary to raise the vehicle and tighten the NEW steer ing k nuck le to

strut bolts and nuts to the correct torque specification.

( + ) STEERING KNUCKLE TO STRUT

ATTACHING BOLTS AND NUTS

TORQUE SPECIFICATION ................ Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 Turn

through 90°

10. Lower the vehicle to the ground and tighten the road wheel attaching nuts to the correct torque specification,

working in a ‘star’ pattern, as shown in 2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10,

WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

11. Install the wheel cover/centre cap.

3.10 FRONT LOWER CONTROL ARM

LT Section No. – 06-200

NOTE 1: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Front lower control arm socket stud nut.

NOTE 2: The following fasteners MUST be replaced

when performing this operation:

Front lower control arm pivot nut.

Front lower control arm rod to front lower

control arm attaching nut.

Front lower control arm rod to insulating

bushing attaching nut.

NOTE 3: The following fasteners MUST be at curb

height before final tightening:

• Front lower control arm pivot nut.

• Front lower control arm rod to front lower

control arm attaching nut.

• Front lower control arm rod to insulating

bushing attaching nut.

REMOVE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and place safety stands under the side frame members.

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the relationship of the wheel to hub. Loosen, then remove the road wheel attaching nuts and remove the

wheel.

4. Turn the steering out on full lock.

5. Loosen the front lower control arm socket

retaining nut (1) until the top of the nut is flush

with the top of the front lower control arm

socket assembly stud thread.

6. Install the r elease Tool No. E9332- A as shown,

then apply force to the top of the front lower

control arm sock et assem bly stud by tightening

the f orcing bolt on the tool, separating the f ront

lower control arm socket assembly from the

knuckle.

NOTE: Once load is applied by the release tool

loading bolt, a sharp tap on the nut end of the tool

will lessen the apply force required.

7. Temporarily jam the front lower control arm

socket assembly stud taper into the knuckle to

hold the stud, before fully removing the

retaining nut. Dis car d the r emoved nut as it has

micro-encapsulation sealant applied and

should be replaced on reassembly.

Figure 3-34

8. Separate the front lower control arm socket

assembly stud from the knuckle.

9. Hold the steering knuckle away from the front

lower control arm by using a suitable length

prop.

10. Loosen the fr ont lower control arm r od fr ont nut

(1) at the front lower control arm rod insulating

bushing assembly (2).

11. Remove the front lower c ontrol arm rod to front

lower control arm attaching nut (3) and washer

(4). Discard the nut.

12. Remove the four nuts (5) securing the front

lower control arm rod insulating bushing to the

crossmember (6), then remove the front lower

control arm rod (7) from the front lower control

arm rod bushing.

13. Remove the front lower control arm pivot bolt

(8) and nut (9). Discard the nut.

14. Remove the front lower control arm (10) and

bright finished washer (11) from the vehicle.

Figure 3-35

REINSTALL

1. Install the front lower control arm on to the

crossmember, install the bolt (‘8’ in Figure 3-

36), then install a NEW nut (‘9’ in Figure 3-36),

but do not fully tighten at this stage.

2. Install the front lower control arm rod (1) to the

front lower c ontrol arm (2) with the convex side

of the cupped washer (3) toward the f ront lower

control arm bushing.

3. Install the front lower control arm rod to front

lower control arm washer (4) with a NEW

attaching nut (5) but do not fully tighten at this

stage.

4. Install front lower control arm rod and the

insulating bushing into the c ros s mem ber , install

the four r etaining nuts and tighten to the correc t

torque specification.

FRONT LOWER CONTROL ARM ROD INSULATING

BUSHING ASSEMBLY ATTACHING

TORQUE SPECIFICATION ...................... 20 – 26 Nm

NOTE: Install a NEW front lower control arm rod

nut on to the f ront of the f ront lower contr ol arm rod

but do not tighten at this stage.

Figure 3-36

5. Using a s uitable f loor jack f itted with a block of wood positioned under the f ront lower c ontrol ar m, rais e the j ac k

suff ic iently to support the weight of the strut as s embly and jam the front lower control arm socket assembly s tud

taper into the knuckle.

6. Install the self-locking nut into the front lower control arm socket assembly stud and tighten the nut to the

correct torque specification.

( 6 ) FRONT LOWER CONTROL ARM

SOCKET ASSEMBLY STUD NUT

TORQUE SPECIFICATION ...................... 50 - 70 Nm

7. Ins tall the road wheel, aligning m ark s m ade pr ior to rem oval. T ighten the wheel nuts progr essively, work ing in a

‘star’ pattern as shown in 2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10, W HEELS

AND TYRES.

8. Remove the safety stands and lower vehicle.

9. Bounce the vehicle up and down several times to settle the suspension.

10. W ith the weight of the vehicle on the suspension components, tighten the front lower control arm pivot bolt to

the correct torque specifications.

( + & ) FRONT LOWER CONTROL

ARM PIVOT NUT

TORQUE SPECIFICATION ................... 95 – 100 Nm

10. T ighten both f ront lower c ontrol arm r od nuts ( at the front lower contr ol arm and the f ront lower control arm rod

insulating bushing), to the correct torque specifications.

Important: The weight of the vehicle m ust be on all f our wheels before tightening the f ront lower control arm rod to

specification. Tensioning the front lower control arm rod nuts when the insulating bushing is incorrectly pre-loaded

will result in reduced insulator bushing life and will adversly affect the ride and handling characteristics of the

vehicle.

( + & ) FRONT LOWER CONTROL ARM ROD

TO CONTROL ARM ATTACHING NUT

TORQUE SPECIFICATION ................... 95 – 110 Nm

( + & ) FRONT LOWER CONTROL ARM ROD TO

INSULATOR BUSHING ATTACHING NUT

TORQUE SPECIFICATION ................ 140 – 155 Nm

12. Tighten the r oad wheel attac hing nuts to the c orr ect torque s pec if ic ation, work ing in a ‘s tar’ patter n, as s hown in

2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

13. Install the wheel cover/ centre cap.

14. Check the wheel alignment, as detailed in 2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

3.11 FRONT LOWER CONTROL ARM SOCKET ASSEMBLY

LT Section No. – 06-200

INSPECT

The following procedure should be used when checking the front lower control arm socket assembly for wear.

1. Jack the vehicle up with the jack lift pad located under the centre of the front crossmember.

2. Holding the road wheel at the top and bottom, c heck f or play in the front lower c ontrol ar m sock et ass embly by

rocking the wheel.

