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Chevrolet Sonic Repair Manual: Front Side Door Outer Panel Replacement

Chevrolet Sonic Repair Manual / Body / Doors and Enclosures / Doors / Front Side Door Outer Panel Replacement

Removal Procedure

Note:

According to different corrosion warranties, only the regional mandatory joining methods are allowed.

  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 the front side door. Refer to Front Side Door Replacement.
  4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
  5. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
  6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.


  7. Grind the edges of the front side door outer panel?€‰(1) to separate the outer door panel from the door shell.

    8. Warning:

    Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.

  8. Remove the front side door outer door panel?€‰(1).
  9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair
  10. Straighten the edges of the door shell.
Installation Procedure
  1. Align the front side door outer panel.
  2. Verify the fit of the front side door outer panel.

  3. Clamp the front side door outer panel?€‰(1) into position.

  4. Continue to hammer in stages along the hem flanges?€‰(1).
  5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  6. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement.
  7. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement.
  8. Install the front side door. Refer to Front Side Door Replacement.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  12. Enable the SIR system. Refer to SIR Disabling and Enabling.
Front Side Door Opening Floor Carpet Retainer Replacement
Front Side Door Opening Floor Carpet Retainer Replacement Callout Component Name 1 Front Side Door Opening Floor Carpet ...

Front Side Door Replacement
Front Side Door Replacement Callout Component Name Warning: Refer to SIR Warning. Preliminary Procedures Mark the ...

Other materials:

Door Locks
Warning Unlocked doors can be dangerous. Passengers, especially children, can easily open the doors and fall out of a moving vehicle. When a door is locked, the handle will not open it. The chance of being thrown out of the vehicle in a crash is increased if the doors are not locked. S ...

Lane Departure Warning (LDW)
For vehicles with this feature, read the entire section before using it. Warning The LDW system is an aid to help the vehicle stay in the driving lane. It does not steer the vehicle. The LDW system may not: . Provide enough time to avoid a crash. . Detect lane markings under bad weather co ...

Tire and Wheel Removal and Installation
Special Tools CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools. Removal Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the wheel cover ...

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