Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (5HB)
- 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 as noted from the original panel (1).
- 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 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 ...
Roof Rail Front Assist Handle Replacement
Roof Rail Front Assist Handle Replacement
Callout
Component Name
1
Roof Rail Front Assist Handle Fastener (Qty:?€‰2) ...
Other materials:
Driver or Passenger Seat Shoulder Belt Replacement (with A69)
Driver or Passenger Seat Shoulder Belt Replacement
Callout
Component Name
Warning: Refer to SIR Warning.
Warning: Refer to SIR Inflator Module Handling and Storage
Warning.
Warning: Refer to SIR ...
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
The wheel exhibits excessive runout.
The wheel is bent.
The wheel is cracked.
The wheel is severely rusted.
The wheel is severely corroded.
Note: Air leaks caused by porosity on aluminum wheels are repairable.
...
Tire-to-Wheel Match-Mounting (Vectoring)
Note: After remounting a tire to a wheel or after replacing a tire
and/or a wheel, remeasure the tire and wheel assembly runout in order to verify
that the amount of runout has been reduced and brought to within tolerances.
Ensure that the tire and wheel assembly is properly balanced ...
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