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:

Towing the Vehicle
Caution Incorrectly towing a disabled vehicle may cause damage. The damage would not be covered by the vehicle warranty. Do not lash or hook to the chassis components — including the front and rear subframes, suspension control arms, and links — during towing and recovery of a disabled ve ...

Radio/Audio System Description and Operation
The entertainment system on this vehicle may have several different configurations available to it. To determine the specific configuration of the vehicle, please see the Service Parts ID Label, and refer to RPO Code List. Each item in the list below represents topics covered in detail below. ...

Fuel Tank Draining
Warning: Refer to Gasoline/Gasoline Vapors Warning. Note: The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valv ...

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