Volkswagen New Beetle. Manual - part 2114

2003-04 SUSPENSION 

General Diagnosis - H2 

TRIM HEIGHT SPECIFICATIONS 

Fig. 1: Trim Height Specifications 
Courtesy of GENERAL MOTORS CORP. 

DIAGNOSTIC INFORMATION 

DIAGNOSTIC STARTING POINT - SUSPENSION GENERAL DIAGNOSIS 

Begin the system diagnosis by reviewing the system Description & Operation. See REAR SUSPENSION - 
H2 . Reviewing the Description and Operation information will help you determine the correct symptom 
diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information, and the 
vehicle RPO, will also help you determine if the condition described by the customer is normal operation. See 
SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS in order to identify the correct procedure for 
diagnosing the system and where the procedure is located.  

SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS 

The following steps must be completed before using the symptom tables.  

1. Determine whether the vehicle is equipped with an electrically assisted or active suspension system. 

Perform electrical diagnosis prior to beginning mechanical diagnosis.  

2. Review the system description and operation in order to familiarize yourself with the system functions. 

Refer to the appropriate description and operation: 

z

General Description in Front Suspension.  

z

General Description in Rear Suspension.  

Visual/Physical Inspection 

z

Inspect for aftermarket devices which could affect the operation of any of the suspension subsystems.  

z

Inspect the easily accessible or visible system components for obvious damage or conditions which could 
cause the symptom.  

z

Inspect for proper tire size and inflation pressure. 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

Symptom List 

z

BALL JOINT INSPECTION (LOWER BALL JOINT)  

z

BALL JOINT INSPECTION (UPPER BALL JOINT)  

z

BODY LEANS OR SWAYS IN CORNERS  

z

MEMORY STEER  

z

NOISE DIAGNOSIS - FRONT SUSPENSION  

z

NOISE DIAGNOSIS - REAR SUSPENSION  

z

POOR DIRECTIONAL STABILITY  

z

RIDE DIAGNOSIS  

z

STRUTS OR SHOCK ABSORBERS ON-VEHICLE TESTING  

z

SUSPENSION BOTTOMS  

z

TRIM HEIGHT INSPECTION PROCEDURE  

z

VEHICLE LEADS/PULLS  

z

WHEEL BEARING DIAGNOSIS  

BALL JOINT INSPECTION (LOWER BALL JOINT) 

1. Raise and support the vehicle.  

2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is 

present. If vertical free play is experienced proceed with the following instructions.  

3. Remove the wheel and tire.  

4. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball 

joint.  

5. Install and position the dial indicator from J-8001 against the end of the ball joint. See SPECIAL 

TOOLS . 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

Fig. 2: Positioning Dial Indicator To Lower Ball Joint 
Courtesy of GENERAL MOTORS CORP. 

6.  

Gently lift or pry the suspension upward then let it settle.  

7. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification, 

replace the ball joint.  

BALL JOINT INSPECTION (UPPER BALL JOINT) 

1. Raise and support the vehicle.  

2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is 

present. If vertical free play is experienced proceed with the following instructions. Remove the wheel 
and tire.  

3. Remove the wheel and tire.  

4. Support the lower control arm with a floor stand or jack, as far outboard as possible.  

5. If a seal is cut or torn, replace the ball joint. 

NOTE:

Do not pry between the lower arm and the wheel drive shaft boot or in 
such a manner that the ball joint seal is contacted. Damage to the wheel 
drive shaft boot will result (4WD). 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2

  

6. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball 

joint.  

7. Check the wheel bearing for looseness in the wheel bearing is present, refer to WHEEL BEARING 

DIAGNOSIS .  

8. Check the upper ball joint for vertical looseness.  

9. Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded.  

10. Install and position the dial indicator from J-8001 against the rim of the upper ball joint. See SPECIAL 

TOOLS . 

Fig. 3: Positioning Dial Indicator To Upper Ball Joint 
Courtesy of GENERAL MOTORS CORP. 

11. Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the 

upper ball joint.  

12. Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm 

(0.079 in). If the reading is too high, replace the upper control arm. 

 

2004 Hummer H2 

2003-04 SUSPENSION General Diagnosis - H2