Page 1 CHEVROLET SONIC 2012 BODY REPAIR MANUAL CHEVROLET SONIC 2012...
Page 2 BACK TO FRONT PAGE CHEVROLET SONIC 2012 BODY REPAIR MANUAL VIEW MAIN INDEX FOREWORD 2012 Chevrolet Aveo Service Manual Volume 1 This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 2012 Chevrolet Aveo.
Page 3: Table Of Contents
CHEVROLET SONIC 2012 BODY REPAIR MANUAL BACK TO FOREWORD TO MODEL INDEX CHEVROLET Section Title PREFACE SONIC GENERAL INFORMATION BODY HARDWARE AND TRIM BODY REPAIR MANUAL BODY REPAIR 2012 BODY SYSTEMS ROOF SEATBELTS SEATS 08 08 RESTRAINTS STEERING SUSPENSION HVAC SYSTEM...
Page 4: Preface
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Index Definition of Danger, Warning, Caution, and Note Safety Glasses Warning Approved Equipment for Collision Repair Warning Safety Goggles and Fuel Warning Batteries Produce Explosive Gases Warning...
Page 5 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Definition of Danger, Warning, Caution, and Note The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers, Warnings, Cautions, Notes or Importants.
Page 6 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Approved Equipment for Collision Repair Warning Warning: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.
Page 7 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Batteries Produce Explosive Gases Warning Warning: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: •...
Page 8 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Battery Disconnect Warning Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component.
Page 9 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Brake Fluid Irritant Warning Warning: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: • Eye contact—rinse thoroughly with water.
Page 10 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Brake Fluid Warning Warning: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed container.
Page 11 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Collision Sectioning Warning Warning: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.
Page 12 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Cracked Window Warning Warning: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury.
Page 13 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Defroster Outlet Warning Warning: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
Page 14 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Electric Coolant Fan Warning Warning: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.
Page 15 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Exhaust Service Warning Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Page 16 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Eye Protection Warning Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. © 2011 General Motors. All rights reserved.
Page 17 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Gasoline/Gasoline Vapors Warning Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion.
Page 18 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Glass and Sheet Metal Handling Warning Warning: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.
Page 19 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Halogen Bulb Warning 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: •...
Page 20 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Hood Hold-Open Device Warning Warning: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.
Page 21 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Parking Brake and Drive Wheels Warning Warning: Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury.
Page 22 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Protective Goggles and Glove Warning Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.
Page 23 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Radiator Cap Removal Warning Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
Page 24 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Relieving Fuel Pressure Warning Warning: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury.
Page 25 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Repair Material Curing Warning Warning: At least 24 hours are required for complete curing of repair material. The repair area should not be physically disturbed until after that time.
Page 26 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Safety Glasses and Compressed Air Warning Warning: Wear safety glasses when using compressed air in order to prevent eye injury. © 2011 General Motors. All rights reserved.
Page 27 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Safety Glasses Warning Warning: Wear safety glasses in order to avoid eye damage. © 2011 General Motors. All rights reserved.
Page 28 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Safety Goggles and Fuel Warning Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. © 2011 General Motors. All rights reserved.
Page 29 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Sensing and Diagnostic Module Handling Warning Warning: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: •...
Page 30 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Sensing and Diagnostic Module Voltage after Ignition is Turned Off Warning Warning: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed.
Page 31 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Servicing the SIR System Warning Warning: When performing service on or around the SIR components or the SIR wiring, follow the procedures listed below in order to temporarily disable the SIR system.
Page 32 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices SIR Inflator Module Handling and Storage Warning Warning: When carrying an undeployed inflator module: • Do not carry the inflator module by the wires or connector.
Page 33 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices SIR Seatbelt Pretensioner Handling Warning Warning: When carrying an undeployed inflatable restraint seat belt retractor pretensioner: • Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped.
Page 34 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices SIR Warning Warning: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: •...
Page 35 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Torque-to-Yield Fastener Warning Warning: This component is equipped with torque-to-yield fasteners. Install a NEW torque-to-yield fastener when installing this component. Failure to replace the torque-to-yield fastener could cause bodily injury and damage to the vehicle or component.
Page 36 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Brake Fluid Damage to Electrical Connections Caution Caution: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas.
Page 37 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components.
Page 38 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Catalytic Converter Movement Caution Caution: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
Page 39 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect.
Page 40 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Component Fastener Tightening Caution Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied.
Page 41 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Exterior Trim Emblem Removal Caution Caution: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. © 2011 General Motors. All rights reserved.
Page 42 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Fastener Caution Caution: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Do not use paints, lubricants, or corrosion inhibitors on fasteners, or fastener joint surfaces, unless specified.
Page 43 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Fuel Tank Strap Fastener Caution Caution: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.
Page 44 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Ignition OFF When Disconnecting Battery Caution Caution: Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.
Page 45 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Installing Hoses without Twists or Bends Caution Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier.
Page 46 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Liftgate Assist Rod Caution Caution: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result.
Page 47 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Steering Column in Lock Position Caution Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system.
Page 48 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Steering Wheel in the Full Turn Position Caution Caution: Do not hold the steering wheel in the full turn position longer than 5 seconds, as damage to the steering pump may result.
Page 49 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Steering Wheel Straight and Column Locked Caution Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation.
Page 50 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Tape Corners of Panel Caution Caution: When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent paint damage.
Page 51 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Torque-to-Yield Fastener Caution Caution: This component is equipped with torque-to-yield fasteners. Install a NEW torque-to-yield fastener when installing this component. Failure to replace the torque-to-yield fastener could cause damage to the vehicle or component.
Page 52 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Vehicle Lifting and Jacking Caution Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: • Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.
Page 53 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX PREFACE Caution Notices Windshield Installation Caution Caution: Do not use spacers when installing a windshield. The stress caused by the spacers may damage the windshield. © 2011 General Motors. All rights reserved.
Page 54: General Information
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION Index Arrows and Symbols Interior Windnoise Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage Air Pressure Test Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label...
Page 55 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General (1) Front of Vehicle (2) View Detail (2) View Detail Ambient Air Mixed with Another Gas or Indicate Temperature Change (4) Motion or Direction...
Page 56 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of...
Page 57 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Purpose Emission System - EEC 09 (Euro-5) Model Year 2012 (VZC) Plant Location Bupyung Plant Sequence 12–17 — Plant Sequence Number Number 1.2L (LDC) or 1.4L (L2N/LDD) Engine ID and VIN Derivative Location Refer to Engine Identification .
Page 58 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label Certification Plate Location The vehicle identification number (VIN) plate is attached to the top of the front end upper tie bar which is located under the radiator opening upper cover.
Page 59 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General RPO Code List The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.
Page 60 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General A60 Lock Control Right Rear Compartment – Lid, Tailgate, Key Activated A66 Window - Power Operated, Passenger A69 Restraint - Seat Belt Tensioner, Front, VAR. 2...
Page 61 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General AJG Restraint System - Seat, Inflatable, Driver & Passenger, Front & Seat Side, Single Stage AKJ Windshield Style - Shade Band AKM Window Type - Clear...
Page 62 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General AY0 Restraint System – Seat, Inflatable, Driver and Passenger Front, Seat Side, Roof Side AYC Restraint System - Seat, Inflatable, Driver & Passenger Front, Seat Side, Roof Side, Single Stage AYF Restaint System - Seat, Inflatable, Driver &...
Page 63 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General C35 Heater - Duct, RR PASS C41 HVAC System - Heater, Outside Air, with Fan C49 Defogger - RR Window, Electric C60 HVAC System - Air Conditioner FRT, MAN Controls...
Page 64 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General D75 Handle O/S Door - Body Color D87 Handle - O/S, L/Gate, R/CMPT, Black D91 Handle - O/S, L/Gate, R/CMPT, Color D9O Sensor - Front Airbag (EFS) - Single DC8 Mirror O/S - LH &...
Page 65 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General E27 Handle – Assist, Passenger E3E Handle - O/S, L/Gate, R/CMPT, Chrome E7Y Fire Extinguisher – 2 kg E91 Pocket – Front Seat Back, Passenger...
Page 66 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General FHS Vehicle Fuel - Gasoline E85 FHT Vehicle Fuel - Gasoline E100 FHY Vehicle Fuel - Diesel B10 FP9 Ratio - Transaxle Final Drive 3.55 FV1 Ratio - Transaxle Final Drive 3.72...
Page 67 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General GAZ Primary Color – Exterior, Olympic White (G) 8624 GBA Primary Color – Exterior, Black (G) 8555 GBE Primary Color - Exterior, Crystal Claret Tintcoat (G) 505Q...
Page 68 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General GQM Primary Color - Exterior, Boracay Blue MET (895T) GQV Primary Color - Exterior, Flame Red GQW Primary Color - Exterior, Urban Grey (658R) J93 Brake System - Power, FRT Disc, RR Drum, ABS, 15”...
Page 69 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General KA1 Heater - Seat, Front KE3 Knob - TRANS CONT Lever, Chrome KG9 Generator – 140 Amp KI2 Knob - TRANS CONT Lever, Polyurethane KL7 Conversion –...
Page 70 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General KTM Key - Primary Foldable, Additional Rigid KTN Equipment - Additional Key (No Buttons) L2I Engine - Gas, 4 Cyl, 1.4L, MFI, L4, DOHC, FAM O, 74 KW, E85 MAX, GME L2N Engine - Gas, 4 Cyl, 1.4L, MFI, L4, DOHC, FAM O, 74 KW, E20 MAX, GME...
Page 71 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General M26 Transmission - Manual 5 Speed, Opel, 65 MM, 1.96 2ND, 1.323 3RD, 0.946 4TH, 0.756 5TH, F17 (WR) M97 Shifter Interlock - Brake, TRANS MDC Molding B/S Upper - Bright MEM Transmission - Manual FWD 5 Speed, Brazil, 180MM, 3.909 1ST, 0.674 5TH (F17;...
Page 72 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General N45 Steering Wheel – 3 Spokes N54 Steering Wheel – 3 Spokes, Sport N81 Tire Spare - Full Size NA3 Emission System – Japan...
Page 73 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General PZY Plate - Skid Front & Rear Q1G Tire All - 185/75R14 SL 89H BW HW1 Q1H Tire All - P195/65R15 SL 89H BW AL2...
Page 74 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General RRL Wheel - 15x6.0, J, Steel, Design 1 RRV Wheel - 16x6.0, J, Aluminum, Design 1 RS7 Wheel - 17x6.5, J, Aluminum, Design 1 T39 Lamp - Turn Signal, AUX T3U Lamp –...
Page 75 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General TM7 Battery – LN2, FLA, 12V, 60AH, 438 ENCCA TN9 Battery – LN1, FLA, 12V, 50AH, 375 ENCCA TR1 Lamp - Tail & Stop TR6 Headlamps Control –...
Page 76 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General UDB Display Instrument – Driver Info Enhanced (Segmented) UDG Display Instrument – Trip Odometer (Segmented) UE1 Communication System - Vehicle, G.P.S.1 UE3 Communication System - Vehicle, G.P.S.3...
Page 77 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General UQK Restraint Provisions - Child, ISOFIX 2 Point Only, Point / LAT CH (INC 2 Top Tether Points) UQL Restraint Provisions - Child, ISOFIX 2 Point Only, Point / LAT CH (INC 3 Top Tether Points)
Page 78 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General VK8 Holder – Eyeglasses VKD License Plate - Front & Rear Mounting, SAE VMO Panel Center - Instrument, Graphite Silver MET VMT Bumper - Front Low Speed, Rear Light Weight...
Page 79 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Fasteners Table 1:Metric Prevailing Torque Fastener Minimum Torque Development Table 2:English Prevailing Torque Fastener Minimum Torque Development Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners.
Page 80 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Application Metric English All Metal Prevailing Torque Fasteners • 6 mm 0.4 N·m 4 lb in • 8 mm 0.8 N·m 7 lb in •...
Page 81 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General • 24 mm 8.5 N·m 75 lb in English Prevailing Torque Fastener Minimum Torque Development Specification Application Metric English All Metal Prevailing Torque Fasteners •...
Page 82 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General • 1/2 in • 9/16 in 2.5 N·m 22 lb in • 5/8 in 3.4 N·m 30 lb in • 3/4 in 5 N·m 45 lb in ©...
Page 83 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Thread Inserts General Purpose Thread Repair Kits. These kits are available commercially. Repair Procedure Warning: Refer to Safety Glasses Warning Note: Refer to the thread repair kit manufacturer instructions regarding the size of the drill and tap to use. Avoid any buildup of chips.
Page 84 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Door Lock and Ignition Lock Folding and Non-Folding Key Cutting High Security keys are available from the service parts system. Obtain the key code from the information card.
