GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Floor Panel Number 6 Cross Bar Replacement

Removal Procedure

    Warning: Refer to Approved Equipment for Collision Repair Warning 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: 1593107 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. Note: Note the number and location of the factory welds for installation of the six bar.

  6. Locate and drill out all the factory spot welds.

    7. Object Number: 1593109 Size: SH
  7. Remove the six bar.

Installation Procedure

    Object Number: 1593110 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: 1593109 Size: SH

    Note: Use 3-dimensional measuring equipment to verify the location of the six bar.

  3. Position the six bar. Clamp the six bar in place.

    4. Object Number: 1593107 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.