Chevrolet Sonic Repair Manual: Rear End Panel Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Glass and Sheet Metal Handling Warning.

Note:

The rear end lower panel reinforcement extension is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Dual Phase Steel.

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. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

Note:

Note the number and location of welds for installation of the service assembly.

6. Locate and mark all the necessary factory welds of the body rear end panel.


7. Drill all factory welds (1).


8. Remove the body rear end panel (1).

Installation Procedure

Note:

If the location of the original plug weld holes can not be determined, space the plug weld holes every 40?€‰mm (1 1/2?€‰in)

.

1. Drill 8?€‰mm (5/16?€‰in)

   holes for plug welding along the edges of the body rear end panel (1) as noted from the original panel.

2. Clean and prepare the attaching surfaces for welding.


3. Position the body rear end panel on the vehicle (1).
4. Verify the fit of the body rear end panel.
5. Clamp the body rear end panel into position.


6. Plug weld accordingly.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
11. Enable the SIR system. Refer to SIR Disabling and Enabling.

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