Chevrolet Sonic Repair Manual: Roof Outer Panel Replacement (4NB)
- 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.
- Cut the adhesive with an appropriate tool.
- Remove the damaged roof panel?€‰(1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
- Installation Procedure
-
- Drill 8?€‰mm (5/16?€‰in)
holes for plug welding along the edges of the service panel as noted from the original panel?€‰(1).
- Clean and prepare the attaching surfaces for welding.
- Apply one-part windshield urethane adhesive?€‰(1) as noted from the original panel.
- Position the roof panel?€‰(1) on the vehicle.
- Verify the fit of the panel.
- Clamp the panel 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)
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 ...
Roof Outer Panel Replacement (5HB)
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair
Warning.
Disable the SIR system. Refer to SIR Disabling and Enabling.
Disconnect the nega ...
Other materials:
Reclining Seatbacks
Warning
If either seatback is not locked, it could move forward in a sudden stop or
crash. That could cause injury to the person sitting there. Always push and pull
on the seatbacks to be sure they are locked.
To recline a manual seatback:
1. Lift the lever.
If necessary, move the safety b ...
Liftgate Weatherstrip Replacement
Liftgate Weatherstrip Replacement
Callout
Component Name
1
Liftgate Weatherstrip
Procedure
Clean the area where the seal will be mounted. Use a suitable solvent
with a mixture of 50?€‰percent isopropyl alc ...
Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn the ignition to LOCK/OFF
in each shift lever position.
For automatic transmission vehicles, the ignition should turn to LOCK/OFF
only when the shift lever is in P (Park).
For manual transmission vehicles, the ignition should turn ...
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