Spark

Drivetrain and Front Suspension Frame Replacement — with EN-49802

Special Tools

EN-49802 Cradle Supporter

For equivalent regional tools refer to Special Tools

1. Raise and support the vehicle. Refer to Vehicle Lifting and Jacking Caution .
2. Remove the front wheel and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Remove both front compartment splash shields. Refer to Front Compartment Splash Shield Replacement .
4. Remove the front under cover.
5. Remove both of the front wheel house linings.
6. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
7. Remove the lower wind guard.



8. Secure the cooling module to the left and right of the upper body structure with a wire.
9. Separate both of the control arm ball joints from the steering knuckles. Refer to Lower Control Arm Replacement .
10. Remove both of the upper stabiliser shaft link nuts and separate the left and right stabiliser shaft link from the strut. Refer to Stabilizer Shaft Link Replacement .
11. Remove the exhaust pipe. Refer to Exhaust Pipe Replacement .



12. Remove the torque strut to transmission mounting bracket bolt and nut (1) and the torque strut to frame bolt (2).
13. Remove the torque strut (3) from the frame.



14. Remove the power steering pipe/hose retaining nuts (1) and separate the pipe from the frame. Refer to Power Steering Gear Outlet Pipe/Hose Replacement .



15. Remove the steering gear assembly to the frame retaining bolts (1) and separate the steering gear assembly from the frame. Refer to Steering Gear Replacement .



16. Mark the frame to body positions (1) with a paint pen or permanent marker.



17. Install the EN-49802 cradle supporter to a hydraulic jack stand and support the frame.



18. Remove the frame to body bolts (1).
19. Slowly lower the jack stand and remove the frame from the vehicle.
20. Remove the following components if replacing the frame:

20.1.

Remove the stabiliser shaft from the frame. Refer to Stabilizer Shaft Replacement .

20.2.

Remove the control arms from the frame. Refer to Lower Control Arm Replacement .

20.3.

Remove the radiator brackets from the frame.

20.4.

Remove the front lower impact bar.

1. Install the following components to the frame if removed:

1.1.	Install the front lower impact bar to the frame.

1.2.	Install the radiator brackets to the frame.

1.3.	Install the control arms to the frame. Refer to Lower Control Arm Replacement .

1.4.	Install the stabiliser shaft to the frame. Refer to Stabilizer Shaft Replacement .




2. With the frame on the EN-49802 cradle supporter and hydraulic jack stand, raise the frame to the vehicle.



3. Hand start all the frame to body retaining bolts while aligning the frame to the paint marks (1).

Caution: Refer to Fastener Caution in the Preface section.




4. Tighten the frame to body retaining bolts (1) to 170 N·m (125 lb ft).
5. Lower the jack stand and remove the EN-49802 cradle supporter.
6. Install the steering gear assembly to the frame retaining bolts. Refer to Steering Gear Replacement .
7. Install the power steering pipe to the frame and tighten the pipe retaining nuts. Refer to Power Steering Gear Outlet Pipe/Hose Replacement



8. Install the torque strut (3) from the frame.
9. Install the torque strut to the frame bolt (2) and tighten to 100 N·m (74 lb ft).
10. Install the torque strut to the transmission mounting bracket bolt and nut (1) and tighten to 80 N·m (59 lb ft).
11. Install the exhaust pipe. Refer to Exhaust Pipe Replacement .
12. Connect both of the stabiliser shaft links to the struts and tighten the upper stabiliser shaft link nuts. Refer to Stabilizer Shaft Link Replacement .
13. Install both of the control arm ball joints to the steering knuckles. Refer to Lower Control Arm Replacement .
14. Remove the wires which secure the cooling module to the upper body structure.
15. Install the lower wind guard.
16. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
17. Install both of the front wheel house linings.
18. Install the front under cover.
19. Install both of the front compartment splash shields. Refer to Front Compartment Splash Shield Replacement .
20. Install the front wheel and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
21. Lower the vehicle.
22. Road test the vehicle in order to test for the following conditions:

•	Steering leads or pulls--Refer to Wheel Alignment Measurement .

•	Abnormal powertrain noise or vibration at tick over--Inspect the engine and transmission mounts for proper alignment and torque.