Chevrolet Sonic Repair Manual: Roof Front Header Panel Replacement
- 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.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
- Remove the sealers and anti-corrosion materials from the repair area. 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.
- Remove the damaged roof front header panel?€‰(1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
Note:
The roof front header panel is made of Ultra High Strength Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Steel.
- 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.
- Position the roof front header?€‰(1) panel on the vehicle.
- Verify the fit of the panel.
- Clamp the roof front header 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)
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Callout
Component Name
Warning: In order to prevent SIR deployment, personal i ...
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 ...
Other materials:
Power Windows
Warning
Leaving children in a vehicle with the keys is dangerous for many reasons.
Children or others could be badly injured or even killed. They could operate the
power windows or other controls or even make the vehicle move. The windows will
function and they could be seriously injured or k ...
Driver Information Center (DIC)
The DIC displays information about your vehicle. It also displays warning messages
if a system problem is detected. See Vehicle Messages. All messages appear in the
DIC display in the instrument cluster.
DIC Operation and Displays
The DIC has different displays which can be accessed b ...
Air Conditioning Compressor and Condenser Hose Replacement (LUV)
Removal Procedure
Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
Remove the drivetrain and front suspension frame skid plate if equipped.
Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
Remove the front fascia assembly. Re ...
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