Chevrolet Sonic Repair Manual: Front End Upper Tie Bar Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Glass and Sheet Metal Handling 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. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



6. Locate and mark all the necessary factory welds of the front upper tie bar assembly.
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
8. Remove the front end upper tie bar support bolts (1) and front end upper tie bar bolts (2).
9. Remove the front end upper tie bar assembly (3).

Installation Procedure

1. Drill 8 mm (5/16 in) plug weld holes as necessary on service parts, in the locations noted from the original assembly (1).
2. Clean and prepare the mating surface for welding, as necessary.


3. Position the front upper tie bar support (1) and front upper tie bar (2) on the vehicle
4. Verify the fit of the front end upper tie bar.

Caution:

Refer to Fastener Caution.

5. Install the front upper tie bar support bolts (3) and tighten to 22 Y (16 lb ft)

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6. Install the front upper tie bar bolts (4) and tighten to 9 Y (80 lb in)

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7. When the service assembly is correctly positioned, plug weld accordingly (1).
8. Measure frequently to ensure proper fit and alignment.
9. Clean and prepare all welded surfaces.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
11. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
14. Enable the SIR system. Refer to SIR Disabling and Enabling.

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