3. If any up or down movement of stud in front lower control arm socket assembly housing is detected, the front

lower control arm and socket assembly must be replaced.

NOTE: The front lower control arm socket is not serviced seperately. If the front lower control arm socket is found to

be faulty, the com plete front lower control arm assem bly m ust be replaced. For inform ation relating to the removal

and installation procedures for the front lower control arm, refer to 3.10 FRONT LOWER CONTROL ARM in this

Section.

3.12 FRONT LOWER CONTROL ARM PIVOT BUSHING

LT Section No. – 06-200

REPLACE

1. Remove the front lower control arm (1) as

detailed in 3.10 FRONT LOWER CONTROL

ARM in this Section.

2. Support the front lower control arm with two

pieces of square scrap (2) and press the

bushing from the arm, using Tool No. AU162.

Figure 3-37

3. Using Tool Nos. AU160-1 and KM157-2, install

the new bushing from the fr ont side of the fr ont

lower control arm (1), until flange (2) on the

outer s leeve is flus h with the front lower control

arm.

Figure 3-38

NOTE 1: Tool No KM157-2 is used in the reverse

direction to some previous ‘V’ car models.

NOTE 2: The front lower control arm pivot bushing

(1) m ay be lubricated with a soapy water solution to

ease the installation process.

NOTE 3: The bus hing MUST be aligned, as shown

in Figure 3-39.

4. Install the front lower control ar m as detailed in

3.10 FRONT LOWER CONTROL ARM in this

Section.

Figure 3-39

3.13 FRONT LOWER CONTROL ARM ROD BUSHING

LT Section No. – 06-200

REPLACE

1. Remove the f ront lower control arm as detailed

in 3.10 FRONT LOWER CONTROL ARM in

this Section.

2. Press the front lower control arm rod bushing

from the front lower control arm (1) using Tool

No AU158 and KM158-2 as shown.

Figure 3-40

3. Press in a new front lower control arm rod

bushing (2) using Tool No.s AU158, AU159

and KM158-2 as shown. To assist in

installation, dip the bushing in a soapy water

solution. Install the bushing with the larger

diameter of the stepped fr ont lower control arm

rod mounting hole toward the rear of the front

lower control arm (1).

NOTE: Press the bushing in until it is centrally

located in the front lower control arm.

4. Install the front lower control ar m as detailed in

3.10 FRONT LOWER CONTROL ARM in this

Section.

Figure 3-41

3.14 FRONT LOWER CONTROL ARM ROD

LT Section No. – 06-200

NOTE 1: The following fasteners MUST be replaced

when performing this operation:

Front lower control arm rod to front lower

control arm attaching nut.

Front lower control arm rod to insulating

bushing attaching nut.

NOTE 2: The following fasteners MUST be at curb

height before final tightening:

• Front lower control arm rod to front lower

control arm attaching nut.

• Front lower control arm rod to insulating

bushing attaching nut.

REMOVE

1. Before raising the vehicle, loosen the front lower control arm rod nut (‘7’ in Figure 3-42).

2. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and place safety stands under the side frame members..

3. Rem ove the wheel cover (steel wheels) or centre cap and dec orative wheel nut caps (alloy wheels) on the side

where the front lower control arm rod is to be removed.

4. Mark the relationship of the road wheel to the hub and brak e rotor. Loosen, then remove road wheel attaching

nuts and remove the road wheel.

5. Rem ove the f ront lower control arm rod to fr ont

lower control arm attaching nut (1) and washer

(2). Discard the nut.

6. Remove the four nuts (3) attaching the front

lower control arm rod insulating bushing (4) to

the crossmember outrigger.

7. Rem ove the front lower c ontrol arm rod (5) and

insulating bushing assembly from the front

lower control arm (6) and remove the rod out

through the crossmember outrigger.

8. Secure the front lower control arm rod in

protected vice jaws, then remove the front

lower contr ol arm rod to fr ont lower control arm

rod insulator bushing retaining nut (7). Discard

the nut.

9. Remove the bright finished washer (8), from

the driver’s side front lower control arm rod.

Figure 3-42

REINSTALL

1. Install the bright finished inner washer onto the

front end of the f ront lower control arm rod (A),

on the driver’s side ONLY.

NOTE: The front end of the f ront lower control arm

rod is identified by the longer length of the

shouldered ends (‘A’ compared to ‘B’).

Figure 3-43

2. Install the front lower control arm rod (1) into

the hole in the crossmember outrigger and then

into the front lower control arm (2), with the

cupped washer (3) installed as shown. Install

the front lower control arm rod to front lower

control arm washer (4) with a NEW attaching

nut (5) but do not fully tighten at this stage.

Figure 3-44

3. Install the f ront lower control arm rod insulating

bushing assembly (1), over the front lower

control arm rod ( 2) and install the four retaining

nuts (3) to the crossmember outrigger studs.

Tighten to the correct torque specification.

FRONT LOWER CONTROL ARM ROD

INSULATOR BUSHING ATTACHING

NUT TORQUE SPECIFICATION.............. 20 – 26 Nm

4. Install a NEW front lower control arm rod

retaining nut (4) but do not fully tighten at this

stage.

NOTE: If fitted, ensure that the spacer washer is

installed over the front lower control arm rod and

then the flat washer, before fitting the front lower

control arm rod insulator bushing.

Figure 3-45

5. Install the road wheel, aligning the marks made prior to rem oval and secure with the attaching nuts, tightening

progressively in a ‘star’ pattern as shown in 2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in

Section 10, WHEELS AND TYRES.

6. Remove the safety stands and lower the vehicle to the ground.

7. Bounce the vehicle up and down several times to settle the suspension.

8. With the vehicle at cur b position, tighten both the front lower c ontrol arm rod to insulating bushing and the front

lower control arm rod to front lower control arm attaching nuts to the correct torque specifications.

( + & ) FRONT LOWER CONTROL ARM ROD TO

INSULATOR BUSHING ATTACHING NUT

TORQUE SPECIFICATION ................ 140 – 155 Nm

( + & ) FRONT LOWER CONTROL ARM ROD

TO CONTROL ARM ATTACHING NUT

TORQUE SPECIFICATION ................... 95 – 110 Nm

Important: The weight of the vehicle must be on all four wheels before tightening each end of the front lower

control arm rod to specification. Otherwise the fluid filled front lower control arm rod insulating bushing will be

incorrectly preloaded, reducing the life of the bushing and effect ride and handling.