Page 85 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Front Side Door Lock Cylinder Coding (Free Wheeling) Special Tools BO-49753 Assembly Tool The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.
Page 86 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General 12. Load the cylinder into the BO-49753 assembly tool so that the clutch (1) indexes with the notch in the opening of the tool (2).
Page 87 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Front Side Door Lock Cylinder Coding (Non Free Wheeling) The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.
Page 88 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General 11. Insert the assembly into the case (5). 12. With the lock cylinder assembly installed in the case (5), install the retainer (6) and stake the retainer in place using a small punch and hammer to peen the case material onto the exposed ends of the installed retainer (6).
Page 89 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Lock Cylinder Coding - Ignition The ignition lock cylinder uses 8 key cut positions, 1–8. The ignition cylinder tumblers (3) are located on alternate sides of the cylinder (5).
Page 90 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Rear Compartment Lid Lock Cylinder Coding The rear compartment lid lock cylinder uses 7 of the 7 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other, are not self-retaining, and are not snap in.
Page 91 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Lifting and Jacking the Vehicle Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle body and structure depending on lifting equipment used.
Page 92 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support.
Page 93 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Exterior Windnoise Warning: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result.
Page 94 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Interior Windnoise Warning: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result.
Page 95 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Air Pressure Test 1. Mask off both the pressure relief valves. 2. Close all the windows. 3. Turn the vehicles ventilation fan to the on position, with the selector on high speed and in the defrost mode.
Page 96 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Soap Suds or Bubble Test 1. Mask off the pressure relief valves. 2. Close all the windows and the doors. 3. Turn the vehicles ventilation fan to the on position, with the selector on high speed and in the defrost mode.
Page 97 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Tracing Powder or Chalk Test Clean the weatherstrips and the contact surfaces with cleaning solvent. 1. Apply powder or chalk in an unbroken line to the contact surface of the weatherstrip surrounding the perimeter of the suspected areas.
Page 98 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Squeaks and Rattles Special Tools • J 39570 Chassis Ear • J 41416 Ultrasonic Leak Detector For equivalent regional tools, refer to Special Tools .
Page 99 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Waterleak Test Preparation Note: This procedure is not used in Brazil. • GM vehicles are designed to operate under normal environmental conditions. • The design criteria for sealing materials and components takes into consideration the sealing forces required to withstand the natural elements.
Page 100 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Recommended Materials (Waterleak Repair) Leak Areas Repair Materials Bolts, Studs, and Screws Strip caulk Large Holes 3M™ Automotive Joint and Seam Sealer Metal joints...
Page 101 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Dust Leaks Dust may leak into the vehicle where water will not. This happens particularly in the lower portion of the interior. Forward motion of the vehicle can create a slight vacuum which pulls air and dust into the vehicle.
Page 102 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Water Hose Test Note: Use a water hose without the nozzle attached. 1. Have an assistant inside of the vehicle in order to locate the leak.
Page 103 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Air Hose Test Caution: The air hose test should only be used on fully cured urethane adhesive. Otherwise, damage to the urethane adhesive bead could result in additional leaks.
Page 104 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Body Waterleak Repair Warning: If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced.
Page 105 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Stationary Window Waterleak Repair Warning: If any water enters the vehicle interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced.
Page 106 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX GENERAL INFORMATION General Special Tools Illustration Tool Number/ Description CH-39570 J-39570 Chassis Ear GE-41416 J-41416 Ultrasonic Leak Detector © 2011 General Motors. All rights reserved.
Page 107: Body Hardware And Trim
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Idex Exterior Trim Instrument Panel and Console Trim Floor Coverings and Headlinings Interior Trim and Paneling © 2011 General Motors. All rights reserved.
Page 108 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Idex Specifications Liftgate Emblem/Nameplate Replacement (Hatchback) Emblem/Nameplate Replacement Rear Compartment Lid Nameplate Replacement (Sedan) Body Panel Paint Protector Replacement (VGC) Radiator Upper Grille Replacement...
Page 109 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Fastener Tightening Specifications Specification Application Metric English 5.0 N·m 44 lb in Liftgate Applique Nut Radiator Grille Bumper Bolt 1.5 N·m 13 lb in 5.0 N·m...
Page 110 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Emblem/Nameplate Replacement Caution: Refer to Exterior Trim Emblem Removal Caution 1. The part and vehicle surface should be 21°C (70°F) prior to installation. The vehicle should remain inside in a temperature range of 21°C (70°F) for 1 hour after assembly to allow the adhesive to develop sufficient bond strength.
Page 111 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Body Panel Paint Protector Replacement (VGC) 1. The paint protective film and vehicle surface temperature should be 13–32°C (55–90°F) for best results.
Page 112 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Body Side Upper Front Applique Replacement Callout Component Name Caution: Refer to Exterior Trim Emblem Removal Caution Preliminary Procedure Open either the left front or right front door in order to access the backside of the body side upper front applique.
Page 113 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Liftgate Side Applique Replacement (Hatchback) Callout Component Name Preliminary Procedure 1. Open and support the rear liftgate assembly. 2. Remove the liftgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement 3.
Page 114 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Rear Compartment Lid Applique Replacement Callout Component Name Preliminary Procedure 1. Open and support the rear compartment lid. 2. Remove the rear compartment lid inner panel trim. Refer to Rear Compartment Lid Inner Panel Trim Replacement 3.
Page 115 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Front License Plate Bracket Replacement Callout Component Name Preliminary Procedure Remove the front license plate if equipped. Front License Plate Bracket Screw (Qty: 4)
Page 116 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Front Bumper Fascia Front Tow Eye Access Hole Cover Replacement Callout Component Name Front Bumper Fascia Front Tow Eye Access Hole Cover Procedure 1.
Page 117 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Rear Bumper Fascia Rear Tow Eye Access Hole Cover Replacement Callout Component Name Rear Bumper Fascia Rear Tow Eye Access Hole Cover Procedure 1.
Page 118 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Radiator Grille Emblem/Nameplate Replacement Callout Component Name Preliminary Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement 2.
Page 119 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Liftgate Emblem/Nameplate Replacement (Hatchback) Callout Component Name Liftgate Emblem / Nameplate Assembly • CHEVROLET • BOWTIE • AVEO • LT Caution:...
Page 120 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Rear Compartment Lid Nameplate Replacement (Sedan) Callout Component Name Rear Compartment Lid Name Plate • CHEVROLET • BOWTIE Caution: Refer to...
Page 121 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Radiator Upper Grille Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Radiator Upper Grille Assembly Screw (Qty: 6)
Page 122 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Radiator Lower Grille Replacement Callout Component Name Preliminary Procedures 1. Remove the front bumper fascia assembly. Refer to Front Bumper Fascia Replacement 2.
Page 123 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Radiator Grille Opening Cover Replacement (Upper Grille Cover) Callout Component Name Preliminary Procedure Remove the radiator upper grille. Refer to Radiator Upper Grille Replacement...
Page 124 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Radiator Grille Opening Cover Replacement (Lower Grille Cover) Callout Component Name Preliminary Procedure Remove the radiator lower grille. Refer to Radiator Lower Grille Replacement...
Page 125 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Roof Panel Joint Finish Molding Replacement Callout Component Name Caution: Refer to Exterior Trim Emblem Removal Caution Preliminary Procedures 1. Begin at the rear edge of the roof panel joint finish molding and carefully pry the molding from the roof ditch clip.
Page 126 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Rear End Spoiler Replacement (Hatchback TTV) Callout Component Name Preliminary Procedure Remove the liftgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement...
Page 127 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Exterior Trim Water Management Description and Operation Plenum Water Flow Direction and Cleaning A large percentage of water will flow off the windshield area into the plenum chamber drain system and then down the outside on the plenum to the underside of the vehicle.
Page 128 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Index Specifications Rear Compartment Floor Panel Carpet Replacement (Sedan) Eliminating Unwanted Odors in Vehicles Rear Compartment Floor Panel Carpet Replacement (Hatchback) Floor Carpet Drying...
Page 129 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Adhesives, Fluids, Lubricants, and Sealers Application Type of Material GM Part Number GM Vehicle Care Odor Eliminator Fluids Refer to Electronic Parts Catalog.
Page 130 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, Refer to Adhesives, Fluids, Lubricants, and Sealers , may control or eliminate odors in the interior and luggage compartment areas of GM vehicles.
Page 131 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: •...
Page 132 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Floor Panel Carpet Replacement Callout Component Name Preliminary Procedures 1. Remove front seats. Refer to Driver or Passenger Seat Replacement 2.
Page 133 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Front Side Door Opening Floor Carpet Retainer Replacement Callout Component Name Front Side Door Opening Floor Carpet Retainer Retainer Front Side Door Opening Floor Carpet Retainer Clip...
Page 134 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Rear Side Door Opening Floor Carpet Retainer Replacement Callout Component Name Preliminary Procedure Remove the rear seat cushion. Refer to...
Page 135 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Rear Compartment Floor Panel Carpet Replacement (Sedan) Callout Component Name Rear Compartment Floor Panel Carpet Assembly © 2011 General Motors. All rights reserved.
Page 136 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Rear Compartment Floor Panel Carpet Replacement (Hatchback) Callout Component Name Rear Compartment Floor Panel Carpet Assembly © 2011 General Motors. All rights reserved.
Page 137 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Headlining Trim Panel Replacement (Hatchback with Sunroof) Callout Component Name Warning: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims.
Page 138 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Headlining Trim Panel Replacement (Hatchback without Sunroof) Callout Component Name Warning: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims.
Page 139 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Headlining Trim Panel Replacement (Sedan with Sunroof) Callout Component Name Warning: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims.
Page 140 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Floor Coverings Headlinings Headlining Trim Panel Replacement (Sedan without Sunroof) Callout Component Name Warning: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims.
Page 141 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Index Instrument Panel Lower Compartment Replacement Specifications Instrument Panel Insulator Replacement Instrument Panel Compartment Door Latch Replacement Instrument Panel Accessory Upper Trim Plate Replacement...
Page 142 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Fastener Tightening Specifications Specification Application Metric English 10 N·m 89 lb in Instrument Panel Inflatable Restraint Module Fasteners 22 N·m...
Page 143 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Insulator Replacement Callout Component Name Instrument Panel Insulator Fastener (Qty: 3) Caution: Refer to Fastener Caution Instrument Panel Insulator ©...
Page 144 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Accessory Upper Trim Plate Replacement Callout Component Name Preliminary Procedure Remove the instrument panel center molding. Refer to...
Page 145 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Center Trim Panel Replacement Callout Component Name Instrument Panel Center Trim Panel (Qty: 2) Procedure Use a flat bladed plastic trim tool in order to disengage the retainers securing the center trim plates to the instrument panel accessory upper trim plates.
Page 146 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Center Upper Molding Replacement Callout Component Name Preliminary Procedure Remove the instrument panel center molding. Refer to...
Page 147 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Upper Trim Panel Replacement - Right Side (Without AR1) Callout Component Name Preliminary Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 148 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Upper Trim Panel Replacement - Right Side (With AR1) Callout Component Name Preliminary Procedure 1. Remove the instrument panel center molding. Refer to Instrument Panel Center Molding Replacement 2.
Page 149 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Upper Trim Panel Replacement - Left Side Callout Component Name Preliminary Procedure 1. Remove the instrument cluster assembly. Refer to Instrument Cluster Replacement 2.
Page 150 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Fuse Block Access Hole Cover Replacement Callout Component Name Instrument Panel Fuse Block Access Hole Cover...
Page 151 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Outer Trim Cover Replacement Callout Component Name Instrument Panel Outer Trim Cover (Left) Procedures Use a flat bladed plastic trim tool in order to disengage the retainers securing the instrument panel outer trim covers to the instrument panel assembly.
Page 152 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Cluster Upper Bezel Replacement Callout Component Name Instrument Panel Cluster Upper Bezel Procedures Use a flat bladed plastic trim tool in order to disengage the retainers securing the instrument panel cluster upper bezel to the instrument cluster assembly.
Page 153 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Lower Trim Pad Cover Replacement Callout Component Name Instrument Panel Lower Trim Pad Fastener (Qty: 2)
Page 154 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Upper Compartment Door Latch Replacement Callout Component Name Instrument Panel Upper Compartment Door Latch Procedures 1. Open the instrument panel compartment door.
Page 155 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Compartment Housing Replacement (RHD) Callout Component Name Preliminary Procedure Remove the instrument panel lower compartment. Refer to...
Page 156 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Compartment Replacement Callout Component Name Preliminary Procedure Remove the right instrument panel upper trim panel. Refer to...
