GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Front End Upper Tie Bar 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: 1644975 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

    6. Important: Do not damage any inner panels or reinforcements.

  6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the tie bar.

    7. Object Number: 2046964 Size: SH
  7. Using a grinder or an equivalent tool, remove the silicon bronze welds (1) completely on each end of the upper fender rails.

    8. Object Number: 1644976 Size: SH
  8. Remove the damaged tie bar.

Installation Procedure

    Object Number: 1644977 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.

    3. Object Number: 2046980 Size: SH
  3. Measure 50 mm (2 in) (a) rearward from the front edge of the upper fender rail.

    4. Object Number: 2046981 Size: SH
  4. Mark the top of the upper fender rail at the location.
  5. At the mark, align a sliding square or similar tool, square to surface to the top of the upper fender rail.
  6. Scribe a line (1) to the top of the upper fender rail.

    7. Object Number: 2046982 Size: SH
  7. Cut the top of the upper fender rail at the scribe line (1).

    8. Object Number: 2046984 Size: SH
  8. Reposition the shaded area of the upper fender rail in order to install the new tie bar
  9. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.

    10. Object Number: 1644975 Size: SH
  10. Position the tie bar to the vehicle using 3-dimensional measuring equipment. Clamp the tie bar into place.

    11. Object Number: 2046984 Size: SH
  11. Position the shaded area of the upper fender rail back into place.

    12. Object Number: 2046985 Size: SH
  12. Using a metal inert gas (MIG) welder, weld (1) the top of the upper fender rail and the tie bar completely.
  13. Clean and prepare all welded surfaces.
  14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  15. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
  16. Install all related panels and components.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  18. Enable the SIR system. Refer to SIR Disabling and Enabling.