Front Suspension System Chevrolet Aveo I

Fastener Tightening Specifications

Fastener Tightening Specifications

General Specifications

General Specifications

Scheme 1

Suspension Component Inspection

Struts Seem Weak

Struts Are Noisy

Leaks

Ball Stud and Knuckle Inspection

1. Raise the front of the vehicle to allow the front suspension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle relative to the control arm.
5. Ball joints must be replaced under the following conditions: The joint is loose. The ball seal is cut. The ball stud is disconnected from the knuckle. The ball stud is loose at the knuckle. The ball stud can be twisted in its socket with finger pressure.

Ball Stud Inspection

Make sure to check the tightness of the ball stud in the knuckle boss during each inspection of the ball joint. One way to inspect the ball stud for wear is to shake the wheel and feel for movement of the stud end or the castellated nut at the knuckle boss.

Another way to inspect the ball stud for wear is to check the fastener torque at the castellated nut. A loose nut can indicate a stressed stud or a hole in the knuckle boss.

Worn or damaged ball joints and knuckles must be replaced.

Excessive Friction Check

Use the following procedure to check for excessive friction in the front suspension

1. Enlist the help of another technician to lift up on the front bumper, raising the vehicle as high as possible.
2. Slowly release the bumper, allowing the vehicle to assume its normal trim height.
3. Measure the distance from the street level to the center of the bumper.
4. Push down on the bumper, release slowly, and allow the vehicle to assume its normal trim height.
5. Measure the distance from the street level to the center of the bumper.
6. The difference between the 2 measurements should be less than 12.7 mm (0.5 in). If the difference exceeds this limit, inspect the control arms, the struts, and the ball joints for damage or wear.

Strut Assembly Inspection

A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock absorbers are used on the rear wheels.

Control Arm Bushing Replacement

Tools Required

1. KM-508-A Control Arm Bushing Remover/Installer. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
2. KM-158 Remover/Installer. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
3. KM-307-B Removal Plate. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .

Disassembly Procedure

1. Remove the control arm. Refer to «Control Arm Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
2. Press off the rear bushing using a press, the KM-158 , and the KM-307-B . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
3. Press out the front bushing using the KM-508-A (2) and KM-158 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .

Assembly Procedure

1. Coat the control arm rear shaft with a multipurpose lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/aveo/i-2003-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in General Information.
2. Press the rear bushing onto the shaft. The flat of the bushing must be on the top side, the same as the ball joint. Use the KM-508-A (1) to support the control arm. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
3. Coat the outside of the front bushing and the inside of the lower control arm with a multipurpose lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/aveo/i-2003-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in General Information.
4. Press the new bushing into the control arm from the back to the front, using the KM-508-A (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
5. Center the bushing.
6. Install the control arm. Refer to «Control Arm Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .

Strut, Strut Component and/or Spring Replacement

Tools Required

1. KM-329-A Spring Compressor. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
2. J 42468 Front Strut Mount Nut Wrench. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .

1. Remove the strut assembly. Refer to «Strut Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
2. Fasten the strut assembly to the KM-329-A . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) . Make sure the hooks are seated on the strut spring properly.
3. Compress the front spring with the KM-329-A . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
4. Use an open end wrench to hold the threaded piston rod while removing the piston rod nut with the J 42468 -A. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
5. Remove the strut mount, strut bearing, spring upper seat, spring upper insulator, hallow bumper, coil spring, and strut step by step.

1. Install the lower spring insulator and the spring.
2. Compress the spring using the KM-329-A . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
3. Install the strut mount, strut bearing spring upper seat, spring upper insulator, hallow bumper, coil spring, and strut step by step.
4. Use an open end wrench to hold the threaded piston rod while installing the piston rod nut with the J 42468 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) . Tighten: Tighten the piston rod nut to 60 N.m (44 lb ft).

Removal Procedure

1. Remove the front wheels.
2. Remove the control arm ball joint and stabilizer shaft link nut, lower.
3. Remove the tie rod end ball joint.
4. Remove the engine mounting reaction rod bolts.
5. Drain the power steering fluid.
6. Remove the power steering pipe fittings.
7. Remove the interim shaft lower joint.
8. Remove the crossmember assembly.
9. Remove the stabilizer bar, power steering gear set, and control arm from the crossmember.

Installation Procedure

1. Install the stabilizer bar, power steering gear set, and control arm from the crossmember.
2. Install the crossmember assembly front to body nut and the crossmember assembly rear to body bolt. Tighten: Tighten the crossmember assembly front to body nut and rear to body bolt to 150 N.m (111 lb ft).
3. Connect the intermediate shaft lower joint and power steering pipe fittings. Tighten: Tighten the power steering pipe fittings to 22 N.m (16 lb ft).
4. Install the engine mounting reaction rod bolts. Tighten: Tighten the engine mounting reaction rod bolts to 60 N.m (44 lb ft).
5. Install the tie rod end ball joint nut. Tighten: Tighten the tie rod end ball joint nut to 45 N.m (33 lb ft).
6. Install the control arm ball joint and stabilizer shaft link nut, lower.

