GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Body and Accessories 🢒 Bumpers 🢒 Front Bumper Impact Bar Replacement

Removal Procedure
  1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

    2. Object Number: 747933 Size: SH
  2. Remove the energy absorber push-in retainers from the front impact bar.
  3. Remove the energy absorber from the front impact bar.

    4. Object Number: 277194 Size: SH
  4. Remove the fog lamps. Refer to Front Fog Lamp Replacement in Lighting Systems.
  5. Remove the front impact bar nuts (3).
  6. Remove the front impact bar (1) from the frame rail (4).

Installation Procedure

    Object Number: 277194 Size: SH
  1. Install the impact bar (1) to the vehicle (4).

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the front impact bar retaining nuts (3) to the impact bar (1).

    3. Tighten
    Tighten the nuts to 27 N·m (20 lb ft).


    Object Number: 747933 Size: SH
  3. Install the energy absorber to the front impact bar.
  4. Install the energy absorber push-in retainers to the impact bar.
  5. Install the fog lamps. Refer to Front Fog Lamp Replacement in Lighting Systems.
  6. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .