Front Suspension (04.01)
Suspension (04.00)
November 2008 Workshop Manual 4-1-3
Maintenance
RH/LH Front Hub and Bearing Assembly
- Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Release pad wear sensor harness clips (x2) from upper suspension arm.
4. Disconnect multiplug from wheel speed sensor.
5. Ease caliper pistons to release pads.
6. Remove caliper Allen bolts (x2), release caliper and tie
aside.
7. Remove retaining screws (x2) and disc.
8. Remove Torx securing wheel speed sensor to vertical link, remove sensor.
9. Remove Allen bolts (x4) securing hub bearing assembly to vertical link. 10. Release/remove hub bearing assembly from vertical link.
Installation
1. Clean hub bearing carrier and mating face on vertical
link.
2. Install hub bearing assembly, install and torque tighten Allen bolts (x4).
3. Clean wheel speed sensor.
4. Install wheel speed sensor, install and torque tighten Torx screw.
5. Clean disc.
6. Install disc, install and torque tighten retaining screws (x2).
7. Connect multiplug to wheel speed sensor.
8. Install caliper, install and to rque tighten Allen bolts (x2).
9. Install pad wear sensor harness clips (x2) in upper suspension arm.
10. Pump brake pedal.
11. Install road wheel(s).
12. Lower vehicle on ramp.
Vibration/Noise
Tyres/road wheel
Road wheel bearing assemblies
Brake components
Suspension components
Spring and damper units
Steering components Check. Install new components as required.
Vehicle Leans to
One Side Unevenly loaded or overloaded vehicle Notif
y customer of incorrect vehicle loading .
Front or rear suspension components Inspect front and rear suspension systems.
Spring and damper assemblies Check spring and damper assemblies.
Incorrect ride height. Lateral tilt out of
specification
Suspension bushes not torqued at ride
height Check ride height.
Check / adjust suspension bushes torque.
Wander Unevenly loaded or overloaded vehicle Notif y customer of incorrect vehicle loading .
ball-joint(s) Check ball-joint(s).
Front road wheel bearing(s) Check road wheel bearings.
Loose, worn or damaged suspension
components Check suspension components.
Loose suspension fasteners Check and tighten suspension fasteners to specification.
Steering components Check steering components for wear and / or free play.
Road wheel alignment (excessive total
front Toe-out) Check / adjust road wheel alignment
(Refer to ’Road Wheel Alignment (04.00)’, page 4-0-2).
SymptomPossible CauseAction
Caution
Be careful with the suspension components. The
suspension components can be damaged if hit, for example, with a metal faced hammer.
Repair Operation Time (ROT)
Road Wheels and Tyres (04.04)
Suspension (04.00)
May 2007 Workshop Manual 4-4-5
Road Test
A tyre vibration diagnostic proc edure always begins with a road test. The road test and customer interview (if available)
will provide much of the information neede d to find the source of a vibration.
During the road test, drive the vehicle on a road that is smoot h and free of undulations. If vibration is apparent, note and
record the following:
• The speed at which the vibration occurs
• What type of vibration occurs in each speed range
• How the vibration is affected by changes in the following types of vibration-sensitivity:
Torque Sensitive - This means that the condition may be improved or made worse by accelerating, decelerating, coasting,
maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive - This means that the vibration always occurs at the same vehicle speed and is not affected by
engine torque, engine speed or the transmission gear selected.
Engine Speed Sensitive - This means that the vibration occurs at varyin g vehicle speeds when a different transmission
gear is selected. It may sometimes be isolated by increasing or decreasing engine speed with the transmission in NEUTRAL
or by stall testing with the transmission in gear. If the condition is engine speed sensitive, the cause is probably not relate d
to the tyres.
If the road test indicates that there is tyre whine, but no sh ake or vibration, the noise originates with the contact between
the tyre and the road surface.
A thumping noise usually means that the tyre has a flat or soft spot making a noise as they slap the roadway. Tyre whine
may be distinguished from axle noise. Tyre whine remains the same over a range of speeds.
Symptoms
SymptomPossible Source(s):Action(s)
Tyres show excess wear on
edge of treads Tyres under-inflated Correct pressure to specification.
Vehicle overloaded Correct as required.
Tyres show excess wear on
edge of treads (having the
correct tyre pressures) Incorrect toe setting Set to specification.
Tyres show excess wear in
center of tread Tyres over-inflated Correct pressure to specification.
