Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

Chevrolet Sonic Repair Manual / Body / Body Exterior / Information / Underbody Rear Side Rail Extension Replacement

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

    Warning:

    Refer to Glass and Sheet Metal Handling 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. Remove the damaged rear side rail extension (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 rear side rail extension (1) as noted from the original panel.

  2. Clean and prepare the attaching surfaces for welding.

  3. Position the rear side rail extension on the vehicle (1).
  4. Verify the fit of the rear side rail extension.
  5. Clamp the rear side rail extension into position.

  6. Plug weld accordingly (1).
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  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.
Special Tools
Illustration Tool Number/ Description EN-45059 J-45059 Angle Meter ...

Spoilers/Aero
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Other materials:

Special Tools (MIT Tool Instructions)
Bluetooth Pairing for Vehicles with Radio RPO: UF7 Either reset the pin code on the radio to 0000, or go under Device Info on the radio and see what the pin code is (to enter it later on the MIT). Turn the BT discoverable ON in the radio Bluetooth settings. Press Pair De ...

Steering Wheel Straight and Column Locked Caution
Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The ste ...

Input Speed Sensor Replacement
Removal Procedure Remove the control solenoid valve and transmission control module assembly. Refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement. Remove the input speed sensor bolt (2) M6 x 23. Unlock t ...

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