Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

Removal Procedure

  1. Warning:

    Refer to Approved Equipment for Collision Repair Warning.

    Warning:

    Refer to Glass and Sheet Metal Handling Warning.

  2. Disable the SIR System. Refer to SIR Disabling and Enabling.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  4. Remove all related panels and components.
  5. Visually inspect the damage. Repair as much of the damage as possible.
  6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  7. Locate and mark all factory welds.
  8. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
  9. Remove the damaged rear side rail extension (1).
Installation Procedure

  1. Drill 8?€‰mm (5/16?€‰in)holes for plug welding along the edges
  2. Drill8?€‰mm (5/16?€‰in)

    holes for plug welding along the edges of the rear side rail extension (1) as noted from the original panel.

  3. Clean and prepare the attaching surfaces for welding.
  4. Position the rear side rail extension on the vehicle (1).
  5. Verify the fit of the rear side rail extension.
  6. Clamp the rear side rail extension into position.
  7. Plug weld accordingly (1).
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  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.
Special Tools
Illustration Tool Number/ Description EN-45059 J-45059 Angle Meter ...
Other materials:

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Now and then, check that the safety belt reminder light, safety belts, buckles, latch plates, retractors, and anchorages are all working properly. Look for any other loose or damaged safety belt system parts that might keep a safety belt system from doing its job. See your dealer to have it re ...

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Warning: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. Leave the lamp switch OFF until th ...

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Rear Side Door Window Regulator Replacement Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning. Preliminary Procedure Remove the front side door window from the guide.

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  • Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement

    Chevrolet Sonic Repair Manual: Underbody Rear Side Rail Extension Replacement