Page 157 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Lower Compartment Replacement Callout Component Name Preliminary Procedure 1. Open the instrument panel lower compartment to the full open position.
Page 158 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Compartment Door Latch Replacement Callout Component Name Instrument Panel Compartment Door Latch Fasteners (Qty: 2) Caution:...
Page 159 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Compartment Door Dampener Replacement Callout Component Name Preliminary Procedure Remove the instrument panel lower compartment. Refer to...
Page 160 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Center Molding Replacement (With U58) Callout Component Name Instrument Panel Center Molding Assembly Procedure 1. Use a flat bladed plastic trim tool in order to release the retainers securing the center molding to the instrument panel assembly.
Page 161 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Center Molding Replacement (Without U58) Callout Component Name Instrument Panel Center Molding Assembly Procedure 1. Use a flat bladed plastic trim tool in order to release the retainers securing the center molding to the instrument panel assembly.
Page 162 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Assembly Replacement Callout Component Name Preliminary Procedure 1. Remove the right and left windshield side garnish moldings. Refer to Windshield Side Garnish Molding Replacement 2.
Page 163 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel Tie Bar Replacement Removal Procedure 1. Remove the Instrument panel assembly. Refer to Instrument Panel Assembly Replacement 2.
Page 164 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim 8. Remove the bolts (1) securing the instrument panel tie bar assembly to the brake pedal bracket. 9. Remove nut (1) securing the instrument panel tie bar to the brake pedal mounting bracket.
Page 165 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim 11. Remove the fasteners (1) securing the instrument panel tie bar assembly to the HVAC module. 12. Remove the bolts (1) securing the instrument panel tie bar assembly to the vehicle body.
Page 166 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim 4. Loosely install the fasteners (1) securing the instrument panel tie bar assembly to the HVAC module. 5. Loosely install the bolts (1) securing the right and left instrument panel tie bar lower support brackets (2) to the front floor tunnel panel.
Page 167 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim 7. Loosely install the bolts (1) securing the instrument panel tie bar assembly to the brake pedal bracket.
Page 168 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim 17. Install the instrument panel fuse block (1) onto the instrument panel tie bar assembly. 18. Install the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement 19.
Page 169 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Cover Replacement (Automatic Transmission) Callout Component Name Front Floor Console Cover Assembly Procedures 1. Apply the parking brake.
Page 170 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Cover Replacement (Manual Transmission) Removal Procedure 1. Use a flat bladed plastic trim tool in order to release the retainers securing the console cover (1) to the console assembly.
Page 171 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Installation Procedure 1. Position the console cover assembly (1) to the console assembly. 2. Feed the transmission control lever boot assembly thru the opening in the console cover assembly (1).
Page 172 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Cup Holder Replacement Callout Component Name Preliminary Procedure Remove the front floor console assembly. Refer to...
Page 173 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Automatic Transmission Control Indicator Opening Cover Replacement Callout Component Name Preliminary Procedure Remove the front floor console cover. Refer to...
Page 174 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Extension Replacement - Right Side Callout Component Name Front Floor Console Extension Procedure Use a flat bladed plastic trim tool in order to release the retainers securing the extension to the console assembly.
Page 175 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Extension Replacement - Left Side Callout Component Name Front Floor Console Extension Procedure Use a flat bladed plastic trim tool in order to release the retainers securing the extension to the console assembly.
Page 176 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Instrument Panel and Console Trim Front Floor Console Replacement Callout Component Name Preliminary Procedures 1. Remove the right and left front floor console extensions. Refer to...
Page 177 BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM BODY HARDWARE AND TRIM Instrument Panel and Console Trim Instrument Panel and Console Trim Instrument Cluster Replacement Callout Component Name Preliminary Procedure 1.
Page 178 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM Index Specifications Center Pillar Lower Trim Panel Replacement Front Side Door Window Switch Bezel Replacement (Left Side) Body Lock Pillar Upper Trim Panel Replacement (Sedan)
Page 179 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Fastener Tightening Specifications Specification Application Metric English 9 N·m 80 lb in Cargo Tie Down Hook Fastener 6 N·m 53 lb in...
Page 180 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Front Side Door Window Switch Bezel Replacement (Left Side) Callout Component Name Preliminary Procedure Remove the front side door trim. Refer to...
Page 181 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Front Side Door Window Switch Bezel Replacement (Right Side) Callout Component Name Preliminary Procedure Remove the front side door trim. Refer to...
Page 182 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Side Door Window Switch Bezel Replacement Callout Component Name Preliminary Procedure Remove the rear side door trim. Refer to Rear Side Door Trim Replacement...
Page 183 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Front Side Door Upper Front Trim Panel Replacement Callout Component Name Front Side Door Upper Front Trim Panel Assembly Procedure Use the appropriate plastic trim tool to aid in the removal of the door trim.
Page 184 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Front Side Door Trim Replacement Callout Component Name Front Side Door Inside Handle Bolt Finish Cap Front Side Door Inside Handle Fastener...
Page 185 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Side Door Upper Rear Trim Panel Replacement (Hatchback) Callout Component Name Rear Side Door Upper Rear Trim Panel Assembly Procedure Pull the door upper rear trim panel away from the rear side door.
Page 186 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Roof Rail Front Stowage Compartment Replacement Callout Component Name Roof Rail Front Stowage Compartment Fastener (Qty: 2) Caution: Refer to Fastener Caution Procedure 1.
Page 187 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Roof Rail Front Assist Handle Replacement Callout Component Name Roof Rail Front Assist Handle Fastener (Qty: 2) Caution: Refer to Fastener Caution Procedure 1.
Page 188 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Roof Rail Rear Assist Handle Replacement Callout Component Name Roof Rail Rear Assist Handle Fastener (Qty: 2) Caution: Refer to Fastener Caution Procedure 1.
Page 189 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Sunshade Replacement Callout Component Name Preliminary Procedure Lower the front of the headliner to access the sunshade electrical connector, if necessary. Refer to...
Page 190 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Sunshade Support Replacement Callout Component Name Sunshade Support Fastener Caution: Refer to Fastener Caution Note: Pull the cover downward to access the fastener.
Page 191 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Windshield Side Garnish Molding Replacement Callout Component Name Preliminary Procedures Disable the SIR system, if equipped. Refer to SIR Disabling and Enabling...
Page 192 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Body Rear Seat Back Trim Panel Replacement (Sedan with AN1) Callout Component Name Preliminary Procedures Remove the rear seat back cushion. Refer to...
Page 193 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Body Rear Seat Back Trim Panel Replacement (Sedan with AMA) Callout Component Name Body Rear Seat Back Trim Panel Retainer Procedure Pull the rear seat back cushion latch release located on the top of the rear seat back cushion, and fold the rear seat back cushion forward.
Page 194 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Center Pillar Upper Trim Panel Replacement (With AHU) Callout Component Name Preliminary Procedure 1. Remove the center pillar lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement 2.
Page 195 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Center Pillar Upper Trim Panel Replacement (Without AHU) Callout Component Name Preliminary Procedures 1. Remove the center pillar lower garnish molding. Refer to Center Pillar Lower Trim Panel Replacement 2.
Page 196 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Center Pillar Lower Trim Panel Replacement Callout Component Name Preliminary Procedure 1. Remove the front side door opening floor carpet retainer. Refer to...
Page 197 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Body Lock Pillar Upper Trim Panel Replacement (Sedan) Callout Component Name Preliminary Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 198 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Body Lock Pillar Upper Trim Panel Replacement (Hatchback) Callout Component Name Preliminary Procedure Disable the SIR system. Refer to SIR Disabling and Enabling...
Page 199 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Quarter Inner Trim Finish Panel Replacement (Hatchback) Callout Component Name Preliminary Procedures 1. Remove the rear side door opening floor carpet retainer. Refer to...
Page 200 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Body Side Trim Panel Replacement (Sedan) Callout Component Name Preliminary Procedures 1. Remove rear side door opening floor carpet retainer. Refer to...
Page 201 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Window Panel Trim Replacement (Sedan) Callout Component Name Preliminary Procedures 1. Remove the body lock pillar upper trim panel. Refer to Body Lock Pillar Upper Trim Panel Replacement 2.
Page 202 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Compartment Stowage Shelf Replacement (Hatchback) Callout Component Name Rear Compartment Stowage Shelf Assembly © 2011 General Motors. All rights reserved.
Page 203 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Side Door Trim Replacement (Hatchback) Callout Component Name Preliminary Procedure Remove the rear side door upper rear trim panel. Refer to...
Page 204 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Side Door Trim Replacement (Sedan) Callout Component Name Rear Side Door Inside Handle Bolt Cap Rear Side Door Inside Handle Fastener...
Page 205 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Luggage Shade Replacement (Hatchback) Callout Component Name Luggage Shade Assembly Procedure Detach luggage shade from upper support. © 2011 General Motors. All rights reserved.
Page 206 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Liftgate Trim Finish Panel Replacement (Hatchback) Callout Component Name Liftgate Trim Finish Panel Fastener Caution: Refer to Fastener Caution Liftgate Trim Finish Panel Retainer (Qty: 8)
Page 207 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Compartment Sill Trim Plate Replacement Callout Component Name Preliminary Procedure Partially remove the rear compartment opening weatherstrip. Refer to Rear Compartment Lid Weatherstrip Replacement...
Page 208 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Compartment Lid Inner Panel Trim Replacement (Sedan) Callout Component Name Preliminary Procedures 1. Remove the rear compartment lid outer bumpers. 2. Remove the latch cover.
Page 209 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Compartment Side Trim Replacement - Left Side (Sedan) Callout Component Name Preliminary Procedures 1. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement 2.
Page 210 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Rear Compartment Side Trim Replacement - Right Side (Sedan) Callout Component Name Preliminary Procedures 1. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement 2.
Page 211 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY HARDWARE AND TRIM InteriorTrim Quarter Outer Panel Pressure Relief Valve Replacement Callout Component Name Preliminary Procedures Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement Pressure Relief Valve ©...
Page 212: Body Repair
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Index Bolted Exterior Body Panels and Closures Frame and Underbody Bumpers and Fascias Paint and Coatings Collision Repair Plastic Panel Information and Repair © 2011 General Motors. All rights reserved.
Page 213 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Index Specifications Rear Compartment Lid Replacement Front Side Door Check Link Replacement Front End Upper Tie Bar Replacement Rear Side Door Check Link Replacement Hood Primary Latch Release Cable Replacement...
Page 214 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Fastener Tightening Specifications Specification Application Metric English 100 N·m 74 lb in Front Bumper Impact Bar Bolt 9 N·m...
Page 215 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures 22 N·m 16 lb ft Liftgate Hinge Bolts Liftgate Hinge Nuts 40 N·m 30 lb ft 9 N·m 80 lb in Radiator Opening Upper Cover Bolts 9 N·m...
Page 216 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front End Upper Tie Bar Replacement Callout Component Name Preliminary Procedures 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 217 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Primary Latch Release Cable Replacement Callout Component Name Preliminary Procedures 1. Remove the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement 2.
Page 218 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Adjustment Callout Component Name Preliminary Procedure Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement...
Page 219 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Replacement Callout Component Name Warning: Refer to SIR Warning Preliminary Procedures 1. Mark the location of the hinge before removing the bolts with a grease pencil.
Page 220 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Adjustment (4 Door Notch Back 69) Callout Component Name Rear Side Door Caution: Refer to Fastener Caution Procedure 1.
Page 221 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Replacement Callout Component Name Warning: Refer to SIR Warning Preliminary Procedures 1. Mark the location of the hinge before removing the bolts with a grease pencil.
Page 222 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Fender Replacement Callout Component Name Preliminary Procedures 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement 2.
Page 223 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Liftgate Adjustment Callout Component Name Liftgate Caution: Refer to Fastener Caution Procedure 1. Loosen the 4 liftgate hinge bolts to adjust the liftgate.
Page 224 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Liftgate Replacement Callout Component Name Preliminary Procedures 1. Disconnect the electrical connectors. 2. Disconnect the liftgate struts. Refer to Liftgate Strut Replacement 3.
Page 225 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Primary Latch Release Cable Handle Replacement Callout Component Name Preliminary Procedure Remove the front side door opening floor carpet retainer. Refer to...
Page 226 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Upper Hinge and Lower Hinge Replacement Callout Component Name Front Side Door Upper Hinge to Body Bolt (Qty: 2)
Page 227 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Hinge Replacement Callout Component Name Preliminary Procedures 1. Remove the hood. Refer to Hood Replacement 2. Remove the front fender. Refer to...
