Chevrolet Sonic manuals
 

Chevrolet Sonic Repair Manual: Roof Front Header Panel Replacement

Chevrolet Sonic Repair Manual / Body / Roof - Fixed, Leisure / Roof Front Header Panel Replacement

Removal Procedure

    Warning:

    Refer to Approved Equipment for Collision Repair Warning.

    Note:

    The roof front header panel is made of Ultra High Strength Steel and should be replaced only at factory joints. Repairing or sectioning of this part is not recommended. Refer to Ultra High Strength Steel.

  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 roof front 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 as noted from the original panel (1).

  2. Clean and prepare the attaching surfaces for welding.

  3. Position the roof front header?€‰(1) panel on the vehicle.
  4. Verify the fit of the panel.
  5. Clamp the roof front 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.
Airbag Roof Side Rail Module Replacement - Rear
Airbag Roof Side Rail Module Replacement - Rear Callout Component Name Warning: In order to prevent SIR deployment, personal i ...

Roof Outer Panel Replacement (4NB)
Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the nega ...

Other materials:

Remote Lock, Unlock, Start
Select Remote Lock, Unlock, Start and the following may display: Remote Unlock Feedback Remote Lock Feedback Remote Door Unlock Remote Unlock Feedback When on, the exterior lamps will flash when unlocking the vehicle with the RKE transmitter. Select On or Off. Remote Lock Feedback T ...

Rear Wheelhouse Liner Replacement (Sedan - Right)
Rear Wheelhouse Liner Replacement Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 1 Rear Wheelhouse Panel Liner ...

Stabilizer Shaft Replacement
Removal Procedure Remove the intermediate steering shaft lower bolt. Refer to Intermediate Steering Shaft Replacement. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Inst ...

© 2014-2025 Copyright www.csmans.com
 
0.0079