GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Spark 🢒 Preface 🢒 Cautions and Notices 🢒 Front Suspension Crossmember Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    2. Object Number: 1224508 Size: SH
  2. Remove the transaxle under cover bolts (1) and the transaxle under cover (2).
  3. Remove the front under longitudinal frame. Refer to Stabilizer Shaft Replacement .

    4. Object Number: 1222815 Size: SH
  4. Remove the damping bush bolt and nut.

    5. Object Number: 1222823 Size: SH
  5. Disconnect the power steering pressure line from the crossmember. Refer to Power Steering Pressure Pipe Replacement .
  6. Place the support jack under the crossmember.
  7. Remove the bumper fascia screws.
  8. Remove the rear bolts (2).
  9. Remove the side bolts (1).
  10. Lower the support jack and remove the crossmember from the vehicle. The right side is shown. The left side is similar.

    11. Object Number: 1222766 Size: SH
  11. Remove the front damping bush bolts and the damping bush from the crossmember.

Installation Procedure

    Object Number: 1222814 Size: SH
  1. Install the front damping bush to the crossmember.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the inner (2) and outer (1) bolts.

    3. Tighten

    • Tighten the inner bolts to 45-55 N·m (33-41 lb ft).
    • Tighten the outer bolt to 35-41 N·m (25-30 lb ft).

    Object Number: 1222819 Size: SH
  3. Install the crossmember to the vehicle with the bolts. The right side is shown. The left side is similar.
  4. Install the rear bolts (1) and the side bolts (2).

    5. Tighten
    Tighten the bolts to 17-27 N·m (13-20 lb ft).

  5. Install the power steering pressure line to the crossmember. Refer to Power Steering Pressure Pipe Replacement .
  6. Install the bumper fascia screws.

    7. Object Number: 1222765 Size: SH
  7. Install the front damping bush bolt (1) and the nut.

    8. Tighten
    Tighten the front damping bush bolt and nut to 68-83 N·m (51-61 lb ft).

  8. Install the front under longitudinal frame. Refer to Stabilizer Shaft Replacement .

    9. Object Number: 1221466 Size: SH
  9. Install the transaxle under cover with the bolts (1).

    10. Tighten
    Tighten the transaxle under cover bolts to 35-55 N·m (25-41 lb ft).

  10. Lower the vehicle.