Page 228 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Liftgate Hinge Replacement Callout Component Name Preliminary Procedures 1. Remove the liftgate. Refer to Liftgate Replacement 2. Lower the rear of the headliner to access the inner bolts. Refer to Headlining Trim Panel Replacement 3.
Page 229 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Compartment Lid Rear Hinge Replacement Callout Component Name Preliminary Procedures 1. Remove the rear window trim panel. Refer to Rear Window Panel Trim Replacement 2.
Page 230 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Upper Hinge and Lower Hinge Replacement Callout Component Name Rear Side Door Upper Hinge to Body Bolts (Qty: 2)
Page 231 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Adjustment Callout Component Name Hood Caution: Refer to Fastener Caution Procedure 1. Loosen the 4 hood hinge nuts.
Page 232 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Replacement Callout Component Name Preliminary Procedure Disconnect the windshield washer nozzle hose. Hood Hinge Nut (Qty: 4) Caution:...
Page 233 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Insulator Replacement Callout Component Name Hood Insulator Plastic Retainer (Qty: 9) Hood Insulator Procedure Ensure the 3 integral tabs are secured to the hood.
Page 234 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Primary and Secondary Latch Replacement Callout Component Name Hood Primary and Secondary Latch Bolt (Qty: 2) Caution: Refer to...
Page 235 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Compartment Lid Adjustment Callout Component Name Rear Compartment Lid Caution: Refer to Fastener Caution Procedure 1. Loosen the rear compartment lid hinge bolts (Qty: 4) to adjust the rear compartment lid.
Page 236 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Compartment Lid Replacement Callout Component Name Preliminary Procedure Remove the rear compartment lid inner panel trim. Refer to...
Page 237 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Check Link Replacement Callout Component Name Preliminary Procedure Remove the front side door trim panel. Refer to...
Page 238 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Check Link Replacement Callout Component Name Preliminary Procedures 1. Move the window to the full up position.
Page 239 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Fuel Tank Filler Door Replacement Callout Component Name Fuel Tank Filler Door Procedure Position the fuel tank filler door to the full open position. Using light outward sliding pressure on the filler door, release the retainer on the fuel tank filler door from the hinge.
Page 240 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Fuel Tank Filler Door Latch Housing Replacement Callout Component Name Preliminary Procedures 1. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement 2.
Page 241 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Hold-Open Rod Replacement Callout Component Name Hood Hold-Open Rod Warning: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.
Page 242 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Compartment Lid Hinge Torque Rod Replacement Callout Component Name Warning: Refer to Hood Hold-Open Device Warning Preliminary Procedure Open and support the rear compartment lid.
Page 243 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Side Seal Replacement Callout Component Name Hood Side Seal Push-In Retainer (Qty: 6) Hood Side Seal © 2011 General Motors. All rights reserved.
Page 244 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Rear Seal Replacement Callout Component Name Hood Rear Seal Procedure 1. Clean the area where the seal will be mounted. Use a suitable solvent with a mixture of 50 percent isopropyl alcohol and 50 percent water by volume, or high-flash naphtha.
Page 245 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Rear Weatherstrip Replacement Callout Component Name Hood Rear Weatherstrip Procedure The hood rear weatherstrip is held in place with 10 plastic retainers that are part of the air inlet grille. Carefully pull the weatherstrip to the right/left to release from the retainers on the air inlet grille.
Page 246 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Radiator Grille Bumper Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement...
Page 247 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Radiator Opening Upper Cover Replacement Callout Component Name Radiator Opening Upper Cover Screw (Qty: 10) Caution: Refer to Fastener Caution...
Page 248 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Liftgate Strut Replacement Callout Component Name Liftgate Strut Warning: When a lift gate hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.
Page 249 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Weatherstrip Replacement - Door Side Callout Component Name Front Side Door Weatherstrip Upper Retainer Procedure 1. Open the front side door to the fully open position.
Page 250 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Front Side Door Weatherstrip Replacement - Body Side Callout Component Name Preliminary Procedure 1. Remove the upper center pillar trim. Refer to Center Pillar Upper Trim Panel Replacement 2.
Page 251 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Liftgate Weatherstrip Replacement Callout Component Name Liftgate Weatherstrip Procedure Clean the area where the seal will be mounted. Use a suitable solvent with a mixture of 50 percent isopropyl alcohol and 50 percent water by volume, or high-flash naphtha.
Page 252 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Compartment Lid Weatherstrip Replacement Callout Component Name Rear Compartment Lid Weatherstrip Procedure 1. Disconnect any electrical connector. 2. Clean the area where the seal will be mounted. Use a suitable solvent with a mixture of 50 percent isopropyl alcohol and 50 percent water by volume, or high-flash naphtha.
Page 253 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Upper Front Auxiliary Weatherstrip Retainer Replacement Callout Component Name Front Side Door Upper Front Auxiliary Weatherstrip Retainer (Qty :10) Note: If the retainers are damaged when removing they must be replaced.
Page 254 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Weatherstrip Replacement - Door Side Callout Component Name Rear Side Door Weatherstrip Upper Retainers (Qty :3) Procedure 1.
Page 255 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Rear Side Door Weatherstrip Replacement - Body Side Callout Component Name Preliminary Procedures 1. Remove the upper center pillar trim. Refer to Center Pillar Upper Trim Panel Replacement 2.
Page 256 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Hood Ajar Indicator Description and Operation Hood Ajar Switch The body control module (BCM) applies B+ to the hood ajar signal circuit and monitors the voltage to determine the position of the hood.
Page 257 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bolted Exterior Body Panels and Closures Special Tools Illustration Tool Number/ Description BO-125 KM-125 Torque Rod Lifter © 2011 General Motors. All rights reserved.
Page 258 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Index Specifications Front Air Deflector Replacement Front Bumper Energy Absorber Replacement Front Bumper Fascia Air Deflector Replacement Front Bumper Upper Impact Bar Replacement Rear Bumper Fascia Replacement (Sedan)
Page 259 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Fastener Tightening Specifications Specification Application Metric English 8 N·m 71 lb in Front Air Deflector Bolts 2.5 N·m 22 lb in Front Bumper Fascia Air Deflector Screws Front Bumper Fascia Bracket Bolts 9 N·m...
Page 260 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Energy Absorber Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Front Bumper Energy Upper Absorber Push-On Retainer (Qty: 2)
Page 261 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Upper Impact Bar Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement...
Page 262 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Lower Impact Bar Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement...
Page 263 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Impact Bar Lower Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper opening cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement...
Page 264 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Replacement Callout Component Name Preliminary Procedures 1. Remove the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement 2.
Page 265 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Guide Replacement Callout Component Name Warning: Refer to Eye Protection Warning Preliminary Procedure Remove the front bumper fascia. Refer to...
Page 266 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Center Support Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement...
Page 267 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Opening Lower Cover Replacement Callout Component Name Front Bumper Fascia Opening Lower Cover Push-In Retainer Front Bumper Fascia Opening Lower Cover Bolt (Qty: 2)
Page 268 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Bracket Replacement Callout Component Name Preliminary Procedure 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement 2.
Page 269 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Air Deflector Replacement Callout Component Name Preliminary Procedure 1. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement 2. Remove the headlamp. Refer to...
Page 270 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Front Bumper Fascia Air Deflector Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement...
Page 271 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Fascia Replacement (Sedan) Callout Component Name Preliminary Procedures 1. Remove the screws from the rear wheelhouse liners to the rear fascia. Refer to...
Page 272 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Fascia Replacement (Hatchback) Callout Component Name Preliminary Procedures 1. Remove the screws from the rear wheelhouse liners to the rear fascia. Refer to...
Page 273 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Fascia Outer Guide Replacement (Sedan) Callout Component Name Warning: Refer to Eye Protection Warning Preliminary Procedure Remove the rear bumper fascia. Refer to...
Page 274 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Fascia Outer Guide Replacement (Hatchback) Callout Component Name Warning: Refer to Eye Protection Warning Preliminary Procedure Remove the rear bumper fascia. Refer to...
Page 275 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Impact Bar Replacement (Hatchback) Callout Component Name Preliminary Procedure Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement...
Page 276 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Rear Bumper Impact Bar Replacement (Sedan) Callout Component Name Preliminary Procedure Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement...
Page 277 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Bumpers and Fascias Special Tools Illustration Tool Number/ Description BO-594-A Hand Rivet Tongs © 2011 General Motors. All rights reserved.
Page 278 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Index Specifications Rear Compartment Floor Panel Replacement Front Wheelhouse Front Panel Replacement Quarter Outer Panel Sectioning (5HB) Front Wheelhouse Panel Reinforcement Replacement Quarter Outer Panel Sectioning (4NB)
Page 279 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Dimensions - Body (5HB) Dimensions - Body (4NB) © 2011 General Motors. All rights reserved.
Page 280 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Dimensions - Body (5HB) Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center.
Page 282 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Engine Compartment 1201 mm 944 mm 599 mm 1300 mm 1409 mm © 2011 General Motors. All rights reserved.
Page 283 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front End Lower 928 mm 1122 mm 1110 mm 633 mm 910 mm 440 mm 852 mm 584 mm © 2011 General Motors. All rights reserved.
Page 284 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear End Lower 1233 mm 1259 mm 627 mm 966 mm © 2011 General Motors. All rights reserved.
Page 286 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Side 985 mm 1319 mm 955 mm 981 mm 611 mm 946 mm 1005 mm 1277 mm 772 mm © 2011 General Motors. All rights reserved.
Page 287 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Dimensions - Body (4NB) Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center.
Page 289 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Engine Compartment 1201 mm 944 mm 599 mm 1300 mm 1409 mm © 2011 General Motors. All rights reserved.
Page 290 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front End Lower 928 mm 1122 mm 1110 mm 633 mm 910 mm 440 mm 852 mm 584 mm © 2011 General Motors. All rights reserved.
Page 291 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear End Lower 1233 mm 1259 mm 627 mm 966 mm 1035 mm 1504 mm 1052 mm 417 mm 965 mm © 2011 General Motors. All rights reserved.
Page 293 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Side 985 mm 1319 mm 955 mm 981 mm 611 mm 946 mm 886 mm 1155 mm 776 mm © 2011 General Motors. All rights reserved.
Page 294 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front Wheelhouse Front Panel Replacement Removal Procedure 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 Note: Sectioning of the front wheelhouse assembly is not recommended.
Page 295 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 4. Position the service front wheelhouse front panel to the vehicle (1). Clamp the front wheelhouse in place. 5. When the service assembly is correctly positioned, plug weld accordingly (1).
Page 296 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front Wheelhouse Panel Reinforcement Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 297 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Position the front wheelhouse panel reinforcement on the vehicle (1). 4. Verify the fit of the front wheelhouse panel reinforcement. 5. Clamp the front wheelhouse panel reinforcement into position.
Page 298 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front Compartment Side Rail Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 299 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Position the front compartment side rail on the vehicle (1). 4. Verify the fit of the front compartment side rail. 5. Clamp the front compartment side rail into position.
Page 300 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front Hinge Pillar Body Sectioning Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Collision Sectioning Warning Warning:...
Page 301 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 9. Drill all the factory welds (1). Note the number and location of welds for installation of the service assembly. 10. Remove the damaged front hinge pillar body (1).
Page 302 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill 8 mm (5/16 in)holes for plug welding along the edges of the front hinge pillar body as noted from the original panel (1).
Page 303 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Body Hinge Pillar Lower Reinforcement Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 304 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill 8 mm (5/16 in)holes for plug welding along the edges of the front hinge pillar body as noted from the original panel (1).
Page 305 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Roof Outer 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.
Page 306 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 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).
Page 307 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 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.
Page 308 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Roof Outer Panel Replacement (4NB) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 309 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 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).
Page 310 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 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.
Page 311 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 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.
Page 312 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 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).
Page 313 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 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.
Page 314 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 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.
Page 315 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rocker Inner Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Note: The rocker inner panel is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints.
Page 316 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. Drill 8 mm (5/16 in)holes for plug welding along the edges of the quarter outer panel (1) as noted from the original panel.
Page 317 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rocker Outer Panel Sectioning Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Collision Sectioning Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 318 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 8. Locate and mark all the necessary factory welds of the rocker outer panel. 9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
Page 319 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill a 8 mm (5/16 in)holes for plug welding along the edges of the rocker outer panel as noted from the original panel (1).
Page 320 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Body Side Frame Rocker Reinforcement Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning Note: The body side frame rocker reinforcement is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints.
Page 321 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 2. Drill a 8 mm (5/16 in)holes for plug welding along the edges of the quarter outer panel (1) as noted from the original panel.
Page 322 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Front Side Door Outer Panel Replacement Special Tools • BO-6392 Flanging Tool Kit • BO-6396 Bonding Pliers For equivalent regional tools, refer to Special Tools Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.
