Chevrolet Sonic Repair Manual: Roof Front Header Panel Replacement

Removal Procedure

Warning:

Refer to Approved Equipment for Collision Repair Warning.

Note:

The roof front header panel is made of Ultra High Strength Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Steel.

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. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Remove the sealers and anti-corrosion materials from the repair area. 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 roof front header panel?€‰(1).

Installation Procedure

1. Drill 8?€‰mm (5/16?€‰in)

   holes for plug welding along the edges of the service panel as noted from the original panel (1).

2. Clean and prepare the attaching surfaces for welding.


3. Position the roof front header?€‰(1) panel on the vehicle.
4. Verify the fit of the panel.
5. Clamp the roof front header panel 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.

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