Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Front Bumper Impact Bar Replacement

Chevrolet Sonic Repair Manual / Body / Body Exterior / Bumpers / Front Bumper / Front Bumper Impact Bar Replacement

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
  5. Remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.
  6. Locate and mark all factory welds.

  7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.

  8. Remove the damaged impact bar (1).
Installation Procedure

    Drill 8 mm (5/16 in) holes for plug welding along the edges of the service
  1. Drill 8 mm (5/16 in) holes for plug welding along the edges of the service panel (1) as noted from the original panel.
  2. Clean and prepare the attaching surfaces for welding.

  3. Position the impact bar (1) on the vehicle.
  4. Verify the fit of the bar.
  5. Clamp the impact bar into position.

  6. Plug weld accordingly (1).
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling.
Front Bumper Impact Bar Lower Bracket Replacement
Front Bumper Impact Bar Lower Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper opening ...

Front Bumper Lower Impact Bar Replacement
Front Bumper Lower Impact Bar Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to ...

Other materials:

Finish Care
Application of aftermarket clearcoat sealant/wax materials is not recommended. If painted surfaces are damaged, see your dealer to have the damage assessed and repaired. Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird droppings, ...

Battery Negative Cable Replacement
Battery Negative Cable Replacement Callout Component Name Preliminary Procedures Disconnect the battery current sensor connector. Remove the battery tray. Refer to Battery Tray Replacement. 1 Bo ...

Cylinder Head Removal
Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure: Loosen the cylinder head bolts 90 degrees. Loosen the cylinder head bolts 180 degrees. Note: Do not damage the guide sleeves (4) and (5). R ...

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