Other excessive tyre wear
problems Incorrect tyre pressure Correct pressure to specification.
Incorrect tyre and wheel usage Install correct tyre and wheel combination.
Geometry out of alignm
ent Check and adjust.
Loose, worn or damaged suspension
components Inspect, repair or install new suspension
components as necessary.
Wheel and tyre assembly out of
balance Balance wheel and tyre assembly.
Excessive lateral or radial runout of
wheel or tyre Check, repair or install a new wheel or tyre as
necessary.
Wheel mounting is difficult Incorrect application or mismatched
parts, including wheel studs and wheel
nuts. Corroded, worn or damaged parts Clean or install new parts.
Wobble or shimmy affecting
wheel runout Damaged wheel (eventually damaging
wheel bearings and causing uneven
tyre wear) Inspect wheel rims for damage and runout.
Install a new wheel rim as necessary.
Excessive vibration, rough
steering or severe tyre wear Loose or incorrect attaching parts Tighten or install new parts.
Road Wheels and Tyres (04.04)
Suspension (04.00)
May 2007 Workshop Manual 4-4-7
Repairs
In view of the high performance capability of the vehicle,
damaged tyres should be renewed and not repaired.
Care of Alloy Road Wheels
Aluminium alloy road wheels are covered with a protective
coating. To prevent corrosion it is essential that this coating
is not damaged. When removing or installing tyres only
equipment utilizing spigot or stud hole clamping must be
used. The equipment must not have any moving parts which
contact the road wheel, and ty re levers must not be used.
To clean road wheels use warm soapy water; stubborn stains
can be removed using a soft brush or by using a proprietary
alloy road wheel cleaner.
Road Wheel Alignment
It is important that correct road wheel alignment be
maintained. Misalignment causes tyre tread to be scrubbed
off laterally because the natural direction of the road wheel
differs from that of the vehicle.
A sharp ‘fin’ protrusion on the edge of each pattern rib is a
sure sign of misalignment.
• ‘Fins’ on the inside edges of the pattern ribs, particularly on the nearside tyre, indicate Toe-in.
• ‘Fins’ on the outside edges, particularly on the offside tyre, indicate Toe-out.
With minor misalignment, the ev idence is less noticeable
and sharp pattern edges may be caused by road camber
even when the road wheel alignment is correct. In such
c a s e s i t i s b e t t e r t o m a k e s u r e b y c h e c k i n g w i t h a n a l i g n m e n t
gauge. Road camber affects the direction of the vehicle by
imposing a side thrus t and , if le ft to follow its natural cou rs e,
the vehicle will drift towards its nearside. This is instinctively
corrected by steering towards the road centre and, as a
result, the vehicle runs crab wise. The diagram shows why
nearside tyres are very sensitive to too much Toe-in and
offside tyres to Toe-out. It also shows why sharp ‘fins’ appear on one tyre but not on
the other, and why the direction of misalignment can be
determined by noting the position of the ‘fins’. Severe
misalignment produces clea
r evidence on both tyres.
Front road wheels on a moving vehicle should be parallel.
Tyre wear can be affected noticeably by quite small
variations from this condition. It will be noted from the
diagram that even with parallel road wheels, the vehicle is
still out of line with its dire ction of movement, but there is
less tendency for the wear to be concentrated on one tyre.
The near front tyre sometimes persists in wearing faster and
more unevenly than the other tyres, even when the
mechanical condition of the vehicle and tyre maintenance
are satisfactory. The more severe the average road camber,
the more marked this tendency will be.
Caution
When a new tyre is installe d, always renew the tyre
valve.
Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
Issue 4, November 2008 Workshop Manual 6-9-1
Brake system (06.00)
Anti-lock Braking System (ABS) (06.09)
The anti-lock braking system (ABS) is a four-channel system
having independent inputs from all four-wheel speed
sensors.
The ABS module, monitors signals from the sensors to
calculate, brake slip and the acceleration / deceleration of
individual wheels. When the brake pedal is depressed, and
the ABS module detects incipient wheel lock-up from the
incoming signals, it triggers the re-circulation pump inside
the module’s hydraulic modulator, and the solenoid valves
for the wheel(s) concerned. Brake pressure, is then
modulated to increase / decrease or remain constant at the
wheel(s) concerned until whee l lock-up is eliminated. The
ABS provides self-diagnosis and any malfunction within the
system will be indicated to the dr iver by the illumination of
the brake warning light and ‘ABS FAULT’ displayed in the
message centre right. Should a fault develop within the ABS,
the brake system will operate conventionally and with the
same standard of performanc e as a vehicle not equipped
with ABS.
