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Chevrolet Sonic Repair Manual: Front End Upper Tie Bar Replacement

Chevrolet Sonic Repair Manual / Chassis / Steering / Tie Rods and Linkage / 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

    Drill 8 mm (5/16 in) plug weld holes as necessary on service parts,
  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.

    5. Caution:

    Refer to Fastener Caution.

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

    .

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

    .



  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.
Tie Rods and Linkage
...

Front End Upper Tie Bar Replacement
Front End Upper Tie Bar Replacement Callout Component Name Preliminary Procedures Disable the SIR system. Refer to SIR Disabling an ...

Other materials:

Airbag System
The vehicle has the following airbags except where noted below: A frontal airbag for the driver. A frontal airbag for the front outboard passenger. A knee airbag for the driver. A knee airbag for the front outboard passenger. A seat-mounted side impact airbag for the driver. A seat-mou ...

Wheel Drive Shaft Inner Joint Inspection
Inspection Procedure Remove the front wheel drive shaft inner joint and boot. Refer to Front Wheel Drive Shaft Replacement. Remove the wheel drive shaft tripod bushing (1) from the tripod housing (3). Remove the wheel drive shaft tripod housi ...

Transmission Case Assemble (Gen 2)
Special Tools 3-9506289 Universal Adapter J-840733 Driver R-0007758 Holding Fixture R-0007761 Universal Handle R-0007770 Holding Fixture Adapter Plates T-9804669 Seal Installer T-0307000 Extractor and Driver Fixture For equivalent regional tools, refer to Special Tools. ...

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