DIY Chevrolet Aveo front pillar repair

In detail: do-it-yourself repair of the front strut of a Chevrolet Aveo from a real master for the site my.housecope.com.

Chevrolet Aveo (2011+). FRONT SUSPENSION STRUCTURE REPAIR

Rice. 7.2. Details of the shock absorber strut: 1 - nut protective cover; 2 - thrust washer; 3 - spring; 4 - shock absorber; 5 - protective casing; 6 - upper support cup; 7 - compression buffer; 8 - the upper support of the rack; 9 - washer; 10 - nut of the upper support; 11 - nut of the shock absorber rod

You will need: a 24 ”spanner wrench, a TORX E50 wrench, a spring remover.

2. Install the spring compression tool ...

4. Loosen the rod nut tightening (if the nut was not loosened when removing the shock absorber strut), keeping the rod from turning with a TORX E50 wrench passed through the key hole ...

5. ... and unscrew the nut from the stem.

6. Remove the upper rack support.

The upper strut support and thrust bearing are a non-separable unit, therefore, in the event of a malfunction or damage to one of these two elements, it is necessary to replace the complete unit. Replace the upper support in case of severe deformation or local bulging of the rubber mass, as well as if the support bearing is corroded, has axial movement in the housing, or is seized when turning.

8. Remove the protective boot from the spring.

Replace the damaged protective cover with a new one.

9. Remove the spring gasket ...

Replace the damaged spring gasket with a new one.

Replace the damaged compression buffer with a new one.

11. Install the shock absorber vertically and several times until it stops, lower and raise the shock absorber rod. Make sure the stem moves without sinking, binding, or knocking. Otherwise, replace the shock absorber. Also, replace the shock absorber if fluid drips are found (slight fogging is allowed on the top of the body) and if the threads on the top of the stem are damaged.

Video (click to play).

Replace shock absorbers only in pairs (right and left at the same time).

Replace the springs only in pairs (right and left at the same time).

12. Install the parts in the reverse order of removal.

Tighten the shock absorber strut mounting nut on the vehicle standing on the ground to the torque specified in Appendix 1.

13. The second post is replaced in the same way.

After replacing the shock absorber, check and, if necessary, adjust the wheel alignment angles. Take advantage of the services of workshops with special equipment.

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I will immediately answer several alleged questions that may be asked after the publication of the photo report:

1. Spare parts are replaced with original GM ones. I will not name the prices, tk. big discounts were given for acquaintance.
2. The work was done in our own garage, on our own under the guidance of a friend (specialist) with a coffee break.
3. Time taken to disassemble and assemble one side was approximately 2-3 hours.

4. In the photo in brackets the dimensions of the key are indicated. Now let's start a photo report.

We raise the car and remove the wheel, I think that everyone can do this, so we will not dwell here in more detail.
We clean all the threaded connections with a metal brush and spray with VDeshka all the cleaned places so that everything can be unscrewed without problems.

After drinking a cup of coffee and a small smoke break, we proceed to disassemble and assemble the front suspension. Image - DIY Chevrolet Aveo front strut repair

We unscrew the nut of the tie rod end with a 19 key, after releasing the lock nut with a 14 key by about 30 degrees. Just do not get carried away too much, otherwise you will break the toe-in.

Next, we take a hammer and hit with good, powerful blows on the steering knuckle to disconnect the tie rod end.

After 2-3 blows, the tip should fly off the fist and move down. We unscrew the tip and in its place we tighten the new tie rod tip to the lock nut. Then we insert the tip back into the steering knuckle, tighten the nut and tighten it with the lock nut. The tip has been replaced.

We unscrew the nut fastening the ball joint to the steering knuckle with a 19 key. I must say right away that it is very tight to unscrew, so you need to sweat.
Next, using a 17 key, holding the bolt head from above, and from below, preferably with a 17 head, unscrew the nuts and remove the bolts securing the ball joint to the lower arm.