Page 323 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Clamp the front side door outer panel (1) into position. 4. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit .
Page 324 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear Side Door Outer Panel Replacement Special Tools • BO-6392 Flanging Tool Kit • BO-6396 Bonding Pliers For equivalent regional tools, refer to Special Tools Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.
Page 325 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Clamp the rear side door outer panel (1) into position. 4. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit .
Page 326 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear Compartment Floor Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 327 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 2. Drill a 8 mm (5/16 in)holes for plug welding along the edges of the rear compartment floor panel as noted from the original panel (1).
Page 328 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 12. Plug weld accordingly (1). 13. Weld accordingly the weld studs as noted. 14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to...
Page 329 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Quarter Outer Panel Sectioning (5HB) • BO-6392 Flanging Tool Kit • BO-6396 Bonding Pliers For equivalent regional tools, refer to Special Tools Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.
Page 330 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 8. Open the wheelhouse flanging (1). 9. Locate and mark all the necessary factory welds of the quarter outer panel. 10. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
Page 331 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. Cut the quarter outer panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to overlap the remaining original panel by 25 mm (1 inch) at each joint location (1).
Page 332 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 6. Position the quarter outer panel on the vehicle (1). 7. Verify the fit of the quarter outer panel. 8. Clamp the quarter outer panel into position.
Page 333 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Quarter Outer Panel Sectioning (4NB) Special Tools • BO-6392 Flanging Tool Kit • BO-6396 Bonding Pliers For equivalent regional tools, refer to Special Tools...
Page 334 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 8. Open the wheelhouse flanging (1). 9. Locate and mark all the necessary factory welds of the quarter outer panel. 10. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
Page 335 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. Cut the quarter outer panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to overlap the remaining original panel by 25 mm (1 inch) at each joint location (1).
Page 336 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 6. Position the quarter outer panel on the vehicle (1). 7. Verify the fit of the quarter outer panel. 8. Clamp the quarter outer panel into position.
Page 337 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Quarter Inner Panel Replacement (4NB) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 338 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill 8 mm (5/16 in)holes for plug welding along the edges of the rear wheelhouse outer panel as noted from the original panel (1).
Page 339 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Quarter Inner Panel Sectioning (5HB) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Collision Sectioning Warning Warning:...
Page 340 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 9. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly. 10. Remove the damaged body lock pillar inner reinforcement (1).
Page 341 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 13. Remove the damaged rear wheelhouse outer panel (1). Installation Procedure 1. Drill 8 mm (5/1 in)holes for plug welding along the edges of the rear wheelhouse outer panel as noted from the original panel (1).
Page 342 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 6. Plug weld accordingly (1). 7. Cut the body lock pillar inner reinforcement in corresponding locations to fit the remaining original panel (1). The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
Page 343 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 15. Position the body lock pillar inner reinforcement (1). 16. Verify the fit of the panel. 17. Clamp the body lock pillar inner reinforcement into position.
Page 344 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Center Pillar Inner Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 345 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill 8 mm (5/16 in)holes for plug welding along the edges of the center pillar inner panel (1) as noted from the original panel.
Page 346 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Center Pillar Reinforcement Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning Note: The center pillar upper stiffener is made of Dual Phase Steel and should be replaced only at factory joints.
Page 347 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 3. Drill a 8 mm (5/16 in)holes for plug welding along the edges of the center pillar reinforcement as noted from the original panel (1).
Page 348 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Center Pillar Sectioning - Outer Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Collision Sectioning Warning Warning:...
Page 349 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 8. Measure up 1 inch from the door opening feature line (1) and mark a horizontal line. 9. Cut access window (1) in the center pillar outer.
Page 350 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 12. Remove the damaged center pillar outer panel section (1). Installation Procedure 1. From the service part, cut the panel in corresponding locations to overlap the remaining original panel by 25 mm (1 in) at each joint location (1).
Page 351 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 4. Position the center pillar outer panel (1) to the vehicle. Clamp the pillar in place. 5. Plug weld accordingly (1). 6. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with gaps of 25 mm (1 in) gaps between them.
Page 352 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear Rail Sectioning Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Collision Sectioning Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 353 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 9. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly. 10. Remove the damaged rear side rail (1).
Page 354 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 6. Cut at the scribe line (1). 7. Remove the rear portion of the rail. 8. Cut the upper outer flanges of the rear portion of the rear rail service part. Cut the flanges back to the first scribe line and remove the tabs 9.
Page 355 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair 13. Tack weld the part into position. 14. Inspect the service rear rail for proper dimensions, using 3-dimensional measuring equipment. 15. Plug weld at each 8 mm (5/16 in)plug weld hole location.
Page 356 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Underbody Rear Side Rail Extension Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 357 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. 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.
Page 358 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Rear End Panel Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning Note: The rear end lower panel reinforcement extension is made of Ultra High Strength Dual Phase Steel and should be replaced only at factory joints.
Page 359 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure Note: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in).
Page 360 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Tail Lamp Pocket Replacement (5HB) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 361 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. Drill 8 mm (5/16 in)holes for plug welding along the edges of the tail lamp pocket (1) as noted from the original panel.
Page 362 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Tail Lamp Pocket Replacement (4NB) Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning Warning: Refer to Glass and Sheet Metal Handling Warning 1.
Page 363 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Installation Procedure 1. Drill 8 mm (5/16 in)holes for plug welding along the edges of the tail lamp pocket (1) as noted from the original panel.
Page 364 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Dual Phase Steel Ultra High Strength Dual Phase Steel High Strength Low Alloy Steel Ultra High Strength Steel Mild Steel © 2011 General Motors. All rights reserved.
Page 365 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Dual Phase Steel This information provides repair recommendations and general guidelines for steel classified as Dual Phase Steel (dual phase steel with a tensile strength up to and including 800 MPa), also known as DP.
Page 366 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair High Strength Low Alloy Steel This information provides repair recommendations and general guidelines for steel classified as High Strength Low Alloy Steel, also known as HSLA.
Page 367 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Mild Steel This information provides repair recommendations and general guidelines for steel classified as Mild Steel. This type of steel normally has a tensile strength less than 270 MPa. This includes the common steel names of: •...
Page 368 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Ultra High Strength Dual Phase Steel This information provides repair recommendations and general guidelines for steel classified as Ultra High Strength Dual Phase Steel (dual phase steel with a tensile strength greater than 800 MPa), also known as DPX.
Page 369 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Ultra High Strength Steel This information provides repair recommendations and general guidelines for steel classified as Ultra High Strength Steel, also know as UHSS. This type of steel normally has a tensile strength greater than 700 MPa.
Page 370 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Collision Repair Special Tools Illustration Tool Number/ Description BO-6392 MKM-6392 Flanging Tool Kit BO-6396 MKM-6396 Bonding Pliers © 2011 General Motors. All rights reserved.
Page 371 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Index Specifications Rear Wheelhouse Panel Liner Replacement (Hatchback - Left) Drivetrain and Front Suspension Frame Skid Plate Replacement Rear Wheelhouse Panel Liner Replacement (Hatchback - Right)
Page 372 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Fastener Tightening Specifications Specification Application Metric English 135 N·m 100 lb ft Drivetrain and Front Suspension Frame Bolt Center 58 N·m 43 lb ft...
Page 373 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody 65 N·m 48 lb ft Steering Linkage Tie Rod Nut 100 N·m 74 lb ft Transmission Rear Mount Bracket Bolts © 2011 General Motors. All rights reserved.
Page 374 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Drivetrain and Front Suspension Frame Skid Plate Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2.
Page 375 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Drivetrain and Front Suspension Frame Replacement Special Tools • EN-45059 Angle Meter • CH-50619 Front Suspension Frame Adjusting Pins For equivalent regional tools, refer to...
Page 376 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody 18. Remove the frame front bolts (1). 19. Remove the frame rear bolts (2). 20. Remove the frame (3) from the vehicle.
Page 377 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody 6. Install the upper frame suspension retaining bolts (1) and tighten to 135 N·m (100 lb ft) 7. Remove the support for the power steering gear.
Page 378 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Front Wheelhouse Liner Inner Front Extension Replacement Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 379 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Front Wheelhouse Liner Replacement (Front) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Front Wheelhouse Liner Screw –...
Page 380 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Front Wheelhouse Liner Replacement (Rear) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 381 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Rear Wheelhouse Panel Liner Replacement (Sedan - Right) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 382 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Rear Wheelhouse Panel Liner Replacement (Hatchback - Left) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 383 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Rear Wheelhouse Panel Liner Replacement (Hatchback - Right) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 384 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Rear Wheelhouse Panel Liner Replacement (Sedan - Left) Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 385 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Rear Wheelhouse Panel Liner Extension Replacement Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation...
Page 386 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Front Compartment Front Insulator Cover Replacement Callout Component Name Front Compartment Front Insulator Cover Screw (Qty: 2) Caution: Refer to Fastener Caution Tighten 2.5 N·m (22 lb in)
Page 387 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Frame and Underbody Special Tools Illustration Tool Number/ Description EN-45059 J-45059 Angle Meter CH-50619 Front Suspension Frame Adjusting Pins © 2011 General Motors. All rights reserved.
Page 388 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Basecoat/Clearcoat Paint Systems Paint Gauges Clearcoat Thickness Anti-Corrosion Treatment and Repair (Base) Rail Dust Damage Repair Clearcoat Repair without Repainting Environmental Fallout (Acid Rain)
Page 389 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Basecoat/Clearcoat Paint Systems Warning: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear.
Page 390 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings 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, as well as any moving or rotating mechanical or suspension parts on the underbody, particularly the parking brake cable.
Page 391 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings 05917 Weld-Thru Coating 08891 Rust Fighter-I The following product is available from *Transtar Autobody Technologies. Contact the company at 1-800-824-2843 or www.tat- co.com...
Page 392 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Clearcoat Repair without Repainting Repair Procedure 1. Thoroughly wash the repair area with Liquid Wash and Wax GM P/N 1052870 or the equivalent.
Page 393 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Environmental Fallout (Acid Rain) Caution: Refer to Clearcoat/Ultraviolet Screeners Caution Note: Always refer to the manufacturer's packaged instructions for the detailed procedures of materials used for compounding and/or polishing.
Page 394 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Paint Gauges Paint thickness gauges measure the total thickness of the vehicle finish. It is important to accurately measure the thickness of the finish on each vehicle as the thickness of the finish will vary on each vehicle.
Page 395 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Clearcoat Thickness The clearcoat on the vehicle is typically 0.059–0.078 mm (1.5–2 mils [0.0015–0.0020 in]) thick. The clearcoat contains ultraviolet screeners. Removing more than 0.5 mils (0.019 in) of the clearcoat may result in early paint failure.
Page 396 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Paint and Coatings Rail Dust Damage Repair Warning: Refer to Eye Protection Warning Note: If rail dust has penetrated into the basecoat, the panel requires refinishing. Ensure all the rail dust has been removed prior to refinishing or the rust spots will return.
Page 397 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Plastic Panel Information and Repair General Plastic Repair Warning: In order to reduce the risk of personal injury when exposed to toxic fumes while grinding, cutting, or applying repair material on any type of sheet molded compound or RIM rigid plastic, observe the following guidelines: •...
Page 398 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Plastic Panel Information and Repair How to Identify Plastic Parts Plastic parts can be identified by the SAE code, which is usually found on the rear of the part, and/or by the characteristics of the plastic.
Page 399 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Plastic Panel Information and Repair Plastic Identification and Refinishing Systems Identifying Chemical Examples of Symbol– Old Composition or Typical Area(s) Where Part is Common / Trade...
Page 400 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY REPAIR Plastic Panel Information and Repair Amberol, Bakelite, Rigid, Phenol Formaldehyde Ashtray Durez, Genal, Phenolic, Thermoset Plyophen, Resinox Bumper Fascia, Cowl Panel, Deflector Azdel, Daplen, Panel, Door Panel, Inner Fender,...
Page 401: Body Systems
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Fixed and Moveable Windows Mirrors Horns Vehicle Access Lighting Wipers and Washers © 2011 General Motors. All rights reserved.
Page 402 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Specifications Rear Side Door Window Regulator Replacement (Hatchback) Windshield Replacement Rear Side Door Window Regulator Motor Replacement Windshield Upper Reveal Molding Replacement...
Page 403 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Fastener Tightening Specifications Specification Application Metric English 11 N·m 97 lb in Front Side Door Window Guide Nuts 11 N·m 97 lb in...
Page 404 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Windshield Replacement Special Tools • BO-24402-A Glass Sealant Remover (Cold Knife) • BO-39032 Stationary Glass Removal Tool • Use an adhesive that is approved by GM...
