2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 1886774

Front Bumper Fascia Energy Absorber Replacement

Removal Procedure

1. Remove the front bumper fascia. Refer to

Front Bumper Fascia Replacement

.

2. Remove the front bumper energy absorber.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 2

Document ID: 1886774

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1886774&pubCellSyskey=9946&pubObj...

1. Install the front bumper energy absorber.
2. Install the front bumper fascia. Refer to

Front Bumper Fascia Replacement

.

Page 2 of 2

Document ID: 1886774

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1886774&pubCellSyskey=9946&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 1886762

Front Bumper Impact Bar Replacement (Hatchback)

Removal Procedure

1. Remove the front bumper fascia.

Refer to

Front Bumper Fascia Replacement

.

2. Remove the front bumper impact beam.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 2

Document ID: 1886762

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1886762&pubCellSyskey=9987&pubObj...

1. Install the front bumper impact beam.
2. Install the front bumper fascia.

Refer to

Front Bumper Fascia Replacement

.

Page 2 of 2

Document ID: 1886762

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1886762&pubCellSyskey=9987&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 1723844

Front Bumper Impact Bar Replacement (Notchback)

Removal Procedure

1. Remove the front bumper fascia. Refer to

Front Bumper Fascia Replacement

.

2. Remove the front bumper impact beam.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 2

Document ID: 1723844

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1723844&pubCellSyskey=9987&pubObj...

1. Install the front bumper impact beam.
2. Install the front bumper fascia. Refer to

Front Bumper Fascia Replacement

.

Page 2 of 2

Document ID: 1723844

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1723844&pubCellSyskey=9987&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 2096316

Front Bumper Fascia Replacement (Notchback)

Removal Procedure

Warning:

Refer to

Battery Disconnect Warning

in the Preface section.

1. Disconnect the negative battery cable.
2. Remove the necessary screws, the retainers, and nuts, from the front wheel well splash

shields.

Warning:

Refer to

Battery Disconnect Warning

in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 4

Document ID: 2096316

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096316&pubCellSyskey=9978&pubObj...

3. Remove the headlamps, the front side marker lamp, and the front fog lamps. Refer to

Headlamp Replacement

,

Front Side Marker Lamp Replacement

and

Front Fog Lamp

Replacement

.

4. Remove the screws from the wheel wells.
5. Remove the retainers from the upper fascia.
6. Remove the screws attaching the fascia to the fender.
7. Remove the retainers from underneath the fascia.

8. Remove the retainers on the top of the fascia.
9. Remove the front bumper fascia.

Installation Procedure

Page 2 of 4

Document ID: 2096316

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096316&pubCellSyskey=9978&pubObj...

1. Install the bumper fascia.
2. Install the retainers on the top of the fascia.

Caution:

Refer to

Fastener Caution

in the Preface section.

3. Install the retainers underneath the fascia.
4. Install the screws attaching the fascia to the fender and tighten to 1.5 N·m (13 lb in).
5. Install the headlamps, the front side marker lamps, and the front fog lamps. Refer to

Headlamp Replacement

,

Front Side Marker Lamp Replacement

and

Front Fog Lamp

Replacement

.

Page 3 of 4

Document ID: 2096316

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096316&pubCellSyskey=9978&pubObj...

6. Install the screws, the retainers, and the nuts to the front wheel well splash shields.

Tighten

7. Connect the negative battery cable.

• Tighten the splash shield screws to 1.5 N·m (13 lb in).

• Tighten the splash shield nuts to 1.5 N·m (13 lb in).

Page 4 of 4

Document ID: 2096316

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096316&pubCellSyskey=9978&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 2046759

Front Bumper Fascia Replacement (Hatchback)

Removal Procedure

Warning:

Refer to

Battery Disconnect Warning

in the Preface section.

1. Disconnect the negative battery cable.
2. Remove the necessary screws, bolts, and nuts, from the front wheel well splash shields.
3. Remove the headlamps. Refer to

Headlamp Replacement

.

4. Remove the fascia grille. Refer to

Fascia Grille Replacement

.

5. Remove the clips (1) from the top of the front fascia.

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 3

Document ID: 2046759

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046759&pubCellSyskey=9978&pubObj...

6. Remove the clips (1) from the bottom of the front fascia.
7. Remove screw (2) from the bottom of the front fascia.

8. Remove the bolts (1) from the inside of the front bumper fascia.
9. Remove the front fascia from the vehicle.

Installation Procedure

1. Install the front fascia from the vehicle.

Page 2 of 3

Document ID: 2046759

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046759&pubCellSyskey=9978&pubObj...

Caution:

Refer to

Fastener Caution

in the Preface section.

2. Install the bolts (1) to the inside of the front bumper fascia and tighten to 1.5 N·m

(13 lb in).

3. Remove the clips (1) from the bottom of the front fascia.

4. Install screw (2) to the bottom of the front fascia and tighten to 1.5 N·m (13 lb in).

5. Install the clips (1) to the top of the front fascia.
6. Install the fascia grille. Refer to

Fascia Grille Replacement

.

7. Install the headlamps. Refer to

Headlamp Replacement

.

8. Install the necessary screws, bolts, and nuts, to the front wheel well splash shields.
9. Connect the negative battery cable.

