GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 ION 🢒 Body Repair 🢒 Collision Repair 🢒 Front Bumper Impact Bar Bracket Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  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. Object Number: 868868 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    6. Object Number: 867608 Size: SH

    Important: Note the number and location of the factory welds for installation of the impact bar bracket - front bumper

  6. Locate and drill out all the factory welds from the outside surface of the rail.

    7. Object Number: 867609 Size: SH
  7. Remove the front bumper impact bar bracket.

Installation Procedure

    Object Number: 867597 Size: SH
  1. Prepare all mating surfaces as necessary.
  2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

    3. Object Number: 867609 Size: SH

    Important: Verify the location of the front rail using 3-dimensional measuring equipment.

  3. Position the impact bar bracket on the rail and clamp in place.

    4. Object Number: 868868 Size: SH
  4. Plug weld accordingly.
  5. Clean and prepare all of the welded surfaces.
  6. Install all of the related panels and components.
  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. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  10. Enable the SIR system. Refer to SIR Disabling and Enabling .