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
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Front Bumper Lower Impact Bar Replacement
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Other materials:

Electrical System Overload
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Dimensions - Body (5HB)
Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured t ...

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