Page 405 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows • Leave a base of auto-adhesive on the pinchweld flange. • The only suitable lubrication is clean water. • Use BO-24402-A Glass Sealant Remover (Cold Knife) .
Page 406 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Windshield Upper Reveal Molding Replacement Callout Component Name Preliminary Procedures Remove the windshield to replace the reveal molding. Refer to Windshield Replacement...
Page 407 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Replacement Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedures 1. Remove the front side door trim panel. Refer to Front Side Door Trim Replacement 2.
Page 408 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Replacement (Sedan) Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedures 1. Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement 2.
Page 409 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Replacement (Hatchback) Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedures 1. Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement 2.
Page 410 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Stationary Window Replacement Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedures Remove the rear side door window. Refer to...
Page 411 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Window Replacement Special Tools • BO-24402-A Glass Sealant Remover (Cold Knife) • BO-39032 Stationary Glass Removal Tool • Use an adhesive that is approved by GM...
Page 412 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows • Leave a base of urethane on the pinchweld flange. • The only suitable lubrication is clear water. • The only suitable lubrication is clear water.
Page 413 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Window Reveal Molding Replacement Callout Component Name Preliminary Procedures Remove the rear window to replace the reveal molding. Refer to...
Page 414 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Liftgate Window Replacement Special Tools • BO-24402-A Glass Sealant Remover (Cold Knife) • BO-39032 Stationary Glass Removal Tool • Use an adhesive that is approved by GM...
Page 415 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Note: Keep the cutting edge of appropriate tool the against the window. Do this from inside the vehicle. 8. Use the appropraite tool to remove the bottom of the window from the auto-adhesive. Keep the cutting edge of the tool against the window.
Page 416 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Switch Replacement (Left Side) Callout Component Name Preliminary Procedure Remove the front side door window switch bezel. Refer to...
Page 417 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Switch Replacement (Right Side) Callout Component Name Preliminary Procedure Remove the front side door widow switch bezel. Refer to...
Page 418 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Switch Replacement Callout Component Name Preliminary Procedure Remove the rear side door window switch bezel. Refer to...
Page 419 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front 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. Do Not remove the window from the vehicle, raise the window to the fully up position, tape in place.
Page 420 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Window Motor Programming - Express Function Window Motor Normalized Procedure A window motor that has not been normalized will no longer perform the express up and express down functions, this may occur during the following conditions: •...
Page 421 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Regulator Motor Replacement Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedure Remove the front side door window regulator.
Page 422 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Regulator Replacement (Sedan) Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedure Remove the front side door window from the guide.
Page 423 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Regulator Replacement (Hatchback) Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedure Remove the front side door window from the guide.
Page 424 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Regulator Motor Replacement Callout Component Name Warning: Refer to Glass and Sheet Metal Handling Warning Preliminary Procedure Remove the rear side door window regulator.
Page 425 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Regulator Handle Replacement Callout Component Name Front Side Door Window Regulator Handle Clip Procedure Use the appropriate tool, remove the clip from handle.
Page 426 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Regulator Handle Replacement Callout Component Name Rear Side Door Window Regulator Handle Clip Procedure Use the appropriate tool, remove the clip from handle.
Page 427 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Rear Guide Replacement Callout Component Name Preliminary Procedure Remove the front side door trim panel. Refer to...
Page 428 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Rear Guide Replacement Callout Component Name Preliminary Procedure Remove the rear side door trim panel. Refer to...
Page 429 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Outer Sealing Strip Replacement Callout Component Name Front Side Door Window Outer Sealing Strip Procedure 1. Do Not remove the outside rearview mirror.
Page 430 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Outer Sealing Strip Replacement (Sedan) Callout Component Name Rear Side Door Window Outer Sealing Strip Procedure Use the appropriate tool, lift one end up and pull away from the door flange to remove.
Page 431 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Outer Sealing Strip Replacement (Hatchback) Callout Component Name Rear Side Door Window Outer Sealing Strip Procedure 1. Use the appropriate tool, lift the front corner of the sealing strip and pull upward and away from the door flange.
Page 432 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Front Side Door Window Weatherstrip Replacement Callout Component Name Preliminary Procedures 1. Remove front side door trim panel. Refer to Front Side Door Trim Replacement 2.
Page 433 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Weatherstrip Replacement (Sedan) Callout Component Name Preliminary Procedures 1. The rear door side window weatherstrip and window is serviced as one assembly. Refer to...
Page 434 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Side Door Window Weatherstrip Replacement (Hatchback) Callout Component Name Preliminary Procedure Remove the rear side door window . Refer to...
Page 435 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Adhesive Installation of Windshields Warning: Refer to Glass and Sheet Metal Handling Warning 1. Use a urethane adhesive systems which meet GM Specification GM 3651G.
Page 436 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 12. Apply glass prep clear to the area approximately 10–16 mm (3/8–5/8 in) around the entire perimeter of the window inner surface.
Page 437 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 17. Install the window reveal molding (1). Refer to Windshield Upper Reveal Molding Replacement 18. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead.
Page 438 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Note: If the locating pins were cut off it will be necessary to tape the window in place until the auto-adhesive cures per auto- adhesive instructions by the manufacturer’s.
Page 439 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Note: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive. 24. Use a soft spray of warm water in order to immediately water test the window.
Page 440 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Adhesive Installation of Rear Windows Warning: Refer to Glass and Sheet Metal Handling Warning 1. Use a urethane adhesive systems which meet GM Specification GM 3651G.
Page 441 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 11. Apply glass prep clear to the area approximately 10–16 mm (3/8–5/8 in) around the entire perimeter of the window inner surface.
Page 442 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 16. Install the window reveal molding (1). Install the window reveal molding. Refer to Rear Window Reveal Molding Replacement 17. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead.
Page 443 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Note: If the locating pins were cut off it will be necessary to tape the window in place until the auto-adhesive cures per auto- adhesive instructions by the manufacturer’s.
Page 444 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 23. Ensure all excess urethane adhesive is cleaned from the body before water test. Note: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.
Page 445 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Adhesive Installation of Liftgate Windows Warning: Refer to Glass and Sheet Metal Handling Warning 1. Use a urethane adhesive systems which meet GM Specification GM 3651G.
Page 446 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 12. Apply glass prep clear to the area approximately 10–16 mm (3/8–5/8 in) around the entire perimeter of the window inner surface.
Page 447 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 17. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead. Cut the applicator nozzle to provided a V cut to apply the auto-adhesive.
Page 448 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows 21. If the locating pins were damaged, align the masking tape (1) lines on the window (2) and the body. 22. Gently depress the window on the auto-adhesive bead until the window reveal molding is seated.
Page 449 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Note: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive. 25. Use a soft spray of warm water in order to immediately water test the window.
Page 450 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Full-Cut Method Description Stationary Window Description Power Windows Description and Operation Urethane Adhesive Description Rear Window Defogger Description and Operation © 2011 General Motors. All rights reserved.
Page 451 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Full-Cut Method Description Note: • If corrosion of the pinch-weld flange is present, or if sheet metal repairs or replacements are required, refinish the pinch- weld flange in order to present a clean, primer-only surface.
Page 452 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Power Windows Description and Operation Power Window System Components The power window system consists of the following components: • Driver window switch •...
Page 453 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Rear Window Defogger Description and Operation Rear Window Defogger System Components The rear window defogger system consist of the following components: •...
Page 454 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Stationary Window Description Most stationary windows, specifically windshields, are retained to the body with adhesive which adheres the window to the body, increasing structural integrity.
Page 455 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Urethane Adhesive Description For replacement of any adhesive-installed window, use the full cut method only. Use adhesive systems which meet GM Specification GM 3651G.
Page 456 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Fixed and Movable Windows Special Tools Illustration Tool Number/ Description BO-24402-A J-24402-A Glass Sealant Cold Knife Remover BO-39032 J-39032 Stationary Glass Removal Tool © 2011 General Motors. All rights reserved.
Page 457 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Specifications Steering Wheel Horn Contact Replacement Horn Replacement Description and Operation © 2011 General Motors. All rights reserved.
Page 458 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Horns Fastener Tightening Specifications Specification Application Metric English 17 N·m 13 lb ft Horn Nut Steering Wheel Horn Contact Bolts 5.5 N·m 49 lb in...
Page 459 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Horns Horn Replacement Callout Component Name Preliminary Procedure Remove the front wheelhouse liner front. Refer to Front Wheelhouse Liner Replacement Horn Nut Caution: Refer to...
Page 460 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Horns Steering Wheel Horn Contact Replacement Callout Component Name Preliminary Procedure Remove the steering wheel inflatable restraint module. Refer to Steering Wheel Inflatable Restraint Module Replacement...
Page 461 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Horns Horns System Description and Operation System Description The horn system consists of the following components: • F51UA 15A fuse • Underhood fuse block (contains a non-serviceable PCB Horn relay) •...
Page 462 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Specifications Front Side Turn Signal Lamp Bulb Replacement Brake Pedal Position Sensor Calibration Parking and Turn Signal Lamp Bulb Replacement Brake Pedal Position Sensor Replacement...
Page 463 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Fastener Tightening Specifications Specification Application Metric English 1.5 N·m 13 lb in Front Fog Lamp Bolt Headlamp Bolt 2.5 N·m 22 lb in 2.5 N·m...
Page 464 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Brake Pedal Position Sensor Calibration Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail.
Page 465 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Brake Pedal Position Sensor Replacement Removal Procedure 1. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement 2.
Page 466 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Headlamp Switch Replacement Callout Component Name Preliminary Procedure Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement...
Page 467 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Hazard Warning Switch Replacement Callout Component Name Preliminary Procedure Remove the heater and air conditioning control. Refer to Heater and Air Conditioning Control Replacement...
Page 468 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Dome Lamp Bezel Replacement Callout Component Name Dome Lamp Bezel Procedures 1. Grasp the bezel assembly and pull downward to release the retainer clips securing the bezel assembly to the headliner.
Page 469 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Windshield Header Courtesy Lamp Replacement Callout Component Name Windshield Header Courtesy Lamp Procedures 1. Grasp the courtesy lamp assembly and pull downward to release the retainer clips securing the courtesy lamp assembly to the dome lamp bezel.
Page 470 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Dome Lamp Bulb Replacement Callout Component Name Preliminary Procedure Remove the windshield header courtesy lamp. Refer to Windshield Header Courtesy Lamp Replacement Dome Lamp Bulb...
Page 471 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Headlamp Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Headlamp Assembly Screw (Qty: 4) Caution:...
Page 472 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Headlamp Bulb Replacement Callout Component Name Preliminary Procedure Open and support the hood assembly. Accessory Bulb Cover (Qty: 2) Warning: Refer to Halogen Bulb Warning...
Page 473 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Headlamp Housing Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Headlamp Housing Bracket Screw (Qty: 2)
Page 474 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Headlamp Aiming Visual Aiming Preparation Procedure Note: Some state and local laws specify requirements for headlamp aim. Comply with all of these laws when performing any headlamp aiming operations.
Page 475 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting 6. The vehicle left tires must be aligned with the reference line extending from the screen with the headlamps aligned with the reference line.
Page 476 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Note: DO NOT cover the headlamp. This may cause excessive heat build up. 8. Turn ON the low beam headlamps. Block the light from projecting onto the screen from the passenger side headlamp.
Page 477 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Fog Lamp Replacement Callout Component Name Preliminary Procedure 1. Remove either the right front or left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement 2.
Page 478 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Fog Lamp Bulb Replacement Callout Component Name Preliminary Procedure 1. Remove either the left front or right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement 2.
Page 479 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Fog Lamp Cover Replacement (Without T3U) Callout Component Name Preliminary Procedure Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement Front Fog Lamp Front Cover Procedure Release the tabs securing the front fog lamp front cover to the front bumper fascia and remove.
Page 480 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Fog Lamp Cover Replacement (With T3U) Callout Component Name Preliminary Procedure Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement Front Fog Lamp Front Cover Procedure Release the tabs securing the front fog lamp front cover to the front bumper fascia and remove.
Page 481 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Fog Lamp Aiming Preparation Procedure Note: Horizontal aim is not adjustable on this vehicle. Vertical aim is done by an adjusting nut located on the rear of the fog lamp.
Page 482 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Side Turn Signal Lamp Replacement Callout Component Name Preliminary Procedures Caution: Refer to Exterior Trim Emblem Removal Caution 1. Apply a layer of masking tape around the turn signal lamp being serviced.
Page 483 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Front Side Turn Signal Lamp Bulb Replacement Callout Component Name Preliminary Procedure Remove the front side turn signal lamp. Refer to Front Side Turn Signal Lamp Replacement...
