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:
Vehicle Alarm System
This vehicle has an anti-theft alarm system.
The indicator light on the instrument panel near the windshield indicates the
status of the system.
Off: Vehicle is disarmed.
On Solid: Vehicle is secured during the delay to arm the system.
Fast Flash: Vehicle is unsecured. A door, the hood, or t ...
Replacing Safety Belt System Parts after a Crash
Warning
A crash can damage the safety belt system in the vehicle. A damaged safety
belt system may not properly protect the person using it, resulting in serious injury
or even death in a crash. To help make sure the safety belt systems are working
properly after a crash, have them inspected ...
Door Lock and Ignition Lock Folding Key Blade Removal and Installation
Special Tools
BO-51098 Flip Key Blade Fixture
For equivalent region tools, refer to Special Tools.
Caution: Failure to properly support the Remote Keyless Entry
(RKE) transmitter assembly while replacing the key blade may cause internal
damage to the transmitter assembly. ...
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