9. T ighten the road wheel attaching nuts to the c or rec t tor que spec if ic ation, working in a ‘star’ patter n, as s hown in

2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

10. Install the wheel cover/centre cap.

11. Check the wheel alignment, as detailed in 2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

3.15 FRONT LOWER CONTROL ARM ROD INSULATING BUSHING

LT Section No. – 06-200

NOTE 1: The following fasteners MUST be replaced

when performing this operation:

Front lower control arm rod to insulating

bushing attaching nut.

NOTE 2: The following fasteners MUST be at curb

height before final tightening:

• Front lower control arm rod to insulating

bushing attaching nut.

REPLACE

1. Remove the lower front lower control arm rod,

front retaining nut (1) and discard. Refer to

3.14 FRONT LOWER CONTROL ARM ROD in

this Section for more details.

2. Remove the four nuts (2) securing the front

lower control arm rod insulating bushing

assembly (3) to the crossmember outrigger

studs. Remove insulator bushing from the

vehicle.

3. Install the f ront lower control arm rod insulating

bushing over the front lower c ontrol arm r od (4)

and install the four retaining nuts onto the

cross member outrigger s tuds and tighten to the

correct torque specification.

FRONT LOWER CONTROL ARM ROD

INSULATOR BUSHING ATTACHING

NUT TORQUE SPECIFICATION.............. 20 – 26 Nm

4. Install a NEW front lower control arm rod

retaining nut but do not fully tighten at this

stage.

NOTE: If fitted, ensure that the spacer washer is

installed over the f ront lower control arm rod befor e

fitting the front lower control arm rod insulator

bushing.

Figure 3-46

5. Install the road wheel, aligning the marks made prior to removal and secure with the attaching nuts. Do not

overtighten.

6. Remove the safety stands and lower the vehicle.

7. Bounce the vehicle up and down several times to settle suspension.

8. With the vehic le at curb position, tighten the f ront lower control arm rod to hydraulic attaching nut to the correct

torque specification.

( + & ) FRONT LOWER CONTROL ARM ROD TO

INSULATOR BUSHING ATTACHING NUT

TORQUE SPECIFICATION ................ 140 – 155 Nm

Important: The weight of the vehicle m ust be on all f our wheels before tightening the f ront lower control arm rod to

specification. Otherwise the fluid filled front lower control arm rod insulating bushing will be incorrectly preloaded,

reducing the life of the insulator bushing and adversly effect ride and handling.

9. Tighten road wheel attaching nuts to the correct torque specification working in a ‘star’ pattern, as shown in

2.3 WHEEL AND TYRE REMOVAL AND INSTALLATION in Section 10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

10. Install the wheel cover/centre cap.

11. Check the wheel alignment, as detailed in 2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

3.16 FRONT SUSPENSION CROSSMEMBER

LT Section No. – 06-200

NOTE 1: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Front lower control arm socket assembly stud

nut.

♦ Steering gear to crossmember mounting nut.

NOTE 2: The following fasteners MUST be replaced

when performing this operation:

Front lower control arm pivot nut.

Crossmember to side member attaching bolt.

Front lower control arm rod to front lower

control arm attaching nut.

Front lower control arm rod to insulating

bushing attaching nut.

NOTE 3: The following fasteners MUST be at curb

height before final tightening:

• Front lower control arm pivot nut.

• Front lower control arm rod to front lower

control arm attaching nut.

• Front lower control arm rod to insulating

bushing attaching nut.

REMOVE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, ra ise the front

of vehicle and place safety stands under the side frame members.

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the relationship of the wheel to the hub and rotor. Loosen, then remove the road wheel attaching nuts.

Remove the road wheel.

4. With a backing set spanner holding the

stabilizer shaf t link inner stud hexagon (1), use

a second spanner to loosen then remove the

retaining nut (2).

5. Separate the stabilizer shaft link (3) from the

stabilizer shaft (4) and remove from the

vehicle.

Figure 3-47

6. Remove the split pin from the steering linkage

outer tie rod socket assembly castellated nut

(1), then loosen the nut until the top of the nut

is level with the top of the steering linkage outer

tie rod socket stud.

7. Install Tool No. 7311 and use a ring spanner

(2) to separate the steering linkage outer tie rod

socket assembly stud from the steering

knuckle.

Figure 3-48

8. Remove the steering gear housing (1) to front

crossmember (2) mounting bolts (3) and nuts

(4). Remove the steering gear housing from the

crossmember mountings (5).

Figure 3-49

9. Turn each wheel out in turn.

10. Loosen the front lower control arm socket

assembly retaining nut (1) until the top of the

nut is flush with the top of the front lower

control arm socket assembly stud thread.

11. Install release Tool No. E9332-A as shown,

then apply force to the top of the front lower

control arm sock et assem bly stud by tightening

the f orcing bolt on the tool, separating the f ront

lower control arm socket assembly from the

knuckle.

NOTE: Once load is applied by the release tool

loading bolt, a sharp tap on the nut end of the tool

will lessen the apply force required.

12. Temporarily jam the front lower control arm

socket assembly stud taper into the knuckle to

hold the stud, before removing the retaining

nut. Discard the removed nut as it has micro-

encapsulation sealant applied and must be

replaced on reassembly.

13. Separate the knuckle from the front lower

control arm socket assembly stud.

Figure 3-50

14. Mark the hood hinge positions with a felt tipped

pen and remove the engine hood.

15. Support the engine on a suitable lifting hook

and rem ove the engine mount to crossm em ber

bolts or nuts, refer to Section 6A1, ENGINE

MECHANICAL - V6 ENGINE or Section 6A3,

ENGINE MECHANICAL - GEN III V8 ENGINE

for details.

16. Support the crossmember (3) on a jack and

remove the four bolts (1 and 2) securing the

crossmember to the side frame members (4).

17. Lower, then remove the crossmember

assembly (3) from vehicle.

18. As required, remove the front lower control

arms, front lower control arm rod insulating

bushings, front lower control arm rods and

stabilizer shaft from the crossmember.

Figure 3-51

REINSTALL

While the majority of the installation process is the reverse of the removal procedures, note the following points:

1. Install the s tabilizer shaf t ins ulating rubber s and brac kets onto the c ros s mem ber , tightening the retaining nuts to

the correct torque specification.