Dynamic Stability Control
Dynamic Stability Control (DSC ) is a closed-loop system
designed to enhance driving safety by improving vehicle
handling when the tyres are at the limits of their grip
capabilities. This is achieved through instantaneous,
electronically controlled, reduction of engine torque and
strategic application of the brakes at individual wheels.
By using the principle that by controlling the brakes
individually it is possible, to an extent, to steer the vehicle.
This principle can be used to enhance driving safety by
correcting the vehicle’s yaw moment (turning force), when
the vehicle fails to follow th e driver’s steering inputs.
Concept
Satisfactory handling is determined according to whether a
vehicle maintains a path, wh ich accurately reflects the
driver
Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
6-9-2 Workshop Manual Issue 4, November 2008
difference between the ideal and actual response within a
tolerance band. This directly influences the forces on the
tires to generate a corrective yaw moment to reduce the side
forces of the tires where appropriate
System Overview
The DSC system embraces capabilities far beyond that of
ABS, or ABS and traction control combined, while relying on
the components of these systems. It also incorporates these
additional sensors for measur ing the vehicle’s motion and
brake system pressure:
Ya w r a t e s e n s o r - located centrally on the transmission
tunnel.
Lateral acceleration sensor - integrated with the yaw rate
sensor.
Steering angle sensor - located on the upper steering
column.
Pressure transducer - located on master cylinder.
The ABS / DSC module supports data exchange with other
vehicle electronic systems via the CAN network; the module
also enables diagnostic interrogation using WDS.
The following components register driver demand and the
ABS / DSC module processes their signals as a basis for
defining an ideal response:
PCM - position of accelerator pedal.
Brake master cylinder pressure transducer - driver’s
braking effort.
Steering angle sensor - position of steering wheel.
There are many supplementary parameters also included in
the processing calculations these include the coefficient of
friction and vehicle speed. The ABS / DSC module monitors
these factors based on signals transmitted by the sensors for:
• Wheel speed
• Lateral acceleration
• Brake pressure
• Yaw rate
Using these parameters, the function of the ABS / DSC
module is to determine the current vehicle status based on
the yaw-rate signal and the slip as estimated by the ABS /
DSC module. It then maintains the vehicle response within
a tolerance of the ‘normal’ behaviour, which is easily
controlled by the driver.
In order to generate the desired yaw behaviour the ABS /
DSC module controls the selected wheels using the ABS
hydraulic system and engine control system. In the event of
engine intervention, the ABS / DSC module calculates the
torque which should be supplied by the engine to the
wheels, and relays this request signal to the PCM which
implements the torque request.
The PCM receives signals from the DSC system via the CAN
bus and reduces engine torque as follows:
• The throttle is positioned to provide the requested engine target torque. • During the transient phase of torque reduction caused by
mechanical and combustion delays, other alternative
torque reduction methods are used to provide a quicker
response.
• The ignition is retarded and / or the fuel is cut-off at the injectors at selected cylinders.
• Ignition and fuelling are reinstated when the engine torque reaches the requested value
Operation Summary
• DSC is switched ‘ON’ when the engine is started
• When the system is operating , the DSC light in the instrument cluster will flash, at the rate of twice a second
• DSC can be switched ‘OFF / ON’ by pressing the DSC switch
• The DSC light in the instru ment cluster will illuminate
continuously when the system is switched ‘Off’.
• ‘DSC OFF’ will be displayed in the message centre right to indicate the system has been switched ‘OFF’
• A malfunction in the traction control system will be indicated to the driver by the following:
• The DSC light in the instru ment cluster will illuminate
continuously
• The message ‘DSC NOT AVAILABLE’ will be displayed in the message centre right
• If vehicle speed control is engaged it will automatically disengage when traction control is operating .
Traction Control
Traction control is a function of DSC, and is operated in
association with DSC. Traction control prevents excessive
wheel-spin at standing starts, or during acceleration. Wheel-
spin is usually caused by ex cessive use of the accelerator
pedal, or slippery, loose or bumpy road surfaces. To prevent
excessive wheel-spin and mainta in vehicle stability such
situations are overcome by the intervention of the traction
control system by:
• Braking the driven-wheel when it starts to slip
• And / or adapting the engine torque to a level corresponding to the traction available on the road
surface.
