Chevrolet Sonic manuals
 

Chevrolet Sonic Repair Manual: Front Side Door Outer Panel Replacement

Chevrolet Sonic Repair Manual / Body / Doors and Enclosures / Doors / Front Side Door Outer Panel Replacement

Removal Procedure

Note:

According to different corrosion warranties, only the regional mandatory joining methods are allowed.

  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 the front side door. Refer to Front Side Door Replacement.
  4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
  5. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
  6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.


  7. Grind the edges of the front side door outer panel?€‰(1) to separate the outer door panel from the door shell.

    8. Warning:

    Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

  8. Remove the front side door outer door panel?€‰(1).
  9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair
  10. Straighten the edges of the door shell.
Installation Procedure
  1. Align the front side door outer panel.
  2. Verify the fit of the front side door outer panel.

  3. Clamp the front side door outer panel?€‰(1) into position.

  4. Continue to hammer in stages along the hem flanges?€‰(1).
  5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  6. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
  7. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
  8. Install the front side door. Refer to Front Side Door Replacement.
  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.
Front Side Door Opening Floor Carpet Retainer Replacement
Front Side Door Opening Floor Carpet Retainer Replacement Callout Component Name 1 Front Side Door Opening Floor Carpet ...

Front Side Door Replacement
Front Side Door Replacement Callout Component Name Warning: Refer to SIR Warning. Preliminary Procedures Mark the ...

Other materials:

Infotainment
Determine which radio the vehicle has and read the following pages to become familiar with its features. Warning: Taking your eyes off the road for extended periods could cause a crash resulting in injury or death to you or others. Do not give extended attention to infotainment tasks wh ...

Instrument Panel Lower Trim Pad Cover Replacement (Without AAL)
Instrument Panel Lower Trim Pad Cover Replacement Callout Component Name 1 Instrument Panel Lower Trim Pad Fastener (Qty:?€‰2) Caution: Refer to Fastener Caution. 2 Instrumen ...

Fuel Tank Draining
Warning: Refer to Gasoline/Gasoline Vapors Warning. Note: The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valv ...

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