STABILIZER SHAFT SUPPORT

BRACKET RETAINING NUT

TORQUE SPECIFICATION ...................... 24 - 30 Nm

2. When ins talling the c ros s member, install the two f ront, blac k colour ed and stepped bolts ( ‘1’ in Figure 3- 51) and

tighten to the correct torque specification. This will correctly align the crossmember to the side frames.

3. Install the two rear , silver coloured, plain shank ed bolts (‘2’ in Figure 3- 51) to the two rear positions and tighten

them to the correct torque specification.

( + ) CROSSMEMBER TO SIDE

MEMBER BOLT (ALL)

TORQUE SPECIFICATION 120 – 125 Nm

4. Install the two f ront lower control arms to the crossm ember, installing the pivot bolts from the rear to the front.

Install the NEW nuts but do not fully tighten at this stage.

5. If the front lower control arms were removed with the crossmember, install the front lower control arm socket

assembly stud into each steering knuckle, install the nut and tighten to the correct torque specification.

( 6 ) FRONT LOWER CONTROL ARM

SOCKET ASSEMBLY STUD NUT

TORQUE SPECIFICATION ...................... 50 – 70 Nm

6. If removed, install both front lower control arm rods, loosely installing the washers and NEW retaining nuts, as

detailed in 3.14 FRONT LOWER CONTROL ARM ROD in this Section. Do not tighten at this time. However,

the front lower control arm rod insulating bushing mounting nuts can be tightened to the correct torque

specification.

FRONT LOWER CONTROL ARM ROD

INSULATOR BUSHING ATTACHING

BOLT TORQUE SPECIFICATION............ 20 - 26 Nm

7. Install the steering gear housing to the crossmember and tighten the mounting nuts to the correct torque

specification.

( 6 ) STEERING GEAR HOUSING TO

CROSSMEMBER MOUNTING

NUT TORQUE SPECIFICATION.............. 70 - 85 Nm

8. Reconnect the engine mounts to the crossmember, refer to Section 6A1 ENGINE MECHANICAL - V6

ENGINE or Section 6A3 ENGINE MECHA NICAL - GEN III V8 ENGINE for details.

9. Install the road wheels, aligning marks made prior to removal. Tighten the road wheel attaching nuts to the

correct torque specification, working in a ‘star’ pattern, as shown in 2.3 WHEEL AND TYRE REMOVAL AND

INSTALLATION in Section 10, WHEELS AND TYRES.

10. Install the engine hood.

11. Remove the safety stands and lower the vehicle.

12. Bounce the vehicle up and down several times to settle the suspension.

13. Tighten the front lower control arm pivot bolt nuts to the correct torque specification.

( + & ) FRONT LOWER CONTROL ARM PIVOT

NUT TORQUE SPECIFICATION........... 95 - 100 Nm

14. With the vehicle at cur b position, tighten the front lower c ontrol arm rod attaching nuts at the front lower control

arm and the insulating bushing, to the correct torque specifications.

( + & ) FRONT LOWER CONTROL ARM ROD TO

CONTROL ARM ATTACHING NUT

TORQUE SPECIFICATION ................... 95 – 110 Nm

( + & ) FRONT LOWER CONTROL ARM ROD

TO INSULATOR BUSHING ATTACHING NUT

TORQUE SPECIFICATION ................ 140 - 155 Nm

Important: The weight of the vehicle m ust be on all f our wheels before tightening the f ront lower control arm rod to

specif ication. If not, the fluid filled fr ont lower control arm r od insulating bushing will be ruptur ed, once the vehicle is

put back into service.

15. Check the wheel alignment, as detailed in 2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

3.17 STABILIZER SHAFT LINK

LT Section No. – 06-205

REPLACE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and place safety stands under side frame members..

2. Remove the wheel cover (steel wheels) or centre cap and decorative wheel nut caps (alloy wheels).

3. Mark the r elationship of the wheel to the hub and br ake rotor, then loos en and r emove the road wheel attaching

nuts and remove the road wheel.

4. Using a suitable size spanner, hold the

stabilizer shaft spacer stud (1) at ‘A’, then use

another spanner to loosen and remove the

stabilizer shaft spacer stud nut (2).

5. Remove the upper washer (3), upper insulator

(4) and centre washer (5).

6. If required, repeat s teps 4 and 5 for the s econd

side.

Figure 3-52

7. With a backing set spanner holding the

stabilizer shaf t link inner stud hexagon (1), use

a second spanner to loosen then remove the

retaining nut (2).

8. Separate the stabilizer shaft link (3) from the

stabilizer shaft (4) and remove from the

vehicle.

Figure 3-53

Techline

The installation procedure is the reverse to

removal, except for the following points.

9. As required, the lower link insulator (1) and

washer (2) may be replaced.

10. Before installation of the stabilizer shaft link (3)

to the stabilizer shaft (4), insert the upper

threaded end of the link into the strut mounting

bracket.

11. Install the link sock et s tud to the stabilizer shaf t

(4), tighten the retaining nut (2) to the correct

torque specification, while holding the inner

stud hex agon (1) with a back ing spanner (refer

to Figure 3-53).

STABILIZER SHAFT LINK

SOCKET RETAINING NUT

TORQUE SPECIFICATION ...................... 45 – 55 Nm

12. Install the seat (5), upper insulator (6) and

washer (7).

13. Install the upper link retaining nut (8) and

tighten to the correc t tor que spec ification, while

holding the link at the upper hexagonal section

(A). DO NOT over-tighten.

STABILIZER SHAFT LINK UPPER

NUT TORQUE SPECIFICATION.............. 13 – 18 Nm

14. Install the road wheels, aligning the marks

made prior to removal, and secure with the

wheel attaching nuts, but do not tighten to

specification at this time.

15. Remove the safety stands and lower the

vehicle.

16. Tighten the road wheel attaching nuts to the

correct torque specification, working in a ‘star’

pattern, as shown in 2.3 WHEEL AND TYRE

REMOVAL AND INSTALLATION in Section

10, WHEELS AND TYRES.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION ................ 110 – 140 Nm

17. Install the wheel cover (steel wheels) or centre

cap and decorative wheel nut caps (alloy

wheels).

