Chevrolet Sonic Repair Manual: Rear End Panel Replacement
- Removal Procedure
-
- Disable the SIR System. Refer to SIR Disabling and Enabling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove all related panels and components.
- Visually inspect the damage. Repair as much of the damage as possible.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Locate and mark all the necessary factory welds of the body rear end panel.
- Drill all factory welds (1).
- Remove the body rear end panel (1).
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.
Note:
Note the number and location of welds for installation of the service assembly.
- Installation Procedure
-
- 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.
- Clean and prepare the attaching surfaces for welding.
- Position the body rear end panel on the vehicle (1).
- Verify the fit of the body rear end panel.
- Clamp the body rear end panel into position.
- Plug weld accordingly.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Enable the SIR system. Refer to SIR Disabling and Enabling.
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)
.
- Drill 8?€‰mm (5/16?€‰in)
Front Fender Replacement
Front Fender Replacement
Callout
Component Name
Preliminary Procedures
Remove the front bumper fascia. Refer to Front Bumper Fascia ...
Roof Panel Joint Finish Molding Replacement
Roof Panel Joint Finish Molding Replacement
Callout
Component Name
Caution: Refer to Exterior Trim Emblem Removal Caution.
...
Other materials:
Time & Date Settings
Select to change the settings:
Set Time Format: Select 12h or 24h.
Set Date Format: Press < or > to select the date display.
Set Time & Date: Select, then press
or
to adjust the value.
Automatic Clock Sync: Select to display the real or user time on the radio.
Select On ...
Door Lock and Ignition Lock Folding and Non-Folding Key Cutting
High Security keys are available from the service parts system.
Obtain the key code from the security card or from the GM Dealer World, Parts,
Key Code Look Up system.
If you have the key code and access to a Triax-E., BD Laser or other code key
cutting machine from the GM Dealer Equipment C ...
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
The wheel exhibits excessive runout.
The wheel is bent.
The wheel is cracked.
The wheel is severely rusted.
The wheel is severely corroded.
Note: Air leaks caused by porosity on aluminum wheels are repairable.
...