Air Spring/Air Bag

Replacement of the front air spring/air bag assembly on a 2023 Chevrolet Bolt EUV, including suspension disassembly and reassembly with proper torque specifications.

Warnings

Tools required

Parts

• Air spring/air bag assembly × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Chock rear wheels securely.
3. Loosen wheel lug nuts while vehicle is on ground, but do not remove.
4. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points.
5. Remove wheel and tire assembly completely.
6. If equipped with active air suspension, depressurize the system using scan tool or manual release procedure.
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes.

Procedure

1. 1

   Disconnect air spring electrical connector
   Locate the air spring electrical connector near the strut tower. Press the release tab and disconnect the connector. Secure the wiring harness away from the work area with zip ties or safety wire to prevent damage during disassembly.
2. 2

   Disconnect sway bar link
   Locate the sway bar link connection at the strut assembly. Hold the shaft with an Allen key to prevent rotation, then remove the sway bar link nut using a wrench. Swing the sway bar link away from the strut.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Remove brake line bracket
   Locate the brake line mounting bracket attached to the strut assembly. Remove the mounting bolts securing the brake line bracket. Carefully support the brake line to prevent strain on the flexible hose.
   ⚠Do not allow brake line to hang unsupported or bend sharply, as this may cause internal damage.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Remove strut-to-knuckle bolts
   Support the steering knuckle and strut assembly. Remove the two bolts connecting the strut to the steering knuckle. You may need to use a pry bar to separate the connection once bolts are removed. Mark the position of any alignment shims or cams for reassembly.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
5. 5

   Access strut tower mounting area
   Open the vehicle hood and locate the strut tower mounting nuts in the engine compartment. Clear any covers or insulation that may obstruct access to the mounting nuts.
6. 6

   Remove strut tower mounting nuts
   While supporting the strut assembly from below (or having an assistant hold it), remove the three strut tower mounting nuts from the engine compartment. Carefully lower the strut assembly down and out of the wheel well.
   ⚠Strut assembly is heavy. Ensure it is properly supported before removing final mounting nut.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
7. 7

   Compress strut spring
   Mount the strut assembly securely in a spring compressor tool. Compress the spring evenly using the compressor until tension is removed from the upper strut mount. Ensure spring compressor is properly engaged on both sides before proceeding.
   ⚠️Compressed springs store tremendous energy. Use a quality spring compressor and follow manufacturer instructions carefully.
8. 8

   Disassemble strut components
   With spring compressed, remove the center strut shaft nut using appropriate tools. Remove the upper strut mount, spring seat, and compressed spring assembly. Note the orientation and position of all components for proper reassembly.
9. 9

   Remove old air spring
   Separate the old air spring/air bag from the strut assembly. Inspect the strut shaft for damage, scoring, or leaking. Clean all mating surfaces with a wire brush to ensure proper seating of the new air spring.
10. 10

    Install new air spring
    Position the new air spring/air bag onto the strut assembly, ensuring it is properly aligned and seated. Verify that all mounting surfaces are clean and free of debris. Check that any alignment marks or tabs are correctly positioned.
11. 11

    Reassemble strut components
    Install the compressed spring, spring seat, and upper strut mount in the reverse order of removal. Ensure all components are properly aligned and oriented as noted during disassembly. Install and tighten the center strut shaft nut to specification.
12. 12

    Release spring compressor
    Carefully and evenly release the spring compressor tool, allowing the spring to seat properly against the upper and lower spring seats. Remove the spring compressor once spring is fully seated and no longer under external compression.
13. 13

    Install strut assembly
    Lift the strut assembly into position in the wheel well. Align the upper strut mount studs with the holes in the strut tower. Install the strut tower mounting nuts finger-tight. Connect the strut to the steering knuckle and install the strut-to-knuckle bolts finger-tight.
14. 14

    Torque strut mounting fasteners
    Tighten the strut tower mounting nuts to specification using a torque wrench. Torque the strut-to-knuckle bolts to specification. Reinstall any alignment shims or cams in their original positions.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)

    Strut Bolts115 Nm (85 lb-ft)
15. 15

    Reconnect components and finalize
    Reconnect the sway bar link, holding the shaft with an Allen key while torquing the nut to specification. Reinstall the brake line bracket with mounting bolts torqued to specification. Reconnect the air spring electrical connector. Install the wheel and tire assembly, torquing lug nuts in a star pattern to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Lower vehicle to ground with full weight on suspension before performing final torque on any suspension components marked as requiring weight on wheels.
2. If vehicle is equipped with active air suspension, use scan tool to recalibrate and test air suspension system operation.
3. Test drive vehicle at low speed and listen for any unusual noises from the suspension.
4. Schedule a professional wheel alignment, as suspension disassembly may have affected alignment settings.

Verification

• Verify air spring electrical connector is fully seated and locked.
• Check that all fasteners are tightened to proper torque specifications.
• With vehicle at ride height, visually inspect air spring for proper seating and no visible damage.
• If equipped with active suspension, verify system shows no fault codes and operates normally through all ride height settings.
• Test drive vehicle and verify normal ride quality and handling with no abnormal noises.
• Recheck all fastener torque values after 50-100 miles of driving.

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