Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (5HB)

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

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 as noted from the original panel (1).


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.

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