Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Rear Side Door Outer Panel Replacement

Chevrolet Sonic Repair Manual / Body / Doors and Enclosures / Doors / Rear Side Door Outer Panel Replacement

Removal Procedure

    Warning:

    Refer to Glass and Sheet Metal Handling Warning.

    Note:

    According to different corrosion warranties, only the regional mandatory joining methods are allowed.

  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 the rear side door. Refer to Rear Side Door Replacement.
  4. Remove the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement.
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.


  6. Grind the edges of the rear side door outer panel (1) to separate the outer door panel from the door shell.

  7. Warning:

    Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

  8. Remove the rear side door outer door panel (1).
  9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  10. Straighten the edges of the door shell.
Installation Procedure
  1. Align the rear side door outer panel.
  2. Verify the fit of the rear side door outer panel.

  3. Clamp the rear side door outer panel (1) into position.

  4. Continue to hammer in stages along the hem flanges (1).
  5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  6. Install the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement.
  7. Install the rear side door. Refer to Rear Side Door Replacement.
  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.
Rear Side Door Opening Floor Carpet Retainer Replacement
Rear Side Door Opening Floor Carpet Retainer Replacement Callout Component Name Preliminary Procedure Remove the rear seat cush ...

Rear Side Door Replacement
Rear Side Door Replacement Callout Component Name Warning: Refer to SIR Warning. Preliminary Procedures Mark the l ...

Other materials:

Bluetooth (Overview)
For vehicles equipped with Bluetooth capability, the system can interact with many cell phones, allowing: Placement and receipt of calls in a hands-free mode. Sharing of the cell phone’s address book or contact list with the vehicle. To minimize driver distraction, before driving, and ...

Wheel Replacement
Replace any wheel that is bent, cracked, or badly rusted or corroded. If wheel nuts keep coming loose, the wheel, wheel bolts, and wheel nuts should be replaced. If the wheel leaks air, replace it. Some aluminum wheels can be repaired. See your dealer if any of these conditions exist. Your d ...

Differential Case Disassemble
Special Tools 6-9607346 Sensor Ring Gear Puller J-810704 Steering Column Center Bar Puller J-810721 Axle Shaft Seal Remover Support Base R-0006749 Support Base R-0407011 Bearing Race Remover R-0007761 Universal Handle for Pullers and Installers S-9407195 Pinion Gear Case Bearing ...

© 2014-2019 Copyright www.csmans.com
   
0.0168