LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 235 (Frame & Underbody) >> Repair Instructions >> Crossmember Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the crossmember, Install the following components:
  2. Using suitable jack stands, raise the crossmember to the vehicle.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the front suspension crossmember mounting bolts.

    Tighten: 

    1. Tighten the left rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees.
    2. Tighten the right rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees.
    3. Tighten the front upper bolts to 110 N.m (81 lb ft) plus an additional 90 degrees.
    4. Tighten the rear inboard bolts to 110 N.m (81 lb ft) plus an additional 90 degrees.
      5. Fig 1: Installing Front Suspension Crossmember Mounting Bolts
      GM490128Courtesy of GENERAL MOTORS CORP.

  4. Install the front suspension support brace. Refer to Front Suspension Support Brace Replacement .
  5. Reposition the steering gear to the crossmember.
  6. Install the power steering gear to crossmember mounting bolts.

    Tighten:  Tighten the bolts to 120 N.m (89 lb ft).

  7. On vehicles with the brake pipe running along the support frame, install the brake pipe into the retainers.
  8. Connect the tie rods to the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  9. Connect the lower control arms to the steering knuckles. Refer to Lower Ball Joint Replacement .
  10. Connect the ABS harness to the lower control arms. Refer to Wheel Speed Sensor Replacement - Front in Antilock Brake System.
  11. Install the front exhaust pipe. Refer to Intermediate Pipe Replacement in Engine Exhaust.
  12. Install the engine strut to the lower engine mount and frame. Refer toEngine Mount Strut Replacement in Engine Mechanical - 2.2L (L61).
  13. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
  14. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
scientia non olet · About LEMON Manuals