1. Remove the crossmember assembly.
2. Remove the stabilizer bar from the crossmember assembly by unscrewing the U-clamp bolts.

1. Install the U-clamp bolts to the stabilizer bar. Tighten: Tighten the U-clamp bolts to the stabilizer bar to 25 N.m (18 lb ft).
2. Remove the crossmember assembly.

1. Lift and suitably support the vehicle, allowing the front suspension to hang free.
2. Remove the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
3. Remove the stabilizer shaft-to-knuckle nut and the shaft-to-link nut.
4. Disconnect the stabilizer shaft from the knuckle by removing the stabilizer shaft link assembly.

1. Install the stabilizer shaft into the vehicle.
2. Install the stabilizer shaft-to-knuckle nut and the shaft-to-link nut. Tighten: Tighten the stabilizer shaft link nuts to 50 N.m (37 lb ft).
3. Install the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
4. Lower the vehicle.

1. Raise and suitably support the vehicle.
2. Place the jackstands under the frame of the vehicle and lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms.
3. Remove the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
4. Remove the control arm. Refer to «Control Arm Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
5. Remove the ball joint mounting bolts.

1. Connect the ball joint to the control arm with the mounting bolts.
2. Install the nuts to secure the bolts from below the control arm. Tighten: Tighten the ball joint-to-control arm nuts to 64 N.m (47 lb ft).
3. Install the control arm. Refer to «Control Arm Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
4. Install the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
5. Lower the vehicle.

1. Remove the front wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
2. Remove the caulking nut.
3. Remove the tie rod end from the knuckle.
4. Remove the control arm ball joint.
5. Remove the brake caliper.
6. Remove the brake disc. Refer to «Brake Caliper Replacement»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
7. Remove the ABS wheel speed sensor, if equipped. Refer to «Wheel Speed Sensor Replacement - Front»(/chevrolet/aveo/i-2003-2008/remont/anti-locktraction-control/#antilock-brake-system) in ABS.
8. Remove the backing plate.
9. Remove the front strut bolts.
10. Remove the knuckle assembly.

1. Install the knuckle assembly to the front strut with bolt and nuts. Tighten: Tighten the knuckle assembly to the front strut with bolt and nuts to 100 N.m (74 lb ft).
2. Install the backing plate with the screws. Tighten: Tighten the backing plate with the screws to 4 N.m (35 lb in).
3. Install the ABS wheel speed sensor. Refer to «Wheel Speed Sensor Replacement - Front»(/chevrolet/aveo/i-2003-2008/remont/anti-locktraction-control/#antilock-brake-system) in ABS.
4. Install the brake disc and caliper. Refer to «Brake Caliper Replacement»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
5. Install the control arm ball joint.
6. Install the tie rod end to the knuckle.
7. Install the front wheels. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.

Tools Required

KM-507-C Ball Joint Remover

1. Raise and suitably support the vehicle.
2. Place the jackstands under the frame of the vehicle.
3. Lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms.
4. Remove the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
5. Disconnect the stabilizer shaft from the control arm by removing the control arm-link bolt assembly. Refer to «Stabilizer Shaft Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
6. Remove the retaining clip and the ball joint-to-knuckle/strut nut from the ball joint.
7. Disconnect the ball joint from the steering knuckle using the KM-507-C .
8. Remove the control arm front mounting bolt.
9. Remove the control arm rear mounting bolts and the bracket.
10. Remove the control arm from the vehicle.

1. Install the control arm onto the vehicle.
2. Connect the front of the control arm to the body of the vehicle with the front mounting bolt and the washer.
3. Apply a thread sealer to the control arm rear mounting bolts.
4. Connect the rear of the control arm to the body of the vehicle with the rear mounting bracket and bolts.
5. Install the stabilizer shaft link bolt assembly. Refer to «Stabilizer Shaft Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
6. Connect the ball joint to the steering knuckle.
7. Tighten the ball joint-to-knuckle nut. Tighten: Tighten the ball joint-to-knuckle/strut nut to 100 N.m (74 lb ft).
8. Connect the retaining clip to the ball joint stud.
9. Install the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
10. Raise the vehicle.
11. Place the jackstands under the control arms.
12. Lower the vehicle.
13. Tighten the control arm rear mounting bolts. Tighten: Tighten the control arm rear mounting bolts to 110 N.m (81 lb ft).
14. Tighten the control arm front mounting bolt. Tighten: Tighten the control arm front mounting bolt to 110 N.m (81 lb ft).
15. Raise the vehicle.
16. Remove the jackstands.
17. Lower the vehicle.

Wheel Hub, Bearing, Knuckle, and Seal Replacement

Tools Required

1. 500-20 Hex Nut. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
2. J 36661-2 Forcing Screw. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
3. J 37105-1 Support Bridge. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
4. J 37105-2 Bearing Adapter. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
5. J 37105-3 Hub Adapter. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .

1. Remove the drive axle from the front wheel hub. Refer to «Strut Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .
2. Remove the inner snap ring.
3. Remove the wheel hub with the J 37105-1 , the J 37105-3 , the 500-20 , and the J 37105-2 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
4. Remove the disc brake splash. Refer to «Disc Brake Splash Shield Replacement - Front»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
5. Remove the outer snap ring.
6. Remove the wheel bearing with the J 37105-1 , the J 37105-2 , the 500-20 , and the J 36661-2 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
7. Clean the bore of the knuckle.

1. Install the outer snap ring and push the wheel bearing into place with the J 37105-1 , the J 37105-2 , the 500-20 , and the J 36661-2 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
2. Install the disc brake splash. Refer to «Disc Brake Splash Shield Replacement - Front»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
3. Install the inner snap ring and push the wheel hub into place with the J 37105-3 , the J 37105-2 , the 500-20 , and the J 36661-2 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system__special-tools) .
4. Install the drive axle into the front wheel hub. Refer to «Strut Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/suspension-front/#front-suspension-system) .

KM-507-C Ball Joint Remover

1. Loosen the strut assembly-to-body nut that attaches the top of the strut assembly to the vehicle.
2. Raise and suitably support the vehicle.
3. Place the jackstands under the frame of the vehicle.
4. Lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms.
5. Remove the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
6. Disconnect the brake caliper from the knuckle/strut assembly and support the caliper. Do not hang the caliper from the hydraulic brake hose. Refer to «Brake Caliper Replacement»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
7. Disconnect the ABS speed sensor electrical connector, if applicable.
8. Remove the ball joint-to-knuckle-strut nut.
9. Separate the steering knuckle assembly from the ball joint using the KM-507-C .
10. Remove the outer tie rod from the steering knuckle assembly. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#power-steering-system) in Power Steering Gear or «Outer Tie Rod Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#manual-rack-pinion-steering-system) in Manual Steering Gear.
11. Push the drive axle shaft from the front wheel hub.
12. Support the drive axle.
13. Lower the vehicle in order to gain access to the strut-to-body nuts and the washers.
14. Remove the strut assembly-to-body nuts.
15. Remove the strut assembly from the vehicle.

1. Install the strut assembly into the vehicle with the strut assembly-to-body nuts. Tighten: Tighten the strut assembly-to-body nut to 60 N.m (44 lb ft).
2. Connect the drive axle to the front wheel hub.
3. Connect the outer tie rod to the steering knuckle assembly. Refer to «Outer Tie Rod Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#manual-rack-pinion-steering-system) in Power Steering Gear or «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#power-steering-system) in Manual Steering Gear.
4. Connect the ball joint to the steering knuckle assembly.
5. Install the ball joint-to-knuckle/strut nut. Tighten: Tighten the knuckle to strut bolts to 100 N.m (74 lb ft).
6. Connect the ABS speed sensor electrical connector, if applicable.
7. Connect the brake caliper to the knuckle/strut assembly. Refer to «Brake Caliper Replacement»(/chevrolet/aveo/i-2003-2008/remont/mechanical-hydraulic/#disc-brake-system) in Front Disc Brakes.
8. Install the wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
9. Install a new drive axle-to-hub caulking nut. Tighten: Tighten the drive axle-to-hub caulking nut to 300 N.m (221 lb ft).
10. Crimp the caulking nut sleeve onto the drive axle shaft.

General Description (SOHC Engine)

The front suspension for this vehicle is a combination knuckle/strut and spring design.

The control arms pivot from the body. The lower control arm pivots use rubber bushings. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the wheel to turn.

The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a nut, and to the lower control arm with rivets.

When servicing the control arm-to-body attachment and the stabilizer shaft-to-body insulators, make sure the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground.

General Description (DOHC Engine)

The front suspension for this vehicle is a combination knuckle/strut and spring design.

The control arms pivot from the body. The lower control arm pivots use rubber bushings. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the wheel to turn.

The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a nut, and to the lower control arm with rivets.

When servicing the control arm-to-body attachment and the stabilizer shaft-to-body insulators, make sure that the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground.

The springs in the front suspension DOHC engine are stronger and the shocks are heavier than are the springs and shocks in the front suspension SOHC engine.

Special Tools

Special Tools Illustration Tool Number/ Description 500-20 Hex Nut J-36661-2 Forcing Screw J-37105-1 Support Bridge J-37105-2 Bearing Adapter J-37105-3 Hub Adapter J-42468 Front Strut Mount Nut Wrench KM-158 Remover/Installer KM-307-B Removal Plate KM-329-A Spring Compressor KM-507-C Ball Joint Remover KM-508-A Control Arm Bushing Remover/Installer

Scheme 2

Scheme 3

Scheme 4

Scheme 5

See also:
• Vehicle Lifting and Jacking Notice
• Fluid and Lubricant Recommendations
• Fastener Notice
• Tire and Wheel Removal and Installation
• Brake Caliper Replacement
• Wheel Speed Sensor Replacement - Front
• Rack and Pinion Outer Tie Rod End Replacement
• Outer Tie Rod Replacement
• Special Tools
• Control Arm Replacement