Chevrolet Sonic Repair Manual: Front Bumper Impact Bar Replacement
- Removal Procedure
-
- Disable the SIR system. Refer to SIR Disabling and Enabling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove all related panels and components.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
- Remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.
- Locate and mark all factory welds.
- Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
- Remove the damaged impact bar (1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
- Installation Procedure
-
- Drill 8 mm (5/16 in) holes for plug welding along the edges of the service panel (1) as noted from the original panel.
- Clean and prepare the attaching surfaces for welding.
- Position the impact bar (1) on the vehicle.
- Verify the fit of the bar.
- Clamp the impact bar into position.
- Plug weld accordingly (1).
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- 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:
Fuel Tank Filler Door Replacement
Fuel Tank Filler Door Replacement
Callout
Component Name
1
Fuel Tank Filler Door
Procedure
Position the fuel tank filler door to the full open position. Using light
outward sliding pressure on the filler door, ...
Brake Fluid Effects on Paint and Electrical Components Caution
Caution: Avoid spilling brake fluid onto painted surfaces, electrical
connections, wiring, or cables. Brake fluid will damage painted surfaces and
cause corrosion to electrical components. If any brake fluid comes in contact
with painted surfaces, immediately flush the area with water. I ...
Brake Rotor/Drum Balance Inspection
Support the vehicle drive axle on a suitable hoist. Refer to Lifting and
Jacking the Vehicle.
Remove the tire and wheel assemblies from the drive axle. Refer to Tire
and Wheel Removal and Installation.
Warning: Refer to Work Stall Test Warning.
Reinstall the wheel nuts in ...
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