GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Body Repair 🢒 Bumpers and Fascias 🢒 Front Bumper Impact Bar Bracket Replacement

Removal Procedure
  1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
  2. Remove the headlamps. Refer to Headlamp Replacement - Left Side, Headlamp Replacement - Right Side, or Headlamp Replacement.
  3. Remove the impact absorber. Refer to Front Bumper Impact Bar Replacement.

    4. Object Number: 1937589 Size: LF
  4. Remove the windshield washer reserve tank.
    5. • Disconnect the windshield washer pump wiring harness plug (1).
    • Disconnect the windshield wash system (2) from pump.
    • Remove the rear window wash system (3) from pump.
    • Remove the 2 hoses from the guide.
    • Remove the 2 bolts (4 and 5).
  5. For vehicles with a high-pressure headlamp wash system, disconnect the pump wiring harness plug.

    6. Object Number: 1941384 Size: LF

    Note: 

       • Depending on the degree of damage, one or both impact absorbers must be replaced. Inspect for twisted screwing points and bent attachment surfaces on the front member.
       • During production, impact bars are spot-welded to the side member closure plate. These welds are not replaced during service.

  6. Remove the impact bar bracket (1).
    7. • Drill out 4 spot welds (I and II).
    • Remove the 4 bolts (arrows).

Installation Procedure

    Object Number: 1937591 Size: SH
  1. Prime the connecting flange side member (2) and the drilled holes (1) in top front.

    2. Caution: Refer to Fastener Caution in the Preface section.

    Note: When replacing the impact bar, the new parts do not require painting in the service department.

  2. Install the impact bar bracket.

    3. Tighten
    Tighten the 4 bolts (1) to 10 N·m (89 lb in).

  3. Mark the heads of the bolts with paint.

    4. Note: Observe protective wax corrosion protection measures.

  4. Apply the cavity sealing/protective wax to the mounting surfaces and connecting flanges.
  5. Connect the wiring harness to impact bar bracket.

    6. Fasten the 2 cable ties.

  6. Install the windshield washer reserve tank.

    7. Tighten
    Tighten the 2 bolts to 3.5 N·m (32 lb in).

    • Install the 2 hoses the into guide.
    • Install the rear window wash system hose to the pump.
    • Install the front window wash system hose to the pump.
    • Connect windshield washer pump wiring harness plug.
  7. For vehicles with a high-pressure headlamp wash system, connect the pump wiring harness plug.
  8. Install the impact bar. Refer to Front Bumper Impact Bar Replacement.
  9. Install the headlamps. Refer to Headlamp Replacement - Left Side, Headlamp Replacement - Right Side, or Headlamp Replacement.
  10. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.