Then, as in the case of the tip, we take a hammer and hit with good, powerful blows on the steering knuckle to disconnect the ball joint.
After 2-3 hits, the ball joint should fly off the fist. After that, it is necessary to bend down the lower arm and remove the ball joint. The installation is carried out in the reverse order. We insert the support into the lower arm, then into the fist and tighten all the nuts.

We unscrew the bolts securing the brake shoe guides.

Using a screwdriver, squeeze the brake cylinder slightly inward, remove the caliper and hang it on a wire so as not to damage the brake hose.
Next, unscrew the bolts securing the brake caliper bracket to the steering knuckle and remove it.

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Now we change the brake disc. Unscrew the two screws with a Phillips screwdriver and remove the brake disc. We put the new disk in place and clamp it with two screws.

Next, we proceed to remove the rack.
Unscrew the top mount of the stabilizer bar.

To do this, unscrew the nut with a 17 wrench, having previously fixed it with a 15 finger wrench. Having unscrewed the stabilizer bar, we turn it to the side, we will return to it later.

Now we begin to unscrew the fastening of the main suspension strut.

Using a 17 key, as well as a second 17 key, while holding the bolt, unscrew the rack mounting nuts. Do not remove the bolts yet!

Next, we open the hood. Remove the protective cover. We take a good box wrench for 22, a good head for 9 and unscrew the upper mount of the suspension strut.

Then we remove the previously unscrewed 2 bolts and remove the rack assembly.

Now we return to the stabilizer bar. We unscrew it now from the bottom.
We remove, insert a new stabilizer post and tighten everything in the reverse order.

Now we are working on the rack itself.
It is necessary to tighten the spring with pullers. They are installed opposite each other, and evenly tighten the spring until the upper cup looses.

We unscrew the cushion mounting nut with a 19 wrench, holding the shock absorber rod with a 9 head.

Remove the pillow with the bearing and remove the spring from the rack.

Now we start assembling in reverse order.

We put a tightened spring on the stand and align it clearly with the groove.

Then we put on the upper spring support, a support pillow with a bearing and tighten it tightly with a 19 key, holding the shock absorber rod. Next, remove the 2nd spring puller.

Then we insert the assembled rack into the body hole, put the rebound stop on the rod and tighten it with a nut.

Then we fasten the strut to the steering knuckle with two bolts (key 17) and lubricate them with "Movil" so that they do not rust and then loosen well.

Now we just need to screw the upper mount of the stabilizer bar to the rack.

Everything! The front suspension has been moved on one side, you can proceed to the other side.

But, taking this opportunity, I decided to check what I have under the fender liner in the place where all the dirt collects and found ...

I had to clean it and grease it with a movil….

Serviceability of the front suspension Aveo Chevroletusually depends on the correct use of the vehicle. But if we take into account the fact that Russian roads are sometimes not of the best quality, then it is better to check the technical condition of the undercarriage units every 10,000 km. mileage. Particular attention should be paid to the ball joints and front shock absorbers, since they are the ones that absorb all the shocks and shocks caused by the hit of the car wheel in a hole or pothole.

  1. Wet stains on the shock absorber body
  2. Distinct knocks in the area of ​​the front shock absorbers when driving over bumps
  3. Unstable entry of the car into a turn
  4. The car does not hold the road well (poor handling)

If you find at least one of the above symptoms of malfunctions, then most likely the reason for this was a malfunction of the front shock absorber or its support. As a rule, the racks are replaced in pairs, i.e. right and left at the same time

In various forums dedicated to Aveo Chevrolet cars, the owners claim that the original struts do not do their job very well, so they recommend installing Kayaba Excel G shock absorbers. Also, prepare the support pads and bearings before replacing

  1. Shock absorbers Kayaba Excel G - 333417 (right) and 333418(left)
  2. Supports according to the original GM catalog - 96653239, or reinforced 95015324
  3. Support bearings GM - 96535010

We suggest that you familiarize yourself with a set of photos that illustrate the replacement of the front struts of the Aveo T250. Introductory information:
1. All spare parts are replaced by Genuine General Motors products.
2. The working process took place in a private garage, without the use of any special technical means and devices.
3. It took an average of 3 hours to completely disassemble and replace parts of one side.
4. In the photographs, the numbers in brackets indicate the dimension of the key involved.
The preparatory stage includes:
1. Lifting the Chevrolet Aveo 2005, parsing the front wheel. Since this operation will not cause difficulties for experienced car owners, we will not provide a detailed description of it.
2. Cleaning all threaded connections with a metal brush. To simplify the dismantling process, the connections are coated with grease.

