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:
Additional Factors Affecting System Operation
Safety belts help keep the passenger in position on the seat during vehicle maneuvers
and braking, which helps the passenger sensing system maintain the passenger airbag
status. See “Safety Belts” and “Child Restraints” in the Index for additional information
about the importance of pr ...
Maintenance
Air Intake
Clear away any ice, snow, or leaves from the air intake at the base of the windshield
that can block the flow of air into the vehicle.
Passenger Compartment Air Filter
The filter removes dust, pollen, and other airborne irritants from outside air
that is pulled into the vehicle.
T ...
Radiator Replacement (LUV)
Removal Procedure
Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct
Replacement.
Remove the front compartment front insulator cover. Refer to Front Compartment
Front Insulator Cover Replacement.
Remove the engine coolant fan shroud. Refer to Engine Coo ...
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