GM Prizm/Nova 1985-1993 Repair Guide

Bumpers

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REMOVAL & INSTALLATION



The bumpers, front or rear, are actually assemblies. The outer surface is the cover or fascia, behind which is found the absorbent material (foam block or honeycomb lattice) and the reinforcing steel bar. The components cannot be removed separately; the entire assembly must be removed from the car and then broken down into individual pieces.


CAUTION
The bumper assemblies are heavy. Always support the bumper from below in at least two places before removing the last bolts. Never lie under the bumper while removing it.

Front Bumper
NOVA

See Figure 1

  1. Remove the headlamp assemblies.
  2.  
  3. Remove the grille.
  4.  
  5. Remove the upper bumper retaining bolts.
  6.  
  7. Support the bumper.
  8.  
  9. Remove the lower bumper bolts and remove the bumper assembly.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Front bumper components - Nova

  1. The fascia may be removed by removing the nuts, bolts and lower retainer. Pay close attention to the location of any washers or shims during disassembly. They must be reinserted in their original location.
  2.  
  3. Inspect the reinforcing bar closely for any sign of twisting, crushing or deformation. Check the mounting bars for straightness. Do not attempt to straighten any bent metal components; they must be replaced.
  4.  
  5. Reassemble the fascia and absorber to the bar and tighten the nuts and bolts.
  6.  
  7. With a helper, place the bumper assembly on the supports and position it to the front of the car.
  8.  
  9. Install the lower bolts snug but not tight, then install the upper bolts snugly.
  10.  
  11. Check the bumper alignment in relation to the bodywork. Seams should be even all the way across the car and the bumper should be at the same height on both sides. Reposition the bumper as necessary and tighten the mounting bolts, lower ones first, to 70 ft. lbs.
  12.  
  13. Install the grille.
  14.  
  15. Install the headlight assemblies.
  16.  

1989-92 PRIZM

See Figure 2

  1. At each wheelwell, remove the 2 screws holding the bumper cover to the fender.
  2.  
  3. Disconnect the turn signal wiring connectors.
  4.  
  5. Support the bumper.
  6.  
  7. Remove the 2 vertical 17mm bolts holding the bumper and remove the bumper from the car.
  8.  
  9. To disassemble the bumper, remove the turn signal assemblies. Remove the upper bolts and the lower nuts from the edges of the bumper. Separate the assembly into its component pieces.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Front bumper components - 1989-92 Prizm

  1. Inspect the reinforcing bar closely for any sign of twisting, crushing or deformation. Check the mounting bars for straightness. Do not attempt to straighten any bent metal components; they must be replaced.
  2.  
  3. Reassemble the fascia and absorber to the bar and tighten the nuts and bolts. Install the turn signal lamps.
  4.  
  5. With a helper, place the bumper assembly on the supports and position it to the body of the car.
  6.  
  7. Install the bolts snug but not tight.
  8.  
  9. Check the bumper alignment in relation to the bodywork. Seams should be even all the way across the car and the bumper should be at the same height on both sides. Reposition the bumper as necessary and tighten the mounting bolts to 70 ft. lbs.
  10.  
  11. Connect the turn signal wiring harnesses.
  12.  
  13. Install the 2 screws at each wheelwell.
  14.  

1993 PRIZM

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the 4 screws from the front grille. Unclip and remove the grille from the vehicle.
  4.  
  5. Remove the 4 screws along the top of the front bumper fascia. Loosen the wheelhousings on both sides of the vehicle to gain access to two front bumper fascia upper support bolts.
  6.  
  7. Remove the two front bumper fascia support bolts, 1 on each side of the fascia.
  8.  
  9. Remove the 5 bolts from the bottom of the front bumper fascia. Pull the front bumper fascia forward, disconnect the turn signal and the side marker bulb sockets and remove fascia from the vehicle.
  10.  
  11. Remove the 4 plastic clips and the front bumper energy absorber from the vehicle.
  12.  
  13. Remove the 4 nuts retaining the front bumper impact bar.
  14.  
  15. Remove the front bumper impact bar from the front bumper impact arms.
  16.  

To install:
  1. Install the front bumper impact bar to the front bumper impact arms; secure with 4 nuts. Tighten the front bumper impact bar nuts to 33 ft. lbs. (45 Nm).
  2.  
  3. Connect the front bumper energy absorber to the vehicle; secure with 4 plastic clips.
  4.  
  5. Connect the front bumper fascia to the vehicle, connecting the turn signal and the side marker bulb sockets.
  6.  
  7. Connect the 5 bolts to the bottom of the front bumper fascia. Tighten the front bumper fascia bolts to 15 ft lbs. (20 Nm).
  8.  
  9. Connect the two bumper fascia upper support bolts, 1 on each side of the front bumper fascia. Tighten the front bumper fascia upper support bolts to 15 ft. lbs. (20 Nm).
  10.  
  11. Install the 4 screws along the top of the front bumper fascia. Clip the front grille into place; secure with 4 screws.
  12.  
  13. Connect the negative (-) battery cable.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: Front bumper components - 1993 Prizm

Rear Bumper
NOVA

See Figure 4

  1. Open the trunk lid and lift the padding or carpet out of the way.
  2.  
  3. Remove the plugs to gain access to the bumper retaining bolts.
  4.  
  5. Support the bumper.
  6.  
  7. Remove the bumper bolts.
  8.  
  9. The fascia may be removed by removing the nuts, bolts and lower retainer. Pay close attention to the location of any washers or shims during disassembly. They must be reinserted in their original location.
  10.  



