Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (4NB)
- 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.
- Visually inspect the damage. Repair as much of the damage as possible.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. 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.
- Cut the adhesive with an appropriate tool.
- Remove the damaged roof panel?€‰(1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
- 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.
- Apply one-part windshield urethane adhesive?€‰(1) as noted from the original panel.
- Position the roof panel?€‰(1) on the vehicle.
- Verify the fit of the panel.
- Clamp the 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)
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 ...
Roof Outer Panel Replacement (5HB)
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:
Brake Assist
This vehicle has a brake assist feature designed to assist the driver in stopping
or decreasing vehicle speed in emergency driving conditions. This feature automatically
uses the stability system hydraulic brake control module to supplement the power
brake system under conditions where the dri ...
Special Tools
Illustration
Tool Number/Description
EL–50334–20
Multi-Media Interface Tester (MIT)
EL–50334–50
USB Cable and Adapter Kit
EL-48028
Digital Radio Test ...
Clutch and Differential Housing Cleaning and Inspection
Warning: Wear safety glasses to avoid injury when using compressed
air or any cleaning solvent. Bodily injury may occur if fumes are inhaled
or if skin is exposed to chemicals.
Clean the clutch housing (1) with a suitable solvent.
Air dry all the parts.
Inspect ...
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