Chevrolet Sonic Repair Manual: Front Side Door Outer Panel Replacement
- Removal Procedure
-
Note:
According to different corrosion warranties, only the regional mandatory joining methods are allowed.
- Disable the SIR System. Refer to SIR Disabling and Enabling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove the front side door. Refer to Front Side Door Replacement.
- Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
- Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Grind the edges of the front side door outer panel?€‰(1) to separate the outer door panel from the door shell.
- Remove the front side door outer door panel?€‰(1).
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair
- Straighten the edges of the door shell.
Warning:
Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.
- Installation Procedure
-
- Align the front side door outer panel.
- Verify the fit of the front side door outer panel.
- Clamp the front side door outer panel?€‰(1) into position.
- Continue to hammer in stages along the hem flanges?€‰(1).
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
- Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
- Install the front side door. Refer to Front Side Door Replacement.
- 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.
Front Side Door Opening Floor Carpet Retainer Replacement
Front Side Door Opening Floor Carpet Retainer Replacement
Callout
Component Name
1
Front Side Door Opening Floor Carpet ...
Front Side Door Replacement
Front Side Door Replacement
Callout
Component Name
Warning: Refer to SIR Warning.
Preliminary Procedures
Mark the ...
Other materials:
Instrument Panel Upper Compartment Door Latch Replacement
Instrument Panel Upper Compartment Door Latch Replacement
Callout
Component Name
1
Instrument Panel Upper Compartment Door Latch
Procedures
Open the instrument panel compartment door.
Unsnap the instrument com ...
Stationary Window Waterleak Repair
Warning: If any water enters the vehicle interior up to the level
of the carpet or higher and soaks the carpet, the sensing and diagnostic module
(SDM) and the SDM harness connector may need to be replaced. The SDM could be
activated when powered, which could cause deployment of the air ...
Range Selector Lever Cable Replacement
Removal Procedure
Set the park brake and chock the wheels.
Disconnect the transmission range selector lever cable
terminal (1) from the transmission manual shift lever pin.
Press the locking tabs inward in order to release
the transmission range selector lev ...
0.006