Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

Chevrolet Sonic Repair Manual / Body / Body Exterior / Information / Underbody Rear Side Rail Extension Replacement

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

    Warning:

    Refer to Glass and Sheet Metal Handling 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. Remove the damaged rear side rail extension (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 rear side rail extension (1) as noted from the original panel.

  2. Clean and prepare the attaching surfaces for welding.

  3. Position the rear side rail extension on the vehicle (1).
  4. Verify the fit of the rear side rail extension.
  5. Clamp the rear side rail extension into position.

  6. Plug weld accordingly (1).
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling.
Special Tools
Illustration Tool Number/ Description EN-45059 J-45059 Angle Meter ...

Spoilers/Aero
...

Other materials:

Rear Seat Outboard Seat Back Airbag Replacement
Rear Seat Outboard Seat Back Airbag Replacement Callout Component Name Warning: Following the deployment of a rear seat side air bag, inspect the following parts for damage. Replace these parts if necessary: ...

Wheel Drive Shafts Description and Operation
Front wheel drive axles are flexible assemblies. Front wheel drive axles consist of the following components: A front wheel drive shaft tripot joint (inner joint) A front wheel drive shaft constant velocity joint (outer joint) A front wheel drive shaft The front wheel drive shaft connec ...

Transmission Control Replacement
Removal Procedure Remove the floor console. Refer to Front Floor Console Replacement. Lift both cable adjustment retainers (1), one for each cable, to release the shift lever and selector lever cable. .1 Pull the shift lever and selector lever cable ret ...

© 2014-2025 Copyright www.csmans.com
 
0.0071