GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Body Repair 🢒 Collision Repair 🢒 Front Bumper Impact 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: 1210236 Size: SH

    Important: This panel is replaced at factory welds

  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. Important: Note the number and location of the factory welds for installation of the front impact bar.


    Object Number: 1210256 Size: SH
  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 1210260 Size: SH
  7. Remove the impact bar.

Installation Procedure

    Object Number: 1210265 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. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

    4. Object Number: 1210260 Size: SH
  4. Position the impact bar on the vehicle using 3-dimensionial measuring equipment. Clamp the tie bar into place.

    5. Object Number: 1210236 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all of the related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Enable the SIR system. Refer to SIR Disabling and Enabling .