GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Malibu 🢒 Body 🢒 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 in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 1210266 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 in Paint and Coatings.

    6. Object Number: 1210272 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: 1210275 Size: SH
  7. Remove the front bumper impact bar bracket.

Installation Procedure

    Object Number: 1210278 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: 1210275 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: 1210266 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 in Paint and Coatings.
  8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  10. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.