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

Front Bumper Impact Bar Replacement for Saturn Astra 2009

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. Object Number: 1941410 Size: LF
  3. Remove the center guide rails.

    4. Drill out the 5 blind rivets (arrow).

  4. Remove the impact absorber wiring harness.

    5. Release the 5 cable ties.


    Object Number: 1941407 Size: LF
  5. Remove the impact bar (3).
    6. • Remove the windshield washer reserve tank bolt (2).
    • Remove the 4 nuts and 4 bolts (1).

Installation Procedure

    Note: Observe protective wax corrosion protection measures.

  1. Seal the cavity.

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

    Note: Use NEW nuts

  2. Install the impact bar.
    3. • Install the 4 bolts/nuts.

    Tighten
    Tighten the 4 nuts to 20 N·m (15 lb ft).

    • Tighten the windshield washer reserve tank bolt.

    Note: Ensure the impact absorber wiring harness is correctly routed.

  3. Install the impact absorber wiring harness.

    4. Fasten the 5 cable ties.

  4. Install the center guide rails.

    5. Install the 5 blind rivets.

  5. Install the headlamp. Refer to Headlamp Replacement - Left Side, Headlamp Replacement - Right Side, or Headlamp Replacement.
  6. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.