Functional Description
Traction control uses the ABS electronic and mechanical /
hydraulic hardware with additional valves to control the
braking pressure at the calipe rs. An engine interface also
enables the engine to respond to torque reduction requests
from the traction control. As with ABS, the signals from the
wheel-speed sensors are supplied to the ABS module, where
they are used to calculate the wheel-slip of the individual
wheels. Traction control intervention is initiated if the slip at
one of the wheels is excessive.
Anti-lock Braking System (ABS) (06.09)
Brake system (06.00)
Issue 4, November 2008 Workshop Manual 6-9-3
Engine Intervention
In the event of wheel-slip the ABS / DSC module calculates
the torque, which should be applied by the engine to reduce
the wheel-slip (this torque does not exceed driver demand).
Engine torque reduction is then requested from the PCM via
the CAN bus. The PCM, in response to these signals, reduces
engine torque by controlling the ignition and fuelling. A
traction control gearshift pattern is automatically selected
within the automatic transmission software whenever
traction control is active.
Brake Intervention
This function operates by increasing the pressure in the
brake caliper of the slipping wheel, by closing the separation
valve and the inlet valve of the non-slipping wheel and
running the modulator pump. This takes fluid from the fluid
reservoir via the non-actuated master cylinder and
pressurizes the brake caliper. The pressure is modulated at
the caliper via the inlet and outlet valves to achieve the
desired wheel-slip target to maximize traction.
ABS / DSC Circuit
Specifications
SR,05UR,05YR,0.5NR,0.5
WR,05NR,05
YG,05WG,05
YU,05WU,05
W,05N,05
W,0.5U,0.5R,0.5
P,0.5Y,0.5
B,0.5WG,0.5GB,0.5
B,0.5BG,0.5
GW,0.5
P,0.5
U,0.5
U,3.0
BK,1.0BK,1.0
P,0.35P,0.35P,0.35 U,3.0
WG,05YG,05
WU,05
SR,05UR,05YR,0.5NR,0.5
WG,05YG,05
WU,05
WG,05YG,05
WU,05YU,05YU,05YU,05Module-ABS
OBD2-Body (B)
Earth-Module ABSEarth-Module ABS
C1184-18C2410-6
Sensor-Brake Pressure
Sensor-Brake Pedal Travel
Sensor-Rear ABS-LH
C0746-7C0746-6
C0746-5
Switch-Brake Boost
Sensor-Yawrate / Acceleration
C2411-6C2411-5C2411-4
C2411-3
C0144-7C0144-3
C0144-2
Sensor-Front ABS-LH
Sensor-Front ABS-RH
C2410-10C2410-9
C2410-8
Sensor-Rear ABS-RH
C0746-4C0144-1C2410-7
C0877-7
K-LINESPL50-KL/FA
C0362-1C0434-1
C2444-2
SIGC2444-1
GND
C2444-3
SENSP
C2446-2
GNDC2446-1
SENSPT
C2446-3
SIG
C0501-47
GNDC0501-16
GND
C0501-2K-LINE
C0501-24
GND
C0501-31
PWM
C0501-30
NC
C0501-25
CAN HS-
C0501-28
SIGC0501-27
NO
C0501-29
CAN HS+C0501-6
CLUST_SP
C0501-17
PWR
C0501-5
GND
C0501-32BATT FEED
C0501-7
SENSPT
C0501-3 SIG
C0501-20 SIGC0501-19
GND
C0501-18 SENSP
C0501-4IGN FEED
C0501-46
F/L/GNDC0501-45
F/L/SIG
C0501-42
R/R/GNDC0501-43
R/R/SIG
C0501-36
R/L/SIG
C0501-34
F/R/SIGC0501-33
F/R/GND
C0501-1
BATT FEEDC0501-37
R/L/GND
C2448-5
C2448-3
C2448-2C2448-1
C2448-4
C1656-3 CLUS_SPC1656-2
CAN HS+C1656-1 CAN HS-
C1656-5
GND
C0516-2-C0516-1+
C0517-2
-C0517-1+
C0502-1
+
C0503-2 -C0503-1+
C0502-2 -
Sensor
Steering Angle
Sheet 61
F4
30.0 AmpsRelay 1
Underbonnet Fusebox
DIODE 1
F28
10.0 Amps
F20
30.0 Amps
F19
30.0 Amps
Earth
Steering Angle
Sensor
C0576-1
C0577-4C2608-1 VBATT
C0573-2
C0571-3
C0573-3
C0578-8SPL5-VIGN/FOR
C1672-5
VPWRC1672-8
GND
011-6-003
Oils/Greases
Brake FluidCastrol Response Super Dot 4
Torque Figures
DescriptionNm.lb. / ft.
