Front Bumper Reinforcement: Service and Repair

Front Bumper Impact Bar Replacement (Z06, ZR1)


Special Tools


J 42058 Frame Adapter Clamp

Removal Procedure

Warning:Refer to Approved Equipment for Collision Repair Warning .

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.Remove all related panels and components.

4.Repair as much of the damage as possible to the factory specifications.

5.Use
J 42058 frame adapter clamp to secure the vehicle if pulling and straightening are required.

6.Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair .





Note:
-Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.

-When removing welds, favor the bumper bar side of the weld joint.

7.Locate and remove all factory welds (1) attaching the front bumper bar to the front frame rails. Note the location of the welds for installation of the new bumper bar.





8.Remove the damaged bumper bar (1).





9.Remove pieces of the bumper bar which are left attached to the rail ends.

10.Straighten and deburr the rail ends. Keep the perimeter and shape of the rail end as original as possible.

Installation Procedure





Note:Due to welding accessibility, it may be necessary to weld the triangle brackets (1) to the bumper bar prior to installation of the bumper bar.

1.Dry fit the bumper bar for proper fit and alignment before welding.

Note:Use a stainless steel brush to remove the oxide layer prior to welding.

2.Clean and prepare all of the welded mating surfaces.





3.Install the front bumper bar (1).

4.Position the bumper bar to the vehicle using 3-dimensional measuring equipment.





Note:Recommend wire alloy is 5356 and wire size is.035. The shielding gas is 100 percent Argon.
A two minute cooling down period is recommend for every 2 minutes or 100 mm (4 in) of welding.

5.Using a PULSED-MIG (P-MIG) welder, weld (1) the bumper bar to the frame rail ends duplicating the factory welds.

6.Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair .

7.Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .

8.Install all related panels and components.

9.Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

10.Enable the SIR system. Refer to SIR Disabling and Enabling .