GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Front Bumper Impact Bar 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. 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.