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:
Hood Hold-Open Rod Replacement
Hood Hold-Open Rod Replacement
Callout
Component Name
1
Hood Hold-Open Rod
Warning: When a hood hold open device is being removed or
installed, provide alternate support to avoid the possibility of damage
...
Front Floor Console Cover Replacement (Manual Transmission)
Removal Procedure
Use a flat bladed plastic trim tool in order to release the retainers
securing the console cover?€‰(1) to the console assembly.
Reach under the console cover assembly?€‰(1) and release the retainer
tabs securing the transmission shif ...
Manual Transmission Shift Lever Cable Adjustment
Special Tools
DT-527-A Adjuster or 5mm drill bit
For equivalent regional tools, refer to Special Tools.
Note: Not using the specified tools may lead to shift system mis-adjustment.
Remove the floor console. Refer to
Front Floor Console Replacement.
Lift upward an ...
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