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:

Front Side Door Adjustment
Front Side Door Adjustment Callout Component Name Preliminary Procedure Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement. 1 Front Side Door Caution: Refer to ...

Body Lock Pillar Upper Trim Panel Replacement (Sedan)
Body Lock Pillar Upper Trim Panel Replacement Callout Component Name Preliminary Procedure Disable the SIR system. Refer to SIR Disabling and Enabling. Remove the body side trim panel. Refer to Body Side Trim Panel Replace ...

Rear Wiper/Washer System Description and Operation
The rear window wiper motor is located inside the hatchback door and is directly connected to the rear window wiper. Ignition voltage is supplied to the rear wiper motor through the wiper switch. The hatchback rear window washer systems equipped with a separate washer fluid pump, hose, and noz ...

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