Figure 3-54

3.18 STABILIZER SHAFT

LT Section No. – 06-205

NOTE: To remove the stabilizer shaft completely from the vehicle, it will first be necessary to remove the

crossmember. Refer to 3.16 FRONT SUSPENSION CROSSMEMBER in this Section. Alternatively, the stabilizer

shaft insulators and mounting brack ets, and/or the spacer stud, nuts, discs or insulators, can all be replaced without

removing the stabilizer shaft from the vehicle.

REMOVE

1. Observing the jacking precautions as outlined in 2.3 JACKING PRECAUTIONS in this Section, raise the front of

the vehicle and support on safety stands.

2. After scribing the crossmember alignment marks on the side frame members, remove the front suspension

crossmember mounting bolts, then lower enough to enable removal of the stabilizer shaft from the vehicle.

3. Remove the nuts securing the support bracket to each side of the crossmember, then remove the stabilizer

shaft, support brackets and insulators from the crossmember.

4. Remove the insulators from the stabilizer shaft.

5. With a backing set spanner holding the

stabilizer shaf t link inner stud hexagon (1), use

a second spanner to loosen then remove the

retaining nut (2).

6. Separate the stabilizer shaft link (3) from the

stabilizer shaft (4) and remove the stabilizer

shaft from the vehicle.

Figure 3-55

REINSTALL

The installation procedure of the stabilizer shaft is the reverse of the removal procedure, noting the following:

1. Assemble the two insulators and support brackets onto the stabilizer shaft and bolt the brackets to the

crossmember outrigger.

NOTE: T he s lot in each ins ulator s hould f ac e f or ward, and the rounded s ec tions on the ins ulator s should s eat in the

mating recesses in the crossmember side frame.

2. Tighten the stabilizer shaft support bracket bolts to the correct torque specification.

STABILIZER SHAFT SUPPORT

BRACKET RETAINING NUTS

TORQUE SPECIFICATION ...................... 24 – 30 Nm

3. Install the stabilizer shaft link socket stud nut and tighten to the correct torque specification.

STABILIZER SHAFT LINK SOCKET

STUD RETAINING NUT

TORQUE SPECIFICATION ...................... 45 – 55 Nm

4. Install the f ront suspens ion cross mem ber, as detailed in 3.16 F RONT SUSPENSION CROSSMEM BER in this

Section.

5. Remove the safety stands and lower vehicle.

4. DIAGNOSIS

GENERAL

When diagnosing suspected front suspension problems, it should be remembered that steering,

wheels and tyres all have an effect on front end performance. Refer to Section 9, STEERING and

Section 10, WHEELS AND TYRES for details.

STRUT DIAGNOSIS

1. Test by quickly pushing up and down on the bumper bar at the front corner of the vehicle. Compare the

resistance to movement with a similar vehicle having acceptable ride quality.

2. Inspect the struts for excessive fluid leakage.

ACCEPTANCE CRITERIA

A strut DOES NOT require replacement, if any or a combination of the following are present:

• An oily build-up at the end of the piston rod, up to 1 cm wide.

• Oily ‘sludge’ accumulated from normal operating conditions to 4 cm from the top of the strut body.

• Road greas e, oil, s and and dus t disc olour ation on the body, does not constitute a leaking strut. If this condition is

evident, the strut should be wiped clean and checked at a later service.

NOTE: Should one strut pr ove to be leak ing and require replac em ent, provided the remaining s trut is s erviceable, it

does not also need to be replaced.

4.1 DIAGNOSIS GUIDE

SYMPTOM AND PROBABLE CAUSE REMEDY

HARD OR HEAVY STEERING

1. Low or uneven tyre pressures.

2. S teering gear or connections too tight or misaligned.

3. I nsufficient fl ui d i n steering gear.

4. Excessive caster.

5. Lower front l ower cont rol arm/s and/or front lower cont rol

arm rod/s bent.

6. S teering knuckle bent.

7. Excessive toe-in.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o tyre placard att ached to the vehicle.

2. A dj ust st eeri ng gear or repl ace com ponents as necessary.

Refer to Section 9, S T EERING.

3. Chec k steeri ng gear f l ui d l e vel . Top up, using only

DEXRON III® fluid. Check sys t em for leaks. Ref e r t o Section

9, STEERING.

4. Chec k front wheel alignment. Adjust as necessary. Refer t o

2.2 WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in

this Section.

5. Chec k alignment of front lower control arms and front l ower

control arm rods. Replace components as necess ary.

Refer to 2.2 W HEEL ALIGNMENT CHECKING AND

ADJUSTMENT in this Section.

6. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

7. Chec k and adjust wheel toe. Refer to 2.2 WHEEL

ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

EXCESSIVE PLA Y OR LOOSENESS IN

STEERING

1. S teering gear or connections loose or worn.

2. Front l ower cont rol arm soc ket loose or worn.

3. Front wheel bearings worn.

4. Loose attachment of crossmember to fram e.

1. A dj ust st eeri ng gear or i nstall new components as required.

Refer to Section 9, S T EERING.

2. Replace front lower cont rol arm assembly. Refer to 3.10

FRONT LOWER CONT ROL A RM in this Section.

3. Replace front wheel hub ass embly assembl y. Ref e r t o 3.3

FRONT WHEEL HUB, BRAKE ROTOR OR BRAKE

SHIELD in this Section.

4. Chec k, align and t i ghten crossmember attaching nuts. Refer

to 3.16 FRONT SUSPENSION CROSSMEMBER in this

Sect i on f or al i gnment proc edures.

ERRATIC STEERING ON APPLICATION OF

BRAKES

1. Low or uneven tyre pressures.

2. E xces sive front brake rotor runout.

3. Front brake pads cont aminated with l ubri cant.

4. I nsuffi cient or uneven caster.

5. S teering knuckle bent.

6. E xces sive play in s teering gear.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o the tyre placard at tached to t he vehi cle.

2. Machi ne front rotors . Refer to S ection 5A, SERVICE AND

PARK BRAKING SYSTEM.

3. Replace brake pads. Correct c ause of lubric ant leakage. Refer

to Section 5A, SERVICE AND PARK BRAKING SYSTEM.

4. Chec k front wheel alignment. Refer to 2.2 WHEEL

ALIGNMENT CHECKING AND ADJUSTMENT in this Section.

5. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

6. A dj ust st eeri ng gear or repl ace worn components. Refer t o

Section 9, STEERING.

