GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 HHR 🢒 Body Repair 🢒 Collision Repair 🢒 Floor Panel Number 6 Cross Bar Extension 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: 1593119 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 spot welds for the installation of the six bar extension.

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

    7. Object Number: 1593120 Size: SH
  7. Remove the six bar extension.

Installation Procedure

    Object Number: 1593121 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: 1593120 Size: SH

    Note: Verify the location of the six bar extension using 3-dimensional measuring equipment.

  3. Position the six bar extension on the vehicle and clamp in place.

    4. Object Number: 1593119 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.