Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (4NB)
- 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 factory welds.
- Drill all factory welds?€‰(1). Note the number and location of welds for installation of the service assembly.
- Cut the adhesive with an appropriate tool.
- Remove the damaged roof panel?€‰(1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
- Installation Procedure
-
- Drill 8?€‰mm (5/16?€‰in)
holes for plug welding along the edges of the service panel as noted from the original panel?€‰(1).
- Clean and prepare the attaching surfaces for welding.
- Apply one-part windshield urethane adhesive?€‰(1) as noted from the original panel.
- Position the roof panel?€‰(1) on the vehicle.
- Verify the fit of the panel.
- Clamp the panel into position.
- Plug weld accordingly?€‰(1).
- 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.
- Drill 8?€‰mm (5/16?€‰in)
Roof Front Header Panel Replacement
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair
Warning.
Note: The roof front header panel is made of Ultra High Strength
Steel and ...
Roof Outer Panel Replacement (5HB)
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair
Warning.
Disable the SIR system. Refer to SIR Disabling and Enabling.
Disconnect the nega ...
Other materials:
Automatic Door Locks
The vehicle is programmed so that when the doors are closed, the ignition is
on, and the shift lever is moved out of P (Park) for automatic transmissions, or
when the vehicle speed is above 13 km/h (8 mph) for manual transmissions, the doors
and the trunk/liftgate will lock.
To unlock the doo ...
Radio Replacement (Without US8)
Radio Replacement
Callout
Component Name
Preliminary Procedure
Remove the instrument panel center molding. Refer to
Instrument Panel Center Molding Replacement.
1
Radio Bolts (Qty: 4)
...
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and
Connection
Removal Procedure
Note: Perform the following procedure when removing the retaining
rings and cooler lines from the quick connect fittings located on the
radiator and/or the transmission.
Pull the plastic cap back from the quick connect fitting
and dow ...
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