Page 3 of 3

Document ID: 2046759

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046759&pubCellSyskey=9978&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 2096335

Rear Bumper Fascia Replacement (Notchback)

Removal Procedure

1. Remove the screws and the mud guards.
2. Remove the screws attaching the splash shields to the fascia.
3. Remove the screws from the bottom of the fascia.
4. Remove the rear luggage compartment side panels.

5. Remove the nuts in the luggage compartment.

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 4

Document ID: 2096335

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096335&pubCellSyskey=9990&pubObj...

6. Remove the bolts in the luggage compartment.

7. Remove the rear upper fascia screws.
8. Remove the tail lamps. Refer to

Tail Lamp Replacement

.

9. Remove the inner upper fascia retainers.

10. Remove the fascia.

Installation Procedure

Caution:

Refer to

Fastener Caution

in the Preface section.

1. Install the fascia with the rear upper fascia screws.

Page 2 of 4

Document ID: 2096335

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096335&pubCellSyskey=9990&pubObj...

Tighten
Tighten the rear upper fascia screws to 1.5 N·m (13 lb in).

2. Install the rear inner upper fascia retainers.
3. Install the tail lamps. Refer to

Tail Lamp Replacement

.

4. Install the bolts in the luggage compartment.

Tighten
Tighten the luggage compartment fascia bolts to 4 N·m (35 lb in).

5. Install the nuts in the luggage compartment.

Tighten
Tighten the luggage compartment fascia nuts to 4 N·m (35 lb in).

Page 3 of 4

Document ID: 2096335

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096335&pubCellSyskey=9990&pubObj...

6. Install the splash shield screws.

Tighten
Tighten the splash shield screws to 1.5 N·m (13 lb in).

7. Install the lower fascia screws.

Tighten
Tighten the lower fascia screws to 1.5 N·m(13 lb in).

8. Install the mud guards with the screws.

Tighten
Tighten the mud guard screws to 1.5 N·m (13 lb in).

Page 4 of 4

Document ID: 2096335

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2096335&pubCellSyskey=9990&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 2046758

Rear Bumper Fascia Replacement (Hatchback)

Removal Procedure

1. Remove the screws and the mud guards.
2. Remove the screws and the splash shields.
3. Remove the tail lamps. Refer to

Tail Lamp Replacement

.

4. Remove the rear bumper fascia nuts (1).
5. Remove the rear bumper fascia bolt (3).
6. Remove the rear bumper fascia clip (2).

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

7. Remove the clips (1) from the rear sill trim (2).
8. Remove the rear sill trim panel (2).

9. Remove the rear side panel trim clips (1) and screw.

10. Remove the rear bumper fascia-to-lower back panel nut through the gap between the rear

side panel trim and the lower back panel.

Page 2 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

11. Remove the rear upper fascia screws (1).
12. Remove the fascia (2).

Installation Procedure

Caution:

Refer to

Fastener Caution

in the Preface section.

1. Install the fascia (1) with the rear upper fascia screws (2).

Tighten
Tighten the rear upper fascia screws to 1.5 N·m (13 lb in).

Object Number: 1248249 Size: SH

Page 3 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

2. Install the rear bumper fascia-to-lower back panel nut (1) through the gap between the rear

side panel trim and the lower back panel.

Tighten
Tighten the rear fascia nut to 4 N·m (35 lb in).

3. Install the rear side panel trim clips (1) and screw.

Tighten
Tighten the rear side panel trim screw to 1.5 N·m (13 lb in).

Page 4 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

4. Install the rear sill trim panel (2).
5. Install the clips (1) to the rear sill trim (2).

6. Install the rear bumper fascia clip (2).
7. Install the rear bumper fascia bolt (3).

Tighten
Tighten the rear bumper fascia bolt (3) to 1.5 N·m (13 lb in).

8. Install the rear bumper fascia nuts (1).

Tighten
Tighten the rear bumper fascia nut (1) to 25 N·m (18 lb ft).

Page 5 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

9. Install the tail lamps. Refer to

Tail Lamp Replacement

.

10. Install the screws and the splash shields.
11. Install the screws and the mud guards.

Page 6 of 6

Document ID: 2046758

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2046758&pubCellSyskey=9990&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 1420384

Rear Energy Absorber Replacement (North American)

Removal Procedure

1. Remove the rear bumper fascia. Refer to

Rear Bumper Fascia Replacement

.

2. Remove the energy absorber.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 2

Document ID: 1420384

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1420384&pubCellSyskey=9997&pubObj...

1. Install the energy absorber.
2. Install the rear bumper fascia. Refer to

Rear Bumper Fascia Replacement

.

Page 2 of 2

Document ID: 1420384

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1420384&pubCellSyskey=9997&pubObj...

2009 Chevrolet Aveo

|

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

|

Body Repair

|

Bumpers and Fascias

|

Repair Instructions

| Document ID: 1419792

Rear Bumper Impact Bar Replacement

Removal Procedure

1. Remove the rear bumper fascia.

Refer to

Rear Bumper Fascia Replacement

.

2. Remove the rear bumper impact beam.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

Page 1 of 2

Document ID: 1419792

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1419792&pubCellSyskey=9951&pubObj...

1. Install the rear bumper impact beam.
2. Install the rear bumper fascia.

Refer to

Rear Bumper Fascia Replacement

.

Page 2 of 2

Document ID: 1419792

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=1419792&pubCellSyskey=9951&pubObj...