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:

What to Add
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Engine Coolant Thermostat Housing Installation
Caution: Refer to Engine Coolant Thermostat Housing Caution. Clean sealing surface. Install a NEW engine coolant thermostat housing seal. Install the engine coolant thermostat housing (2). Caution: Refer to Fastener Caution. Note: Screw in the 4  ...

Radiator Outlet Hose Replacement (LUV)
\\ Radiator Outlet Hose Replacement Callout Component Name Preliminary Procedures Drain the engine coolant. Refer to Cooling System Draining and Filling. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet ...

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