Page 484 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Parking and Turn Signal Lamp Bulb Replacement Callout Component Name Preliminary Procedures 1. Open and support the hood assembly. 2. Reposition the air cleaner inlet duct on the passenger side of the engine compartment.
Page 485 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting High Mount Stop Lamp Replacement (Sedan) Callout Component Name Preliminary Procedure 1. Remove the rear window panel trim. Refer to Rear Window Panel Trim Replacement 2.
Page 486 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting High Mount Stop Lamp Replacement (Hatchback) Callout Component Name Preliminary Procedure Open and support the liftgate assembly. High Mount Stop Lamp Bolt (Qty: 2)
Page 487 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Cargo Center Courtesy Lamp Bulb Replacement (Hatchback) Callout Component Name Rear Compartment Courtesy Lamp Refer to Rear Compartment Courtesy Lamp Replacement Cargo Lamp Bulb...
Page 488 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Cargo Center Courtesy Lamp Bulb Replacement (Sedan) Callout Component Name Rear Compartment Courtesy Lamp Refer to Rear Compartment Courtesy Lamp Replacement Cargo Lamp Bulb...
Page 489 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Backup Lamp Bulb Replacement (Sedan) Callout Component Name Preliminary Procedure Remove the tail lamp assembly. Refer to Tail Lamp Replacement Back Up Lamp Bulb Socket Procedure Rotate the back up lamp bulb socket counter-clockwise and remove from the tail lamp housing.
Page 490 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear License Plate Lamp Replacement (Sedan) Callout Component Name Preliminary Procedure 1. Insert a small flat-blade at the arrow location at the lamp housing edge.
Page 491 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear License Plate Lamp Replacement (Hatchback) Callout Component Name Preliminary Procedure 1. Open and support the lift gate assembly. 2. At the left side of the lamp, insert a small flat-blade into the lamp housing edge and push slightly sideways to disengage the lamp housing from the rear applique.
Page 492 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear License Plate Lamp Bulb Replacement (Sedan) Callout Component Name Preliminary Procedure Remove the rear license plate lamp housing. Refer to Rear License Plate Lamp Replacement...
Page 493 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear License Plate Lamp Bulb Replacement (Hatchback) Callout Component Name Preliminary Procedure Remove the rear license plate lamp housing. Refer to Rear License Plate Lamp Replacement...
Page 494 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Tail Lamp Replacement (Sedan) Callout Component Name Preliminary Procedure Open and secure the rear compartment lid. Tail Lamp Bolt/Screw (Qty: 2) Caution: Refer to...
Page 495 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Tail Lamp Replacement (Hatchback) Callout Component Name Preliminary Procedure Open and support the liftgate assembly. Tail Lamp Bolt/Screw (Qty: 2) Caution: Refer to Fastener Caution Tighten 2.5N·m (22 lb in)
Page 496 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Stop and Turn Signal Lamp Bulb Replacement (Sedan) Callout Component Name Preliminary Procedure Remove the tail lamp assembly. Refer to Tail Lamp Replacement Tail Lamp Socket Procedure Rotate the lamp socket counter-clockwise and remove the socket from the lamp housing.
Page 497 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Stop and Turn Signal Lamp Bulb Replacement (Hatchback) Callout Component Name Preliminary Procedure Remove the tail lamp assembly. Refer to Tail Lamp Replacement Tail Lamp Socket (Qty: 3) Procedure Rotate the lamp socket counter-clockwise and remove the socket from the lamp housing.
Page 498 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear Compartment Courtesy Lamp Replacement (Hatchback) Callout Component Name Rear Compartment Courtesy Lamp Assembly Procedure 1. Use the appropriate trim tool in order to release the lamp assembly from the rear quarter trim panel.
Page 499 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Rear Compartment Courtesy Lamp Replacement (Sedan) Callout Component Name Rear Compartment Courtesy Lamp Assembly Procedure 1. Use the appropriate trim tool in order to release the lamp assembly from the rear quarter trim panel.
Page 500 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Exterior Lighting Systems Description and Operation Headlamps The headlamps are controlled by the multifunction lever located on the left side of the steering column. The headlamps will only come on with the Ignition switch in the RUN position.
Page 501 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Lighting Interior Lighting Systems Description and Operation Interior Courtesy Lamp The courtesy lamp is located on the headliner just behind the front seats. The lamp switch has 3 positions. If the switch is left in the center position, the lamp will go ON whenever a door is opened and go OFF when it is closed.
Page 502 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Outside Rearview Mirror Motor Replacement Specifications Outside Rearview Mirror Replacement (Power) Outside Rearview Mirror Glass Replacement Outside Rearview Mirror Replacement (Manual) Outside Rearview Mirror Housing Replacement...
Page 503 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Fastener Tightening Specifications Specification Application Metric English 2 N·m 18 lb in Inside Rearview Mirror Fastener Outside Rearview Mirror Motor Fastener 5 N·m 44 lb in 10 N·m...
Page 504 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Adhesives, Fluids, Lubricants, and Sealers Application Type of Material GM Part Number Inside Mirror Adhesive Kit Adhesive Refer to Electronic Parts Catalog © 2011 General Motors. All rights reserved.
Page 505 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Replacement (Power) Callout Component Name Preliminary Procedures 1. Remove the front side door upper front trim panel. Refer to Front Side Door Upper Front Trim Panel Replacement 2.
Page 506 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Replacement (Manual) Callout Component Name Preliminary Procedures 1. Remove the front side door upper front trim panel. Refer to Front Side Door Upper Front Trim Panel Replacement 2.
Page 507 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Housing Rear Cover Replacement Callout Component Name Preliminary Procedures Remove the outside rearview mirror glass. Refer to Outside Rearview Mirror Glass Replacement Outside Rearview Mirror Housing Cover 1.
Page 508 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Remote Control Rearview Mirror Switch Replacement Callout Component Name Preliminary Procedure Remove the front side door widow switch bezel. Refer to Front Side Door Window Switch Bezel Replacement...
Page 509 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Motor Replacement Callout Component Name Outside Rearview Mirror Glass Procedure Remove the outside rearview mirror glass. Refer to Outside Rearview Mirror Glass Replacement...
Page 510 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Glass Replacement Removal Procedure Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
Page 511 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Rearview Mirror Housing Replacement Callout Component Name Preliminary Procedures 1. Remove the outside rearview housing cover. Refer to Outside Rearview Mirror Housing Rear Cover Replacement 2.
Page 512 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Inside Rearview Mirror Replacement Callout Component Name Inside Rearview Mirror Cover Procedure 1. Remove the wire harness cover, sliding the cover upward releasing the cover from the support.
Page 513 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Mirrors Outside Mirror Description and Operation Power Mirror System Components The power mirror system consists of the following components: • Outside rearview mirror switch • Mirror selector switch •...
Page 514 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Specifications Front Side Door Outside Handle Rod Adjustment Front Side Door Inside Handle Cable Replacement Front Side Door Outside Handle Rod Replacement Rear Side Door Inside Handle Cable Replacement...
Page 515 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Fastener Tightening Specifications Specification Application Metric English 5 N·m 44 lb in Front Side Door Lock Cylinder Clamp Screw Front Side Door Lock Screws 10 N·m...
Page 516 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Inside Handle Cable Replacement Callout Component Name Preliminary Procedure Remove the front side door latch. Refer to Front Side Door Latch Replacement Front Side Door Inside Handle Cable Cover Open the inside handle cable cover to access the release.
Page 517 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Inside Handle Cable Replacement Callout Component Name Preliminary Procedure Remove the rear side door latch. Refer to Rear Side Door Latch Replacement Rear Side Door Inside Handle Cable Cover Open the inside handle cable cover to access the release.
Page 518 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Lock Cylinder Replacement Callout Component Name Front Side Door Lock Cylinder Screw Access Plug Use the appropriate tool, remove the plug.
Page 519 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Door Lock Cylinder Replacement Callout Component Name Rear Side Door Lock Cylinder Opening Cover Screw Access Plug Use a flat-bladed tool to remove the cover.
Page 520 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Outside Handle Replacement Callout Component Name Front Side Door Outside Handle Procedure 1. Remove the front side door water deflector.
Page 521 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Outside Handle Bracket Replacement Callout Component Name Preliminary Procedures 1. Remove the front side door trim panel. Refer to Front Side Door Trim Replacement 2.
Page 522 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Bracket Replacement Callout Component Name Preliminary Procedures 1. Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement 2.
Page 523 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Liftgate Latch Replacement Callout Component Name Preliminary Procedures 1. Remove the liftgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement 2. Remove the liftgate latch cover.
Page 524 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Replacement (Sedan) Callout Component Name Preliminary Procedures Remove the rear side door lock cylinder opening cover. Refer to...
Page 525 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Replacement (Hatchback) Callout Component Name Preliminary Procedures Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 526 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Latch Replacement Callout Component Name Preliminary Procedure Remove the front side door trim panel. Refer to Front Side Door Trim Replacement...
Page 527 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Compartment Lid Latch Replacement Callout Component Name Preliminary Procedure Remove the rear compartment lid inner panel trim. Refer to Rear Compartment Lid Inner Panel Trim Replacement...
Page 528 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Latch Replacement Callout Component Name Preliminary Procedure Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 529 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Lock Cylinder Opening Cover Replacement Callout Component Name Front Side Door Lock Cylinder Opening Cover Procedure 1. Remove the front side door lock cylinder, Do Not remove the outside door handle. Refer to...
Page 530 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Lock Cylinder Opening Cover Replacement Callout Component Name Rear Side Door Lock Cylinder Opening Cover Procedure 1. Remove the rear side door lock cylinder, Do Not remove the outside door handle. Refer to...
Page 531 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Locking Rod Replacement Callout Component Name Preliminary Procedure 1. Remove the front side door window rear guide. Refer to Front Side Door Window Rear Guide Replacement 2.
Page 532 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Lock Cylinder Rod Replacement Callout Component Name Preliminary Procedure 1. Remove the rear side door window rear guide. Refer to Rear Side Door Window Rear Guide Replacement 2.
Page 533 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Outside Handle Rod Adjustment Callout Component Name Preliminary Procedures Remove the front side door trim panel. Refer to Front Side Door Trim Replacement...
Page 534 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Outside Handle Rod Replacement Callout Component Name Preliminary Procedure Remove the front side door outside handle bracket. Refer to Front Side Door Outside Handle Bracket Replacement...
Page 535 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Locking Rod Replacement (Sedan) Callout Component Name Preliminary Procedure Remove the rear side door lock. Refer to Rear Side Door Latch Replacement .
Page 536 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Locking Rod Replacement (Hatchback) Callout Component Name Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 537 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Locking Rod Bellcrank Replacement Callout Component Name Preliminary Procedures Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 538 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Rod Adjustment Callout Component Name Preliminary Procedures Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 539 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Rod Replacement (Sedan) Callout Component Name Preliminary Procedures Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 540 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Outside Handle Rod Replacement (Hatchback) Callout Component Name Preliminary Procedures Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement...
Page 541 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Ensure the door is properly aligned within the door opening before proceeding with the striker adjustment.
Page 542 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Front Side Door Lock Striker Replacement Callout Component Name Front Door Lock Striker Screws (Qty: 2) Caution: Refer to Fastener Caution Tighten 22 N·m (16 lb ft)
Page 543 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Liftgate Latch Striker Replacement Callout Component Name Preliminary Procedure Remove the rear compartment sill trim plate. Refer to Rear Compartment Sill Trim Plate Replacement...
Page 544 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Compartment Lid Latch Striker Replacement Callout Component Name Preliminary Procedure Remove the rear compartment sill trim plate. Refer to Rear Compartment Sill Trim Plate Replacement...
Page 545 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Ensure the door is properly aligned within the door opening before proceeding with the striker adjustment.
Page 546 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Rear Side Door Lock Striker Replacement Callout Component Name Rear Side Door Lock Striker Screw (Qty: 2) Caution: Refer to Fastener Caution Tighten 22 N·m (16 lb ft)
Page 547 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Liftgate Release Switch Replacement Callout Component Name Preliminary Procedure Remove the liftgate side applique. Refer to Liftgate Side Applique Replacement Liftgate Release Switch Procedure Depress the retainers on the back side of the switch and push the switch out from the applique.
Page 548 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Door Lock Switch Replacement Callout Component Name Preliminary Procedure Remove the heater and air conditioning control. Refer to Heater and Air Conditioning Control Replacement...
Page 549 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Door Ajar Indicator Description and Operation Power Door Locks Description and Operation Fuel Fill Door Description and Operation Trunk/Liftgate Ajar Indicator Description and Operation Luggage Compartment Description and Operation ©...
