Front Suspension Page 3–1

28-FEB-2003 Page 3–1

Section 3

Front Suspension

ATTENTION

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.

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

2 Wheel Alignment.................................................................................................................................... 3

3 Service Operations................................................................................................................................4

3.1 Service Notes and Cautions..................................................................................................................................4

4 Specifications......................................................................................................................................... 5

Front Suspension Details......................................................................................................................................5

Front Spring Details...............................................................................................................................................5

Front Stabilizer Bar Details....................................................................................................................................6

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

Front Control Arm Details......................................................................................................................................7

Front Wheel Bearings............................................................................................................................................7

Suspension and Trim Height Specifications........................................................................................................7

Front Wheel Alignment Specifications.................................................................................................................9

Techline

Front Suspension Page 3–2

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1 General Information

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

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

V2 Series Service Information.

• The trim height, wheel alignment and general specifications are unique.

NOTE

There are three suspension options available for

MY 2004 WK Series Models; Standard

(Production Option FE1), Sports (Production

Option FE2) and Automatic Level Ride (FX3).

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

Section 0A, 9.3 Body And Option Identification

Plate. For all other information regarding the

suspension application fitted to a particular

vehicle, refer to 4. Specifications in this Section.

Front Suspension Page 3–3

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2 Wheel Alignment

With the following exceptions, MY 2004 WK Series front suspension wheel alignment information carries over from MY

2003 VY Series vehicles. For information not covered in this Section, refer to Sectio n 3, 2. Wheel Alignment in the MY

2003 VY Series and V2 Series Service Information.

• The wheel alignment specifications are unique, refer to 4. Specifications in this Section.

NOTE

Even though some of the 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.

Front Suspension Page 3–4

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3 Service Operations

With the following exceptions, MY 2004 WK Series front suspension service operation information carries over from MY

2003 VY Series vehicles. For information not covered in this Section, refer to Sectio n 3, 3. Service Operatio ns in the MY

2003 VY Series and V2 Series Service Information.

• The trim height specifications are unique, refer to 4. Specifications in this Section.

3.1 Service Notes and Cautions

NOTE

Whenever a road wheel and/or brake disc is

removed from or installed to a MY 2004 WK

Series vehicle, it MUST be done in accordance

with the procedure provided in Section 10,

2.3 Wheel Removal And Reinstallation in the MY

2003 VY Series and V2 Series Service

Information.

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 Section 5B, 4.4 ABS & TCS

Function Check (V6 engines) or 5.4 ABS &

TCS Function Check (GEN III V8 engines) in

the MY 2003 VY Series and V2 Series Service

Information.

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4 Specifications

Front Suspension Details

SUSPENSION

CONFIGURATION COMPRESSION - 2/3 COMPRESSION

OF BUMPER (mm) REBOUND (mm)

LEVEL 1 to 4 & FE1 81 114

FE2 67 127

FX3 81 114

RHD LEVEL 5 & FE1 75 122

LHD LEVEL 5 & FE1 81 114

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 3-1

SUSPENSION

CONFIGURATION NUMBER OF

COILS FREE LENGTH

(mm) INSIDE

DIAMETER

(mm)

SPRING TYPE

AND RATE PRODUCTION

ID CODE

RHD & FE1 5.74 363 VARIABLE

37 - 35 N/mm

(3600 ± 110 N

@ 218 mm)

LHD & FE1 6.05 444

VARIABLE

19 - 23 N/mm

(3700 ± 110 N

@ 210 mm)

FE2 6.11 355

136 ±1.5 VARIABLE

24 - 31 N/mm

(3660 ± 110 N

@ 210 mm)

RHD & FX3 5.74 363 VARIABLE

37 - 35 N/mm

(3600 ± 110 N

@ 218 mm)

LHD & FX3 6.05 444

VARIABLE

19 - 23 N/mm

(3700 ± 110 N

@ 210 mm)

Front Suspension Page 3–6

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Front Stabilizer Bar Details

Identification of the front stabilizer bar 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 bar diameters (2).

Figure 3-2

SUSPENSION

CONFIGURATION DIAMETER

(mm) PRODUCTION

ID CODE

RHD LEVEL 4 27 YB

RHD LEVEL 5 26 YA

LHD 26 YA

Front Strut Details

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

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

Identification of the front strut assemblies 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 3-3

SUSPENSION

CONFIGURATION RIGHT-HAND

ID CODE LEFT-HAND

ID CODE

RHD LEVEL 4 & FE1 NV NW

RHD LEVEL 5 & FE1 MC MD

LHD & FE1 MC MD

FE2 ZP ZX

RHD LEVEL 4 & FX3 NV NW

RHD LEVEL 5 & FX3 MC MD

LHD & FX3 MC MD

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Front Control Arm Details

Forged with rubber bushes for attachment to the front crossmember and tens ion rod. Ball joint is a press fit

into the control arm and is not serviced separately.

Front Wheel Bearings

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

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

Suspension and Trim Height Specifications

Figure 3-4

Legend

A Front Suspension Height Location

B Rear Suspension Height Location

C Front Trim Height Check Location

D Rear Trim Height Check Locati on

1 Wheelbase: All Models - 2938 mm

2 Reference Point: All Models - 584.5 mm

3 Trim Height Spacing: All Models - 1765 mm

4 Ground Line

Figure 3-5 - Rear Trim Height Checking Location

(Front Similar) Figure 3-6 - Front and Rear Suspension Height

Checking Location

Legend Legend

1 Door

2 Trim

3 Ground Line

A Trim Height

1 Wheel Rim

2 Fender Opening

A Suspension Height

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NOTE

The following suspension/trim height dimensions

are for reference only and are only intended to be

a guide. Refer to Section 3, 3.2 Suspension and

Trim Height, Check in the MY 2003 VY and V2

Series Service Information for ride height

variations and additional procedures.

MY 2004 WK MODELS SUSPENSION HEIGHT (mm) TRIM HEIGHT (mm)

VEHICLE

DESCRIPTION SUSPENSION

CONFIGURATION FRONT

('A' in Fig. 3-54) REAR

('B' in Fig. 3-54) FRONT

('C' in Fig. 3-54) REAR

('D in Fig. 3-54)

Level 1 FE1 594 588 190 201

Level 1 FE2 586 580 176 186

Level 1 FX3 594 588 190 201

Level 2 FE1 606 600 190 201

Level 2 FE2 599 593 176 186

Level 2 FX3 606 600 190 201

Level 3 FE2 611 605 176 186

Level 4 FE1 606 600 190 201

Level 4 FX3 606 600 190 201

RHD Level 5 FE1 613 606 185 192

LHD Level 5 FE1 606 600 190 201

Level 5 FX3 618 612 190 201

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Front Wheel Alignment Specifications

FRONT WHEEL ALIGNMENT AT KERB 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 changing.

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

Camber adjusting bolt: After loosening both lower strut to steering knuckle bolts and nuts, adjust camber by turning

the adjusting bolt clockwise to decrease negative camber and anti-clockwise to increase negative camber. After

adjustment, both bolts and nuts MUST be replaced with new parts and tightened to the recommended torque setting.

The rear wheel alignment should be checked and corrected if necessary (refer to Section 4A, Rear Suspension)

before checking front wheel alignment.

Fuel Mass with Full Tank - All Models 56 kg