Chevrolet Sonic Repair Manual: 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

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.

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