GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Sonoma Pickup - 4WD 🢒 Engine 🢒 Engine Electrical 🢒 Front Bumper Impact Bar Replacement

Removal Procedure

    Object Number: 604526 Size: SH
  1. Remove the grille. Refer to Grille Replacement in Exterior Trim.
  2. Remove the radiator air intake baffle. Refer to Air Inlet Grille Panel Replacement in Body Front End.
  3. Remove the front wheel opening flare extension, if equipped. Refer to Front Wheel Opening Flare Replacement in Exterior Trim.
  4. Remove the nut and the bolt that retain the brace to the bumper impact bar.
  5. Disconnect the fog lamp connectors, if equipped. Refer to the appropriate procedure in Lighting Systems:
    6. •  Headlamp Replacement
    •  Front Fog Lamp Replacement
  6. Remove the nuts and the bolts that retain the bumper impact bar to the frame.
  7. Remove the bumper impact bar from the vehicle.
  8. If replacing the bumper impact bar, perform the following:
    9. 8.1. Remove the license plate bracket, if equipped. Refer to Front License Plate Bracket Replacement .
    8.2. Remove the air deflector from the bumper impact bar. Refer to Front Bumper Fascia Air Deflector Replacement .

Installation Procedure

    Object Number: 604526 Size: SH
  1. Install the following components if removed:
    2. 1.1. Install the air deflector to the bumper impact bar. Refer to Front Bumper Fascia Air Deflector Replacement .
    1.2. Install the license plate bracket. Refer to Front License Plate Bracket Replacement .
  2. Install the bumper impact bar to the vehicle.

    3. 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.

  3. Install the bolts and the nuts that retain the bumper impact bar to the frame.

    4. Tighten
    Tighten the bumper impact bar to the frame bolts to 40 N·m (30 lb ft).

  4. Install the fog lamp connectors, if equipped. Refer to the appropriate procedure in Lighting Systems.
    5. •  Headlamp Replacement
    •  Front Fog Lamp Replacement
  5. Install the nuts and the bolts that retain the bumper impact bars to the brace.

    6. Tighten
    Tighten the bumper impact bar to the brace bolts to 40 N·m (30 lb ft).

  6. Install the front wheel opening flare extension, if equipped. Refer to Front Wheel Opening Flare Replacement in Exterior Trim.
  7. Install the radiator air intake baffle. Refer to Air Inlet Grille Panel Replacement in Body Front End.
  8. Install the grille. Refer to Grille Replacement in Exterior Trim.