4.1 DIAGNOSIS GUIDE - Cont'd

SYMPTOM AND PROBABLE CAUSE REMEDY

VEHICLE PULLS TO ONE SIDE

1. Low or uneven tyre pressures.

2. Rear wheels not tracki ng with f ront wheels.

3. Front brake pads cont aminated with l ubri cant.

4. Toe-in incorrect.

5. I n correct or uneven c aster or camber.

6. Rear axle assembly s hi fted.

7. S teering knuckle bent.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o tyre placard att ached to the vehicle.

2. Chec k alignment of rear wheels with front wheels and

correct as necessary. Refer t o Secti on 4A , REAR

SUSPE NS ION for detail s of rear wheel alignm ent.

3. Replace brake pads. Correct c ause of lubric ant leakage. Refer

to Section 5A, SERVICE AND PARK BRAKING SYSTEM.

4. A dj ust toe-in to specificati on. Refer to 2. 2 WHEEL

ALIGNMENT CHECKING AND ADJUSTMENT in this Section.

5. Chec k wheel alignment. Adjust as nec essary. Ref er to 2.2

WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

6. Chec k attac hi ng bol ts for looseness and front lower control

arm bus hi ng for wear. Refer to Section 4A, REAR

SUSPENSION.

7. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

FRONT OR REAR WHEEL TRAMP

1. Wheels and tyres out of balance.

2. Front struts or rear shock absorbers operating

incorrectly, leaking fluid or inoperative.

1. B al ance wheels and tyres. A l so check for ecc entric or

bulged tyres. Repl ace as necessary. Ref er to Sect i on 10

WHEELS AND TYRES.

2. Chec k operation and replace com ponents as nec essary.Ref er

to 3.8 FRONT ST RUT UNI T i n t hi s sect i on or S ection 4A,

REAR SUSPENSION as necessary.

ROAD SHOCKS

1. Incorrect tyre pressures.

2. S teering gear incorrectly adjus ted.

3. Front struts or rear shock absorbers operating

incorrec tly or unevenly, leaking flui d or i noperative.

4. Compress i on or rebound rubbers damaged or missing.

5. Unbalanced wheels.

6. I ncorrect wheel alignment.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o tyre placard att ached to the vehicle.

2. A dj ust st eeri ng gear. Refer to S ection 9, STEERI NG for

details.

3. Chec k operation and replace com ponents as nec essary.

Refer to 3.8 FRONT S T RUT UNI T i n this sec tion or

Sect i on 4A, REAR SUSPENSION as necessary.

4. Replace missing or damaged parts. Refer to 3.8 FRONT

STRUT UNIT i n this Section or Section 4A, REAR

SUSPENSION as necessary.

5. B al ance wheels as detail ed i n Section 10, WHEELS AND

TYRES.

6. Chec k and adjust. Refer to 2. 2 WHEEL ALI GNMENT

CHECKING AND ADJUSTMENT in this Section.

SCUFFED TYRES

1. Toe-in incorrect.

2. Tyres improperly infl ated.

3. Wheels or tyres out-of-true.

4. Front lower control arm soc ket/s worn.

5. Uneven cas ter and cam ber.

6. Lower front lower control arm/s or front lower control arm

rod/s bent.

7. Steering knuckle bent.

1. A dj ust toe-in. Refer to 2.2 WHEEL ALI G NMENT CHE CK ING

AND ADJUSTMENT in this Section.

2. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o the tyre placard at tached to t he vehi cle.

3. Chec k for wheel and tyre wobble. Check that the wheels

and tyres are correctly mounted. Bal ance wheels and

tyres. Ref e r t o S ection 10, WHEELS AND TYRES .

4. Replace worn components. Refer to 3.10 FRONT LOWER

CONTROL ARM in this Sect i on.

5. Chec k wheel alignment. Adjust as nec essary. Ref er to 2.2

WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

6. Chec k alignment of front lower control arm/s and f ront lower

control arm rod/s .

Replace components as necessary. Refer to 3. 10 CONTROL

ARM and 3.14 FRONT LOWER CONTROL A RM ROD in thi s

Section.

7. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

4.1 DIAGNOSIS GUIDE - Cont'd

SYMPTOM AND PROBABLE CAUSE REMEDY

CUPPED TYRES

1. Tyres improperly infl ated.

2. Wheels and tyres out-of-bal ance.

3. Dragging brakes.

4. Front lower control arm soc ket/s and/or wheel bearings

worn.

5. Uneven caster.

6. Steering knuckle bent.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o the tyre placard at tached to t he vehi cle.

2. B al ance wheels and tyres. A l so check for ecc entric or

bulged tyres. Repl ace as necessary. Ref er to Sect i on 10

WHEELS AND TYRES.

3. Chec k for sei zing of the brake c al i pers and/or park brake

mec hanism . Refer to S ection 5A, SERVICE AND PARK

BRAKING SYSTEMS.

4. Replace worn components. Refer t o 3.10 CONTROL ARM

or 3.3 FRONT WHEEL HUB ASSEMBLY, BRAKE ROTOR

OR BRAKE SHIELD in this Section.

5. Chec k wheel alignment. Adjust as nec essary. Ref er to 2.2

WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in this

Section.

6. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

FRONT WHEEL SHIMMY

1. Low or uneven tyre pressures .

2. Steeri ng connections incorrec t l y adj usted or worn.

3. Front lower control arm soc ket/s and/or wheel bearings

worn.

4. Wheels and tyres out-of-bal ance.

5. Wheels or tyres out-of-true.

6. Inc orrect or uneven cas ter or incorrec t toe-in setting.

7. Steering knuckle bent.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o the tyre placard at tached to t he vehi cle.

2. A dj ust st eeri ng gear or i nstall new components as needed.

Refer to Section 9, S T EERING.

3. Replace worn components. Refer t o 3.10 CONTROL ARM or

3.3 FRONT WHEE L HUB A SSEMBLY, B RA KE ROTOR OR

BRAKE SHIELD in this Section.

4. B al ance wheels and tyres. A l so check for ecc entric or

bulged tyres. Repl ace as necessary. Ref er to Sect i on 10

WHEELS AND TYRES.

5. Chec k for wheel and tyre wobble. Check that the wheels

and tyres are correctly mounted. Bal ance wheels and

tyres. Ref e r t o S ection 10, WHEELS AND TYRES .

6. Chec k and adjust. Refer to 2. 2 WHEEL ALI GNMENT

CHECKING AND ADJUSTMENT in this Section.

7. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

CAR WANDERS

1. Low or uneven tyre pressures .

2. Steeri ng connections loose or worn.

3. Steeri ng gear connections adjusted too tightl y.

4. Front lower control arm soc ket/s worn.

5. Wheel t oe settings outside specifi cations.

6. Inc orrect or uneven cas ter.

7. Steeri ng knuckl e bent .

8. Rear axle shifted.

9. Loose attachm ent of front suspensi on crossmemeber to

side members.

1. I nflate tyres to specified press ure f or specifi c load

conditi ons. Refer t o the tyre placard at tached to t he vehi cle.

2. A dj ust st eeri ng gear or i nstall new components as needed.

Refer to Section 9, S T EERING.

3. Tes t steering system for binding with f ront wheels off the

ground. Refer t o S ections 9, STEE RI NG.

4. Replace worn components. Refer to 3.10 FRONT LOWER

CONTROL ARM in this Sect i on.

5. A dj ust toe-in. Refer to 2.2 WHEEL ALI G NMENT CHE CK ING

AND ADJUSTMENT in this Section.

6. Chec k wheel alignment. Adjust as nec essary. Ref er to 2.2

WHEEL ALIGNMENT CHECKING AND ADJUSTMENT in

this Section.

7. Replace steeri ng knuckle. Refer to 3. 9 S T EERING KNUCK LE

in this Section.

8. Chec k all att achment fast eners for sec uri ty, tight eni ng t o

specificati on, as required. Refer to Sec tion 4A, RE A R

SUSPENSION.

9. Chec k, align and t i ghten all fas teners to s pecification. Ref er to

3.16 FRONT SUSPENSION CROSSMEMBER.

5. SPECIFICATIONS

SUSPENSION TRAVEL

SUSPENSION CONFIGURATION COMPRESSION – 2/3

COMPRESSION OF BUMPER

(mm)

REBOUND

(mm)

COUPE 61 115

SEDAN FE1 83 93

SEDAN FR1 103 73

SEDAN FE2 61 115

WAGON FE1 83 93

WAGON FR1 105 71

WAGON FE2 61 115

UTILITY FE1 105 71

UTILITY FE2 61 115

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 3-56

SUSPENSION

CONFIGURATION NUMBER OF

COILS FREE LENGTH

(mm) INSIDE

DIAMETER SPRING TYPE

AND RATE PRODUCTION I.D.

CODE

COUPE 5.25 355 VARIABLE

24 – 31 N/mm

(3660 ± 110N

@ 200mm)

SEDAN FE1 6.05 444 VARIABLE

19 – 23 N/mm

(3700 ± 110N

@ 210mm)

SEDAN FR1 5.74 363 VARIABLE

27 – 35 N/mm

(3600 ± 110N

@ 230mm)

SEDAN FE2 5.25 355 VARIABLE

24 – 31 N/mm

(3660 ± 110N

@ 200mm)

WAGON FE1 6.05 444 VARIABLE

19 – 23 N/mm

(3700 ± 110N

@ 210mm)

WAGON FR1 5.74 363 VARIABLE

27 – 35 N/mm

(3600 ± 110N

@ 230mm)

WAGON FE2 5.25 355 VARIABLE

24 – 31 N/mm

(3660 ± 110N

@ 200mm)

UTILITY FE1 5.74 363 VARIABLE

27 – 35 N/mm

(3600 ± 110 N

@ 230mm)

UTILITY FE2 5.74 351

136 ± 1.5

VARIABLE

27 – 35 N/mm

(3850 ± 110 N

@ 209mm)

FRONT STABILIZER SHAFT DETAILS

Identification of the front stabilizer shaft 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.

The table also provides stabilizer shaft diameters

(2).

SUSPENSION

CONFIGURATION DIAMETER

(mm) PRODUCTION

I.D. CODE

COUPE 27 YA

SEDAN FE1 27 YA

SEDAN FR1 26 YB

SEDAN FE2 27 YA

WAGON FE1 27 YA

WAGON FR1 27 YA

WAGON FE2 27 YA

UTILITY FE1 27 YA

UTILITY FE2 27 YA

Figure 3-57

FRONT STRUT DETAILS

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

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

Identification of the front s trut assem blies f itted 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.

SUSPENSION

CONFIGURATION RIGHT-HAND

PRODUCTION

ID CODE

LEFT-HAND

PRODUCTION

ID CODE

COUPE ZJ ZK

SEDAN FE1 MD MC

SEDAN FR1 RS LS

SEDAN FE2 RT LT

WAGON FE1 MD MC

WAGON FR1 RS LS

WAGON FE2 RT LT

UTILITY FE1 RS LS

UTILITY FE2 RT LT

Figure 3-58

FRONT LOWER CONTROL ARM DETAILS

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

crossmember and front lower control arm rod. Front lower control

arm socket assembly is a press fit into the front lower control arm

and is not serviced seperately.

FRONT WHEEL BEARINGS

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

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

SUSPENSION A ND TRIM HEIGHT SPECIFICATIONS

A Front S uspension Height Location

B Rear S uspension Height Location

C Front Trim Height Chec k Location

D Rear Trim Height Check Location

1. Wheelbase:

Sedan – 2788 mm

Coupe – 2788 mm

Station Wagon – 2938 mm

Utility – 2938 mm

2. Reference Point: All Models – 584.5 mm

3. Trim Height Spacing:

Sedan – 1615 mm

Coupe – 1615 mm

St ation Wagon – 1765 mm

Utilit y – 2938 mm

4. Ground Line

Figure 3-59

1. Door 2. Trim 3 Ground Line ‘A’ Trim Height 1. Wheel Rim 2. Fender Opening ‘A’ Suspens i on Hei ght

Figure 3-60 – Rear Trim Height Checking Location (Front

Similar) Figure 3-61 – Front and Rear Suspension Height Checking

Location

NOTE: T he follow ing suspension/trim height dimensions are for reference only and are only intended to be

a guide. Refer to 3.2 SUSPENSION AND TRIM HEIGHT, CHECK for ride height variations and additional

procedures.

MY 2003 VY AND V2 MODELS SUSPENSION HEIGHT

(mm) TRIM HEIGHT

(mm)

VEHICLE

DESCRIPTION TRANSMISSION SUSPENSION FRONT

(‘A’ in

Fig. 3-61)

REAR

(‘B’ in

Fig. 3-61)

FRONT

(‘C’ in

Fig. 3-60)

REAR

(‘D in

Fig. 3-60)

Coupe Level 1 Automatic FE2 611 609 172 186

Coupe Level 3 Manual/Automatic FE2 624 622 176 190

Level 1 and 2 Sedan Manual/Automatic FE1/FR1 605 594 192 201

Level 1 and 2 Sedan

(exc ‘S’ and ‘SS’) Manual/Automatic FE2 583 581 172 186

‘S’ Sedan Manual/Automatic FE2 605 603 172 186

‘SS’ Sedan Manual/Automatic FE2 611 609 172 186

Level 3 Sedan Automatic FE1/FR1 618 607 192 201

Level 3 Sedan Automatic FE2 596 608 172 186

Level 1 and 2 Wagon Manual/Automatic FE1/FR1 601 583 192 210

Level 1 and 2 Wagon Manual/Automatic FE2 586 568 177 195

Level 1 Utility Manual/Automatic FE1 616 641 210 235

‘S’ Utility Manual/Automatic FE1 629 654 210 235

‘S’ Utility Manual/Automatic FE2 619 654 202 233

‘SS’ Utility Manual/Automatic FE2 619 644 185 210

FRONT WHEEL ALIGNMENT SPECIFICATIONS

FRONT WHEEL ALIGNMENT AT CURB WEIGHT

Wheel Alignment Angle Specifications - All Models

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 adjusting.

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

• Cam ber adjusting bolt: After loosening both lower strut to steering

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

necessary (refer to Section 4A, REAR SUSPENSION) before

checking front wheel alignment.

Fuel Mass with Full Tank - All Models 56 kg

Figure 3-62

6. TORQUE SPECIFICATIONS Nm

+ Brake Caliper Retaining Bolts..................................Stage 1 : 80 - 90

Stage 2 : Turn through 40° - 50°

Stabilizer Shaft Link Socket Stud Retaining Nut................... 45 - 55

Stabilizer Shaft Support Bracket Retaining Nut.................... 24 - 30

Stabilizer Shaft Link Upper Nut............................................. 13 - 18

6 Front Wheel Hub Assembly To Steering Knuckle

Attaching Bolt........................................................................ 100 - 115

Steering Linkage Outer Tie Rod Socket Assembly Stud

Castellated Nut ..................................................................... 50 - 80

Steering Linkage Outer Tie Rod To Steering Linkage Outer

Tie Rod Socket Assembly Lock Nut ..................................... 40 - 60

+ Steering Knuckle To Strut Attaching Bolt.................Stage 1: 85

Stage 2: 100

Stage 3: Turn through 90°

Wheel Speed Sensor (Abs) Cable Retaining Screw............. 6 - 14

Upper Strut Bearing Retaining Nut ....................................... 70 - 85

+ Upper Strut Locating Plate Retaining Nut............................. 50 - 60

6 Front Lower Control Arm Socket Assembly Stud Nut........... 50 - 70

Steering Linkage Outer Tie Rod Socket Assembly Stud

Castellated Nut ..................................................................... 58 - 71

+ & Front Lower Control Arm Pivot Bolt And Nut ........................ 95 - 100

+ & Front Lower Control Arm Rod To Front Lower Control Arm

Attaching Nut ........................................................................ 95 - 110

+ & Front Lower Control Arm Rod To Insulating Bushing

Retaining Nut........................................................................ 140 - 155

Front Lower Control Arm Rod Insulating Bushing

Assembly Attaching Nut........................................................ 20 - 26

+ Crossmember To Side Frame Bolt....................................... 100 - 125

6 Steering Gear Housing To Crossmember Mounting Nut...... 70 - 85

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

Fasteners must be replaced after loosening.

• Vehicle mus t be at curb height before final tightening.

♦ Fasteners either have micro encapsulated sealant applied or incorporate a

mechanical thread lock and should only be re-used once. If in doubt, replacement is

recommended.

7. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

180

SPRING COMPRESSOR

Previously released.

7311

STEERING LINKAGE OUTER TIE

ROD SOCKET ASSEMBLY

REMOVER

Previously released.

Can also be used on earlier ‘V’ cars

for the same purpose.

7A42

PRESS PLATES

Previously released.

9A10

STEERING LINKAGE OUTER TIE

ROD SOCKET ASSEMBLY

REMOVER

Previously released for ‘V’ car.

AJ24292-C

PRESS TOOL

Previously released for ‘VQ’

vehicles.

Used to remove wheel studs from

front wheel hub assembly.

AU158

FRONT LOWER CONTROL ARM

ROD BUSHING REMOVER AND

INSTALLER MANDREL

Previously released for ‘V’ car.

Used with KM158-2 for removing

bush and AU159 and KM157-2 for

installing.

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

AU158-2

FRONT LOWER CONTROL ARM

ROD BUSHING INSTALLING

SUPPORT SLEEVE

Previously released for ‘V’ car.

Used with AU158 and AU159.

AU159 FRONT LOWER CONTROL ARM

ROD BUSHING REPLACER

SLEEVE

Previously released for ‘V’ car.

AU160-1 SUPPORT

Previously released.

Used to support front lower control

arm when installing a new inner

insulator.

AU162 FRONT LOWER CONTROL ARM

PIVOT BUSHING

REMOVAL MANDREL

Used with AU160-1 and KM157-2.

Previously released for ‘V’ car.

AU534 TORQUE LIMITING SOCKET

Previously released.

Used in conjunction with an impact

gun to tighten wheel nuts.

This is a mandatory

tool.

E7115 ANGLE WRENCH

Previously released for 'J' and 'V'

cars.

Used to tighten component

fasteners when angle torque is

required.

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

E9332-A FRONT LOWER CONTROL ARM

SOCKET ASSEMBLY RELEASE

TOOL

Previously released.

Used to release the front lower

control arm socket from the

steering knuckle.

KM157-2

FRONT LOWER CONTROL ARM

PIVOT BUSHING INSTALLER

Previously released for ‘V’ car.

Used with AU158 and AU159.

KM158-2

FRONT LOWER CONTROL ARM

ROD BUSHING INSTALLING

SUPPORT SLEEVE

Previously released for ‘V’ car.

Used with AU158 and AU159.

KM468 HOLDING BAR

Previously released for 'J' car.

Used to hold front wheel hub

assembly from rotating.