Using a 19 wrench, unscrew the nut attached to the tie rod end. Before that, you need to slightly release (by 30 degrees) the lock nut, using a wrench of 14. Try to monitor the safety of the toe-in of the wheels.

We hit the steering knuckle with a few hard hammer blows to remove the rudder rod end.

After displacement of the tip (3 blows with a hammer should be enough), unscrew it and replace it with a new one, screwing it all the way against the lock nut. The new tip must be placed in its place in the swivel fist, and then tighten the main nut by tightening the lock. Thus, the front suspension of the Chevrolet Aveo has acquired a new part, you can go on.

In the next step, we will replace the ball joint. Its fastening nut can be removed with a 19 spanner. When loosening it, you may have to apply a little more force due to the tight movement. Holding the bolt with a 17 wrench, remove the nuts and mounting bolts of the support.

By analogy with the tip, we inflict several blows on the swivel fist so that the support moves away from the fist. Further, bending the lever to the lower side, you can completely dismantle it.The new part is installed through the sequential execution of the described actions in the reverse order: installation of the support into the lever, then into the fist, the nuts are installed in the places assigned to them and tightened.

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We consistently remove the fasteners of the guide pads.

Using a screwdriver, move the brake cylinder inward, dismantle the caliper, leaving it suspended on the wire to secure the hose. We tighten the bolts and caliper brackets towards the steering knuckle and remove it.

To detach the brake disc and replace it, it is enough to remove two screws. Then you can install a new disk.

Now the front pillar is being replaced on the Chevrolet Aveo, for which you need to unscrew their fasteners using a key of 17. While unscrewing the nut, hold its finger with a 15-key.

The fastening of the main suspension post is removed with two 17 keys, one of which you need to hold the bolt. After removing the nuts, it is not necessary to remove the bolts from the seats.

Opening the hood, remove the cover for protection. With a spanner wrench 22 and head 9, dismantle the upper rack mount. We go back one step and take out the remaining bolts, after which the rack can be completely removed.

Having unscrewed the stabilizer post from below, remove it and replace it with a new part, tightening the fasteners.

We examine the removed rack, tighten the spring until the upper cup looses.

The mounting nut of the cushion is dismantled with a 19 key, while the shock absorber rod is held by the 9th head.

Now the cushion, together with the bearings, can be removed, as well as the main spring.

This is followed by the dismantling of the stopper.

After the front pillar of the Chevrolet Aveo has been removed, you can proceed to the reverse steps. First of all, we return the spring back, aligning it with the groove.

The upper support, the pillow with the bearing are installed in their places, working with the keys, we hold the shock absorber rod. We remove the removable springs.

The assembled stand is installed in the corresponding hole in the body, the stopper is aligned with the stem.

The swivel knuckle and strut are bolted to each other, pre-oiled to corrode.

The upper mount of the stabilization mechanism returns to the rack.

We carefully check all the fasteners, we tighten the nuts if necessary. This completes the one-sided disassembly of the Aveo, you can start sorting through the rack from the other side.
Along the way, you can clean the fender liner in places where dirt accumulates.

The suspension of the Chevrolet Aveo is far from ideal, so driving on small bumps is accompanied by dull bumps that are well audible in the cabin. If the diagnostics show that all the suspension assemblies are in order, then the reason for the dull "bubbling" is most likely support cushions of the front pillars.

According to experts, the factory support cushions (code: 96653239) are weak and not designed for use on our harsh roads. Therefore, it is recommended to replace the original supports of the front struts with reinforced ones (code: 95015324).

