Chevrolet Sonic Repair Manual: Roof Rear Header Panel Replacement (5HB)
- 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.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
- Remove the sealers and anti-corrosion materials from the repair area. 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.
- Remove the damaged rear header 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 (1) as noted from the original panel.
- Clean and prepare the attaching surfaces for welding.
- Position the roof rear header?€‰(1) panel on the vehicle.
- Verify the fit of the panel.
- Clamp the roof rear header 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 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:
Starting the Engine
The vehicle has a Computer-Controlled Cranking System. It assists in starting
the engine and protects components. If the ignition key is turned to START and then
released when the engine begins cranking, the engine will continue cranking for
a few seconds or until the engine starts. If the eng ...
Communication Interface Module Bracket Replacement
Communication Interface Module Bracket Replacement
Callout
Component Name
Preliminary Procedure
Remove the instrument panel lower compartment. Refer to
Instrument Panel Lower Compartment Replacement
1
...
Drive Range, Sixth Gear (Gen 1)
As vehicle speed increases, the transmission control module (TCM) processes input
signals from the automatic transmission input and output speed sensors, the throttle
position sensor and other vehicle sensors to determine the precise moment to command
ON the normally-low 26 pressure control so ...
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