Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement
- 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.
- Remove the damaged rear side rail extension (1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
Warning:
Refer to Glass and Sheet Metal Handling Warning.
- Installation Procedure
-
- 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.
- Clean and prepare the attaching surfaces for welding.
- Position the rear side rail extension on the vehicle (1).
- Verify the fit of the rear side rail extension.
- Clamp the rear side rail extension 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)
Special Tools
Illustration
Tool Number/ Description
EN-45059
J-45059
Angle Meter
...
Spoilers/Aero
...
Other materials:
Infants and Young Children
Everyone in a vehicle needs protection! This includes infants and all other children.
Neither the distance traveled nor the age and size of the traveler changes the need,
for everyone, to use safety restraints. In fact, the law in every state in the United
States and in every Canadian province ...
Plastic Collar Quick Connect Fitting Service
Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning.
Note: There are several types of plastic collar fuel and evaporative
emission quick connect fittings used on this vehicle.
Bartholomew (1)
Q Release (2)
Squeeze to Rele ...
Drivetrain and Front Suspension Frame Replacement
Special Tools
EN-45059 Angle Meter
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Support the radiator and condenser from above using the upper brackets
on each side.
Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle.
Re ...
0.0089