Chevrolet Sonic manuals
 

Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (5HB)

Chevrolet Sonic Repair Manual / Body / Roof - Fixed, Leisure / Roof Outer Panel Replacement (5HB)

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

  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.
  6. Locate and mark all factory welds.

  7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
  8. Cut the adhesive with an appropriate tool.

  9. Remove the damaged roof panel?€‰(1).
Installation Procedure

    Drill 8?€‰mm (5/16?€‰in)holes for plug welding along the edges
  1. Drill 8?€‰mm (5/16?€‰in)

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

  2. Clean and prepare the attaching surfaces for welding.

  3. Apply one-part windshield urethane adhesive as noted from the original panel (1).

  4. Position the roof panel?€‰(1) on the vehicle.
  5. Verify the fit of the panel.
  6. Clamp the panel into position.

  7. Plug weld accordingly (1).
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  12. Enable the SIR system. Refer to SIR Disabling and Enabling.
Roof Outer Panel Replacement (4NB)
Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the nega ...

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Other materials:

Lane Departure Warning (LDW)
If equipped, LDW is intended to help avoid unintentional lane departures at speeds of 56 km/h (35 mph) or greater. LDW uses a camera sensor to detect the lane markings. The LDW indicator, , appears green if a lane marking is detected. If the vehicle departs the lane, the indicator will chang ...

Front Side Door Window Switch Bezel Replacement (Left Side)
Front Side Door Window Switch Bezel Replacement Callout Component Name Preliminary Procedure Remove the front side door trim. Refer to Front Side Door Trim Replacement. 1 Front Side Door Window S ...

Tools and Equipment
Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools will also mi ...

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