Chevrolet Sonic manuals
 

Chevrolet Sonic Repair Manual: Roof Rear Header Panel Replacement (5HB)

Chevrolet Sonic Repair Manual / Body / Roof - Fixed, Leisure / Roof Rear Header Panel Replacement (5HB)

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

  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 rear header panel?€‰(1).
Installation Procedure

    Drill 8?€‰mm (5/16?€‰in)holes for plug welding along the edges
  1. Drill 8?€‰mm (5/16?€‰in)

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

  2. Clean and prepare the attaching surfaces for welding.

  3. Position the roof rear header?€‰(1) panel on the vehicle.
  4. Verify the fit of the panel.
  5. Clamp the roof rear 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.
Roof Rail Rear Assist Handle Replacement
Roof Rail Rear Assist Handle Replacement Callout Component Name 1 Roof Rail Rear Assist Handle Fastener (Qty:?€‰2) ...

Moonroof/Sunroof
...

Other materials:

Tire Sealant and Compressor Kit
Warning Idling a vehicle in an enclosed area with poor ventilation is dangerous. Engine exhaust may enter the vehicle. Engine exhaust contains carbon monoxide (CO) which cannot be seen or smelled. It can cause unconsciousness and even death. Never run the engine in an enclosed area that has n ...

Front Lower Grille Replacement
Front Lower Grille Replacement Callout Component Name Preliminary Procedures Remove the front bumper fascia assembly. Refer to Front Bumper Fascia Replacement. Remove the front bumper fascia energy absorber. Refer to Fron ...

Crankshaft Front Oil Seal Installation
Special Tools EN-6351 Mounting Sleeves For equivalent regional tools, refer to Special Tools. Clean the sealing surfaces. Slide the EN-6351 sleeves  (2) protective sleeve onto the crankshaft journal. Slide the crankshaft front oil seal (1) over the protective sleev ...

© 2014-2025 Copyright www.csmans.com
 
0.0048