Chevrolet Sonic Repair Manual: Body Side Frame Rocker Reinforcement Replacement

Chevrolet Sonic Repair Manual / Body / Frame and Structure / Body Side Frame Rocker Reinforcement Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Glass and Sheet Metal Handling Warning.

Note:

The body side frame rocker reinforcement is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Dual Phase Steel.

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.
Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
Locate and mark all the necessary factory welds of the body side frame rocker reinforcement.

Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.

Remove the damaged body side frame rocker reinforcement (1).

Installation Procedure

Align the body side frame rocker reinforcement.

Drill a 8?€‰mm (5/16?€‰in)
holes for plug welding along the edges of the quarter outer panel (1) as noted from the original panel.
Clean and prepare the attaching surfaces for welding.

Position the body side frame rocker reinforcement on the vehicle (1).
Verify the fit of the body side frame rocker reinforcement.
Clamp the body side frame rocker reinforcement into position.

Plug the 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.

Frame and Structure

...

Driver or Passenger Seat Back Cushion Frame Replacement

Driver or Passenger Seat Back Cushion Frame Replacement Callout Component Name Preliminary Procedures Remove the driver or passenge ...

Other materials:

Windshield Wiper Arm Replacement
Windshield Wiper Arm Replacement Callout Component Name Preliminary Procedure Open and support the hood assembly. 1 Windshield Wiper Arm Nut Cap Tip: Use a small flat-bladed tool in order to ...

Brake Pressure Modulator Valve Bracket Replacement
Removal Procedure Remove the brake pressure modulator valve (BPMV) and bracket assembly. Refer to Brake Pressure Modulator Valve Replacement. Remove the BPMV bolts (1). Remove the BPMV bracket. Installation Procedure Install the BPMV br ...

Engine Replacement (Automatic Transmission)
Special Tools J-45859 Wheel Drive Shaft Remover CH-807 Closure Plugs For equivalent regional tools, refer to Special Tools. Removal Procedure Remove the battery and battery tray. Refer to Battery Tray Replacement. Relieve the fuel system pressure. Refer to Fuel Pressur ...

0.0051