Reinforced A-pillar support cushions

The procedure for replacing the supports of the front struts on the Chevrolet Aveo is not spelled out, it all depends on their condition, but we note that, according to operating experience, the time for their replacement occurs at 60-80 thousand km.

The procedure for replacing the support cushions is quite simple for an average motorist. The main thing in this matter is to prepare all the necessary tools.

By replacing the A-pillar support cushion yourself, you can save the cost of replacement parts.

  • Keys for 9, 14, 17, 19, 22.
  • A device for tightening the spring.
  • WD-40 or other means to facilitate loosening of nuts.

Before proceeding with the replacement, familiarize yourself with the Chevrolet Aveo A-pillar design.

Dismantling the front pillar of the Chevrolet Aveo

Remove the plastic cover

Loosen the cup retaining nut

Use wrenches 19 and 9 to loosen the nut.

Jack up the car and remove the wheel

Unscrew the nuts securing the stabilizer and stand

Finally unscrew the fastening nut and remove the rack

unscrew the nut securing the support cushion with a 22 wrench.

Unscrew the nut with a 22 wrench

This completes the replacement of the front cushion of the Chevrolet Aveo front strut!

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Image - DIY Chevrolet Aveo front strut repair

Serviceability of the chassis is the key to the safe movement of the machine. On the Chevrolet Aveo t300 (t250), one of the vulnerable nodes responsible for adequate control of the car is the front pillar, as well as the support bearing in the pillow (support). With proper operation, this element is able to work about 100,000 kilometers, but over time, any unit becomes unusable (bad roads, aggressive driving, quality of spare parts).

There comes a time when it is necessary to repair the suspension. It is advisable not to delay the replacement, since this will entail premature failure of other elements, and the price of the Chevrolet Aveo t250 rack is significantly higher than that of the bearing. How to recognize a malfunction in time, diagnose, as well as replace the support bearing of the Chevrolet Aveo T300, is described below.

The part has a sufficient safety factor to come out long enough. However, there are factors due to which the support bearings of the front shock absorbers on the Chevrolet Aveo T250 can fail earlier.

  • careless driving on poor road surfaces;
  • overly dynamic driving style;
  • ingress of abrasive, moisture or dirt directly into the support bearing;

The following factors indicate a malfunction:

  • knocking in the area of ​​\ u200b \ u200bthe wheels (under the hood), when the steering wheel is turned, as well as on irregularities;
  • late reaction of the car to manipulation of the steering wheel;
  • beating on the steering wheel;
  1. We find the upper attachment point under the hood and put our hand there;
  2. The assistant turns the steering wheel;
  3. If beating is felt, this means that the upper support must be replaced;
  4. Also rest your palm on the glass, where the support bearing is located, and swing the car from bottom to top. If you feel beats and knocks - urgently start replacing;
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To accurately understand the whole procedure, it is advisable to watch the videos presented.

Checking the backlash of the Chevrolet Aveo t300 support:

How the front pillar of the Aveo t300 1.6 knocks: identify the malfunction:

Rack Aveo Т250, upper Cymbal backlash:

The picture below shows a diagram of the node device. The list of elements includes:

Image - DIY Chevrolet Aveo front strut repair

  1. Decorative cap;
  2. Fastening nut;
  3. Lock-nut;
  4. Shock absorber support Chevrolet Aveo т300;
  5. Support bearing Chevrolet Aveo т300;
  6. Anther;
  7. Spring;
  8. Rack;
  9. Bolt of the lower fastening of the rack;
  10. Fixing nut;
  11. Top insulator;
  12. Sealant;
  13. Upper boot;

If we needed to change the support, then elements numbered 4 and 5 must be replaced, and if work is being done to replace the racks, then part number 13 will have to be changed. It is also advisable to check the condition of all anthers and seals (No. 7, 27, 28, 29) in order to prevent rapid wear of new elements.

Image - DIY Chevrolet Aveo front strut repair

Image - DIY Chevrolet Aveo front strut repair