Modulator to Bracket 5 4
Modulator / Bracket to body 9 7
Brake hose unions 17 1413
10.5
17 Nm. 17 Nm.
17 Nm.
14 Nm.
14 Nm. 14 Nm.
Automatic Control System (07.05)
Transmission (07.00)
Issue 4, November 2008 Workshop Manual 7-5-1
Transmission (07.00)
Automatic Control System
(07.05)
Maintenance
Paddle Shift Switch Assembly - Renew -
(Sportshift Only)
Remove
1. Remove the top and bottom shrouds from the steering column (Refer to ’Top and Bottom Shrouds for the
Steering Column - Remove and Install’, page 11-4-4).
2. Remove the screw that attaches the paddle shift switch assembly (switch assembly) to the steering column (Refer
to Figure. 1).
3. Move the paddle shift switch assembly to get access to the electrical connector.
4. Disconnect the electrical connector for the paddle shift switch assembly (see Figure 2). 5. Remove the switch assembly.
Install
1. Connect the electrical connector for the switch
assembly.
2. Put the switch assembly in position on the steering column.
3. Install the screw that attaches the switch assembly.
4. Remove the top and bottom shrouds from the steering column (Refer to ’Top and Bottom Shrouds for the
Steering Column - Remove and Install’, page 11-4-4).
5. Connect the vehicle battery.
Sportshift Drive Switc h-Renew-Sportshift
Only
Removal
1. Battery isolation switch OFF.
2. Remove upper centre panel using special tool (501 115) to hook into either one of the two centre air vents (see
Figure 1).
Repair Operation Time (ROT)
!
!
Repair Operation Time (ROT)
!
Issue 5, January 2010 Workshop Manual 11-1-1
Steering (11.00)
Contents
Steering Gear (11.01) .......................................... 11-1-2Diagnostics - Symptom Chart................................. 1-2
Specifications.......................................................... 1-4
Power Steering (11.02) ........................................ 11-2-1 Description ............................................................. 2-1
Specifications.......................................................... 2-1
Maintenance ........................................................... 2-2Power Steering System - Bleed ............................... 2-2
Procedure .............................................................. 2-2
Power Steering Pump-Renew ................................. 2-2
Power Assisted Steering (PAS) Rack -
Remove and Install................................................. 2-2
RH/LH Track Rod End-Renew .............................. 2-11
Power Steering Pump to Rack Hose Assembly
-Renew ................................................................ 2-11
Power Steering Rack to Cooler Hose-Renew ........ 2-12
Steering Column (11.04)...................................... 11-4-1 Description ............................................................. 4-1
Specifications.......................................................... 4-1
Maintenance ........................................................... 4-1Top Shroud for the Steering Column
- Remove and Install .............................................. 4-1
Bottom Shroud for the Steering Column
- Remove and Install .............................................. 4-1
Steering Column Gaiter-Renew .............................. 4-2
Upper Steering Column Assembly-Renew .............. 4-3
Top and Bottom Shrouds for the Steering Column
- Remove and Install .............................................. 4-4
Steering Column Lower Shaft Assembly-Renew ...... 4-5
Steering Column Switches (11.05)....................... 11-5-1 Maintenance ........................................................... 5-1Ignition Switch-Renew (Pre-08 MY Only) ............... 5-1
Steering Column Stalk Assembly Switch-Renew
(Pre-08 MY Only) ................................................... 5-1
Cruise Control Switch-Renew................................. 5-2
Indicator Switch for the Steering Column
- Remove and Install .............................................. 5-2
Airbag Rotary Coupler Assembly - Remove and
Install ..................................................................... 5-2
Wiper Switch for the Steering Column
- Remove and Install .............................................. 5-4
Steering Wheel (11.06) ........................................ 11-6-1 Specifications.......................................................... 6-1
Maintenance ........................................................... 6-1Steering Wheel-Renew .......................................... 6-1
Driver’s Airbag Module - Remove and Install .......... 6-1