Chevrolet Sonic manuals
 

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

Chevrolet Sonic Repair Manual / Body / Roof - Fixed, Leisure / 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

    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 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.
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:

Lockout Protection
If the driver side power door lock switch is pressed when the driver door is open and the key is in the ignition, all of the doors will lock and then the driver door will unlock. If Unlocked Door Anti Lockout is turned on and: the vehicle is off, the driver door is open, and door locking is r ...

Engine Oil Change
When a %CHANGE message displays in the DIC, have the engine oil and filter changed within the next 1 000 km/600 mi. If driven under the best conditions, the engine oil life system might not indicate the need for vehicle service for more than a year. The engine oil and filter must be changed ...

Engine Coolant Thermostat Installation
Caution: Refer to Engine Coolant Thermostat Housing Caution. Clean the engine coolant sealing surfaces. Install the engine coolant seal (1). Install the engine coolant thermostat assembly (2). Caution: Refer to Fastener Caution. Install the 4R ...

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