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 ...

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:

Parking Brake Cable Replacement (Disc Brake)
Removal Procedure Remove the front floor console. Refer to Front Floor Console Replacement. Ensure that the parking brake lever is in the fully released position. Using ONLY HAND TOOLS, remove the adjusting nut (1) from the end of the front park brake c ...

Tire and Wheel Assembly Runout Measurement - Off Vehicle
Raise and support the vehicle. Mark the location of the wheels to the wheel studs and mark the specific vehicle position on each tire and wheel – LF, LR, RF, RR. Remove the tire and wheel assemblies from the vehicle. Closely inspect each tire for proper and even bead seating. If an ...

Air Conditioning Compressor and Condenser Hose Replacement (LUW)
Removal Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. Disconnect the A/C refrigerant pressure sensor electrical connector. Remove air conditioning compressor and condenser hose nut (1). Remove air conditioning compressor ...

© 2014-2026 Copyright www.csmans.com
 
0.0065