Chevrolet Sonic Repair Manual: Center Pillar Reinforcement Replacement

Chevrolet Sonic Repair Manual / Body / Frame and Structure / Center Pillar Reinforcement Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Warning:

Refer to Glass and Sheet Metal Handling Warning.

Note:

The center pillar upper stiffener is made of Dual Phase Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to 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.
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 the necessary factory welds of the center pillar reinforcement.

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

Remove the damaged center pillar reinforcement (1).

Installation Procedure

Prepare all mating surfaces as necessary.
Align the center pillar reinforcement.

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

Position the center pillar reinforcement on the vehicle (1).
Verify the fit of the center pillar reinforcement.
Clamp the center pillar reinforcement 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.

Special Tools

Illustration Tool Number/ Description EN-45059 J-45059 Angle Meter ...

Drivetrain and Front Suspension Frame Skid Plate Replacement

Removal Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the mounting bolts?€‰(1) for the front suspension frame skid p ...

Other materials:

Brake Fluid Effects on Paint and Electrical Components Caution
Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. I ...

Instrument Panel Tie Bar Replacement
Removal Procedure Remove the Instrument panel assembly. Refer to Instrument Panel Assembly Replacement. Remove the steering column and wheel from the vehicle. Refer to Steering Column Replacement. Remove the air inlet grill panel. Refer to Air Inlet Grille Panel Replacem ...

Control Valve Body Assembly Assemble (Gen 2)
Control Valve Body Assembly Assemble Callout Component Name 1 Valve Body Ball Check Valve (Qty: 6) 2 Valve Channel Plate 3 Control Valve Body Bolt ...

0.0062