Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (5HB)
- 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 as noted from the original panel (1).
- 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 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 ...
Roof Rail Front Assist Handle Replacement
Roof Rail Front Assist Handle Replacement
Callout
Component Name
1
Roof Rail Front Assist Handle Fastener (Qty:?€‰2) ...
Other materials:
Pretensioner Handling and Scrapping
Scrapping Procedure
During the course of a vehicles useful life, certain situations may arise
which will necessitate the disposal of a live (undeployed) pretensioner. The
following information covers the proper procedures for the disposing of a live
(undeployed) pretensioner. Deplo ...
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure
Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct
Replacement.
Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
Note: Move retainer clamp (1) in direction of the arrow. ...
Transmission Fluid Level and Condition Check
Removal Procedure
Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
Remove the front suspension skid plate, if equipped.
Refer to Drivetrain and Front Suspension Frame Skid
Plate Replacement
Place a basin underneath the vehicle.
Clean away all ...
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