Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (4NB)

Chevrolet Sonic Repair Manual / Body / Roof - Fixed, Leisure / Roof Outer Panel Replacement (4NB)

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair 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. Cut the adhesive with an appropriate tool.

  9. Remove the damaged roof panel?€‰(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 service panel as noted from the original panel?€‰(1).

  2. Clean and prepare the attaching surfaces for welding.

  3. Apply one-part windshield urethane adhesive?€‰(1) as noted from the original panel.

  4. Position the roof panel?€‰(1) on the vehicle.
  5. Verify the fit of the panel.
  6. Clamp the panel into position.

  7. Plug weld accordingly?€‰(1).
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  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.
Roof Front Header Panel Replacement
Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Note: The roof front header panel is made of Ultra High Strength Steel and ...

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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:

Scheduling Service Appointments
When the vehicle requires warranty service, contact your dealer and request an appointment. By scheduling a service appointment and advising the service consultant of your transportation needs, your dealer can help minimize your inconvenience. If the vehicle cannot be scheduled into the service ...

Overview (Radio with CD/USB)
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