Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement
- 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.
- Visually inspect the damage. Repair as much of the damage as possible.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. 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 side rail extension (1).
Warning:
Refer to Approved Equipment for Collision Repair Warning.
Warning:
Refer to Glass and Sheet Metal Handling Warning.
- Installation Procedure
-
- Drill 8?€‰mm (5/16?€‰in)
holes for plug welding along the edges of the rear side rail extension (1) as noted from the original panel.
- Clean and prepare the attaching surfaces for welding.
- Position the rear side rail extension on the vehicle (1).
- Verify the fit of the rear side rail extension.
- Clamp the rear side rail extension 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)
Special Tools
Illustration
Tool Number/ Description
EN-45059
J-45059
Angle Meter
...
Spoilers/Aero
...
Other materials:
Safety Belt Pretensioners
This vehicle has safety belt pretensioners for front outboard occupants. Although
the safety belt pretensioners cannot be seen, they are part of the safety belt assembly.
They can help tighten the safety belts during the early stages of a moderate to
severe frontal, near frontal, or rear crash ...
Adding Equipment to the Airbag-Equipped Vehicle
Adding accessories that change the vehicle's frame, bumper system, height, front
end, or side sheet metal may keep the airbag system from working properly. The operation
of the airbag system can also be affected by changing any parts of the front seats,
safety belts, the airbag sensing and ...
Anti-Corrosion Treatment and Repair (Base)
Warning: When applying sound deadeners, or anti-corrosion materials
due care and preventative measures must be exercised to prevent any material
from being sprayed into door and quarter panel mechanisms such as door locks,
window run channels, window regulators and seat belt retractors, ...
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