Click image to see an enlarged view

Fig. Fig. 4: Rear bumper components - Nova

  1. Inspect the reinforcing bar closely for any sign of twisting, crushing or deformation. Check the mounting bars for straightness. Do not attempt to straighten any bent metal components; they must be replaced.
  2.  
  3. Reassemble the fascia and absorber to the bar and tighten the nuts and bolts.
  4.  
  5. With a helper, place the bumper assembly on the supports and position it to the body of the car.
  6.  
  7. Install the bolts snug but not tight.
  8.  
  9. Check the bumper alignment in relation to the bodywork. Seams should be even all the way across the car and the bumper should be at the same height on both sides. Reposition the bumper as necessary and tighten the mounting bolts to 70 ft. lbs.
  10.  
  11. Install the plugs over the bolts.
  12.  
  13. Reinstall the trunk mat.
  14.  

1989-92 PRIZM

See Figure 5

  1. At each wheelwell, remove the 2 screws holding the bumper cover to the fender.
  2.  
  3. Remove the 2 nuts on each side holding the bumper mounting posts to the bodywork.
  4.  
  5. Support the bumper.
  6.  
  7. Remove the 4 nuts (14mm) holding the bumper to the frame of the car and remove the bumper assembly.
  8.  
  9. To remove the bumper cover, remove the 7 nuts from the lower edge and remove the 6 bolts from inside the upper perimeter of the bumper.
  10.  



Click image to see an enlarged view

Fig. Fig. 5: Rear bumper components - 1989-92 Prizm

  1. Inspect the reinforcing bar closely for any sign of twisting, crushing or deformation. Check the mounting bars for straightness. Do not attempt to straighten any bent metal components; they must be replaced.
  2.  
  3. Reassemble the fascia and absorber to the bar and tighten the nuts and bolts.
  4.  
  5. With a helper, place the bumper assembly on the supports and position it to the body of the car.
  6.  
  7. Install the mounting bolts snug but not tight.
  8.  
  9. Check the bumper alignment in relation to the bodywork. Seams should be even all the way across the car and the bumper should be at the same height on both sides. Reposition the bumper as necessary and tighten the mounting bolts.
  10.  
  11. Install the nuts holding the mounting posts to the bodywork.
  12.  
  13. Install the 2 screws at each wheelwell.
  14.  

1993 PRIZM

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Open the deck lid. Remove the three plastic retaining clips along the top of the rear bumper fascia.
  4.  
  5. Remove the two bolts and the right-side rear wheelhousing.
  6.  
  7. Remove 1 rear bumper fascia support bolt from each side of the rear bumper fascia.
  8.  
  9. Disconnect the two bolts from the bottom of the rear bumper fascia.
  10.  
  11. Remove the two screws from the bottom of the rear bumper fascia.
  12.  
  13. Remove 1 nut from each rear combination lamp assembly (accessible from inside the luggage compartment.
  14.  
  15. Remove the two bolts from each rear combination lamp assembly and remove the lamp assemblies from the vehicle.
  16.  
  17. Remove 1 bolt from each side of the rear bumper fascia. Pull the rear bumper fascia rearward, disconnect license plate lamp bulb sockets and remove fascia from the vehicle.
  18.  
  19. Remove 1 plastic clip from each rear bumper energy absorber and energy absorbers from the rear bumper impact bar.
  20.  
  21. Remove the 4 nuts from the rear bumper impact bar and remove the impact bar from the vehicle.
  22.  

To install:
  1. Connect the rear bumper impact bar to the vehicle; secure with 4 nuts. Tighten the rear bumper impact bar nuts to 33 ft. lbs. (45 Nm).
  2.  
  3. Connect the rear bumper energy absorbers to the rear bumper impact bar; secure each with 1 plastic clip.
  4.  
  5. Connect the rear bumper fascia to the vehicle, connecting the license plate lamp bulb sockets.
  6.  
  7. Connect 1 bolt to each side of the rear bumper fascia. Tighten the rear bumper fascia bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Connect the rear combination lamp assemblies to the vehicle; secure each with two bolts and 1 nut. Tighten the rear combination lamp assembly bolts and nuts to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the two screws to the bottom of the rear bumper fascia.
  12.  
  13. Connect two bolts to the bottom of the rear bumper fascia. Tighten the rear bumper fascia bolts to 15 ft. lbs. (20 Nm).
  14.  
  15. Connect 1 rear bumper fascia support bolt to each side of the rear bumper fascia. Tighten the rear bumper fascia support bolts to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the right-side rear wheelhousing to the vehicle; secure with two bolts. Tighten the right-side rear wheelhousing to 89 inch lbs. (10 Nm).
  18.  
  19. Connect the three plastic retaining clips along the top of the rear bumper fascia. Close the deck lid.
  20.  
  21. Connect the negative (-) battery cable.
  22.  



Click image to see an enlarged view

Fig. Fig. 6: Rear bumper components - 1993 Prizm

 
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