Page 550 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Door Ajar Indicator Description and Operation Door Ajar Indicator System Components The door ajar indicator system consists of the following components: • Body control module (BCM) •...
Page 551 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Fuel Fill Door Description and Operation Fuel Door Release System Components • Body control module (BCM) • Fuel door release actuator The locking and unlocking of the fuel door is a function of the power door lock system. The fuel door release actuator is supplied by the door lock control circuit and the driver door unlock control circuit.
Page 552 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Luggage Compartment Description and Operation Luggage Compartment Release System Components • Body control module (BCM) • Exterior rear compartment lid release switch (Sedan) •...
Page 553 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Power Door Locks Description and Operation Door Lock System Components The power door lock system consists of the following components: • Door lock switch, located in the instrument panel center stack •...
Page 554 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Vehicle Access Trunk/Liftgate Ajar Indicator Description and Operation Door Ajar Indicator The body control module (BCM) monitors the voltage level of the liftgate ajar signal circuit which is normally at the system voltage when the liftgate or trunk lid is closed.
Page 555 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Index Windshield Wiper Blade Replacement Specifications Windshield Wiper and Washer Switch Replacement Rear Window Wiper Blade Replacement Windshield Washer Nozzle Hose Replacement Windshield Wiper Motor Replacement...
Page 556 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Fastener Tightening Specifications Specification Application Metric English 2.5 N·m 22 lb in Air Inlet Grille Panel Screw 10 N·m 89 lb in...
Page 557 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Wiper and Washer Switch Replacement Callout Component Name Preliminary Procedure Remove the upper trim cover and the lower trim cover from the steering column. Refer to...
Page 558 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Nozzle Hose Replacement Callout Component Name Preliminary Procedure Remove the hood insulator. Refer to Hood Insulator Replacement Windshield Washer Nozzle Hose Procedure 1.
Page 559 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Nozzle Replacement Callout Component Name Preliminary Procedure Remove the hood insulator. Refer to Hood Insulator Replacement Windshield Washer Nozzle Procedure 1.
Page 560 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Rear Window Washer Nozzle Replacement Callout Component Name Preliminary Procedure Remove the inside high mount stop lamp. Refer to High Mount Stop Lamp Replacement...
Page 561 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Solvent Container Hose Replacement Callout Component Name Preliminary Procedure Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement...
Page 562 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Solvent Container Filler Tube Replacement Callout Component Name Preliminary Procedure 1. Open and support the hood assembly. 2. Grasp the top portion of the windshield washer container filler tube and rotate the tube 1/8 turn counterclockwise to unlock from the windshield washer solvent container lock tabs.
Page 563 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Solvent Container Replacement Callout Component Name Preliminary Procedures 1. Remove the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement 2.
Page 564 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Washer Pump Replacement Callout Component Name Preliminary Procedure Remove the front left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement...
Page 565 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Air Inlet Grille Panel Replacement Callout Component Name Preliminary Procedure 1. Remove both wiper arm assemblies. Refer to Windshield Wiper Arm Replacement 2.
Page 566 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Wiper Arm Replacement Callout Component Name Preliminary Procedure Open and support the hood assembly. Windshield Wiper Arm Nut Cap Use a small flat-bladed tool in order to release the finish cap from the wiper arm assembly.
Page 567 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Rear Window Wiper Arm Replacement Callout Component Name Preliminary Procedure Using a small flat-bladed tool, release the locking tabs and lift the end of the wiper arm nut cover in order to access and remove the rear wiper arm nut.
Page 568 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Wiper Blade Replacement Callout Component Name Preliminary Procedure 1. Service Up and hold the wiper arm off the windshield when performing the wiper blade replacement.
Page 569 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Rear Window Wiper Blade Replacement Callout Component Name Preliminary Procedure Lift the rear window wiper arm off the rear window and release the rear window wiper blade from the rear window wiper arm.
Page 570 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Wiper Motor Replacement Callout Component Name Preliminary Procedure Remove the wiper system module. Refer to Windshield Wiper System Module Replacement Windshield Wiper Motor Bracket Screw (Qty: 2)
Page 571 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Rear Window Wiper Motor Replacement (Hatchback) Callout Component Name Preliminary Procedure 1. Open and support the liftgate assembly. 2. Remove the rear window wiper arm assembly. Refer to Rear Window Wiper Arm Replacement 3.
Page 572 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Wiper System Module Replacement Callout Component Name Preliminary Procedures 1. Open and support the hood assembly. 2. Remove the air inlet grille panel. Refer to...
Page 573 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Rear Window Wiper Motor Grommet Replacement Callout Component Name Preliminary Procedure Remove the rear window wiper motor. Refer to Rear Window Wiper Motor Replacement...
Page 574 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield Glass Cleaning Clean the windshield with windshield cleaner, or equivalent. The cleaner should not harm the paint finish or scratch the glass. The glass is clean when the water no longer beads, but sheets across the entire glass surface.
Page 575 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Wiper Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water.
Page 576 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Wiper Chatter Repair Some vehicles may exhibit a condition where the windshield wipers chatter and/or wipe unevenly. Several items may contribute to this condition.
Page 577 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Wiper/Washer System Description and Operation Wiper/Washer System Components The wiper/washer system consists of the following electrical components: • Windshield Wiper Relay • Windshield Wiper Speed Control Relay •...
Page 578 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Windshield wiper intermittent operation is a low speed wiper motor function with a variable delay interval between the wiper motor cycles. The duration of the delay is controlled by the front wiper control switches intermittent 1 thru intermittent 5 settings. The wiper operation is as follows 1.
Page 579 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX BODY SYSTEMS Wipers and Washers Special Tools Illustration Tool Number/Description BO-49385 BO-6626 KM-6626 S0201912 Wiper Arm Puller © 2011 General Motors. All rights reserved.
Page 580: Roof
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Index Specifications Sunroof Sunshade Replacement Sunroof Air Deflector Replacement Sunroof Window Seal Replacement Sunroof Housing Front Drain Hose Replacement Sunroof Switch Replacement Sunroof Housing Rear Drain Hose Replacement...
Page 581 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Fastener Tightening Specifications Specification Application Metric English 9 N·m 80 lb in Sunroof Module Bolts Sunshade Motor/Actuator Screws 6 N·m 53 lb in 5 N·m...
Page 582 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Air Deflector Replacement Callout Component Name Preliminary Procedure Remove the sunroof module. Refer to Sunroof Module Assembly Replacement Sunroof Air Deflector Cycle the sunroof window to the full rearward position.
Page 583 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Housing Front Drain Hose Replacement Callout Component Name Preliminary Procedure It is only necessary to lower the headliner. Only do those steps in the headliner replacement procedure that will lower the headliner enough to gain access to the part.
Page 584 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Housing Rear Drain Hose Replacement Callout Component Name Preliminary Procedures 1. It is only necessary to lower the headliner. Only do those steps in the headliner replacement procedure that will lower the headliner enough to gain access to the part.
Page 585 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Module Assembly Replacement Callout Component Name Preliminary Procedures 1. Remove the sunroof window. Refer to Sunroof Window Replacement 2. Remove the headliner. Refer to Headlining Trim Panel Replacement 3.
Page 586 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Motor/Actuator Initialization/Teach Process Note: If the sunroof motor is new, cycle the sunroof seven (7) times to teach the motor/actuator initialization process. Perform the initialization/teach procedure on a reinstall motor or a new motor.
Page 587 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Actuator Motor Replacement Callout Component Name Preliminary Procedure Remove the dome lamp bezel. Refer to Dome Lamp Bezel Replacement Sunroof Actuator Motor Screw (Qty: 3)
Page 588 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Sunshade Replacement Callout Component Name Preliminary Procedures Remove the sunroof module. Refer to Sunroof Module Assembly Replacement Sunroof Sunshade Stops (Qty :2) Sunroof Sunshade Procedure 1.
Page 589 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Window Seal Replacement Removal Procedure 1. Remove the sunroof window panel. Refer to Sunroof Window Replacement 2. Remove the seal from the window panel frame by pulling the seal away at one point and continuing around the perimeter of the frame.
Page 590 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Switch Replacement Callout Component Name Preliminary Procedure Remove the dome lamp bezel. Refer to Dome Lamp Bezel Replacement Sunroof Switch Procedure 1. Disconnect electrical connector.
Page 591 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Window Height and Opening Fit Adjustment Note: Correct adjustment cannot be achieved if the sunroof window is closed from vent position. 1. Cycle the sunroof window from full open to closed position.
Page 592 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Window Replacement Callout Component Name Sunroof Window Bolt (Qty: 4) Caution: Refer to Fastener Caution Tighten 5 N·m (44 lb in) Sunroof Window Procedure 1.
Page 593 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX ROOF Roof Sunroof Description and Operation (Tilt and Slide) The Tilt/Slide sunroof consists of a moving glass panel and a manual sunshade. In the Tilt/Slide sunroof system the rear of the glass tilts up above the roof line for venting, and slides between the headliner and the roof panel to open fully.
Page 594: Seatbelts
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Index Specifications Rear Seat Center Shoulder Belt Replacement (Sedan) Repairs and Inspections Required After a Collision Shoulder Belt Replacement - Rear (Sedan) Seat Belt Latch Stop Installation...
Page 595 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Fastener Tightening Specifications Specification Application Metric English 45 N·m 33 lb ft Driver or Passenger Seat Belt Buckle Fastener Driver or Passenger Seat Shoulder Belt Fastener 45 N·m...
Page 596 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Repairs and Inspections Required After a Collision Warning: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: •...
Page 597 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Seat Belt Latch Stop Installation Callout Component Name Preliminary Procedure 1. Locate the hole in the seat belt webbing where the original seat belt stop button was located.
Page 598 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Front Seat Belt Buckle Replacement Callout Component Name Preliminary Procedures Remove the front seat. Refer to Driver or Passenger Seat Replacement Driver or Passenger Seat Belt Buckle Fastener...
Page 599 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Rear Seat Belt Buckle Replacement Callout Component Name Preliminary Procedure Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement Rear Seat Belt Buckle Fastener (Qty: 2)
Page 600 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Rear Seat Center Shoulder Belt Replacement (Sedan) Callout Component Name Preliminary Procedures Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement...
Page 601 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Shoulder Belt Replacement - Rear (Sedan) Callout Component Name Preliminary Procedure Remove the rear window panel trim. Refer to Rear Window Panel Trim Replacement...
Page 602 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Front Seat Belt Guide Adjuster Replacement (with AHU) Callout Component Name Preliminary Procedures Remove the center pillar upper trim panel. Refer to Center Pillar Upper Trim Panel Replacement...
Page 603 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts Seat Belt System Description and Operation Restraint System Note: If the vehicle has been in a collision, refer to Repairs and Inspections Required After a Collision The vehicle has front and rear seat belts that are the primary means of occupant restraint.
Page 604 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEAT BELTS Seat Belts - The rear seat belt indicator in the Driver Information Center will illuminate for 35 seconds. • When the ignition switch is turned ON, a rear seat belt is not buckled for the duration of the ignition cycle, the rear doors are closed and the speed exceeds 10 kph (6.5 mph) the following events will occur:...
Page 605 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Index Specifications Driver or Passenger Seat Recliner Handle Replacement (2 Way Uplevel) Driver or Passenger Seat Replacement Child Seat Back Cushion Cover Replacement Front Seat Outer Recliner Upper Finish Cover Replacement...
Page 606: Seats
BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Fastener Tightening Specifications Specification Application Metric English 40 N·m 30 lb ft Front Seat Mounting Bolt 45 N·m 33 lb ft Front Seat Armrest Mounting Bolt Front Seat Cushion Frame Bolt 22 N·m...
Page 607 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Replacement Callout Component Name Warning: Refer to SIR Warning Preliminary Procedures 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 608 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Outer Recliner Upper Finish Cover Replacement Callout Component Name Front Seat Outer Recliner Upper Finish Cover Caution: Do not twist the cover during removal. Twisting the cover may cause the component to break.
Page 609 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Riser Finish Cover Replacement Callout Component Name Front Seat Riser Finish Cover Caution: Do not twist the cover during removal. Twisting the cover may cause the component to break.
Page 610 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Adjuster Handle Replacement (4 Way Standard) Callout Component Name Preliminary Procedure Remove the front seat outer recliner upper finish cover. Refer to...
Page 611 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Adjuster Handle Replacement (4 Way Uplevel) Callout Component Name Front Seat Adjuster Handle Cover Procedure Use a flat-bladed tool to push inward on the three tabs to release the handle cover from the handle assembly.
Page 612 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Storage Tray Replacement Callout Component Name Front Seat Storage Tray Procedure Carefully disengage the tray by pulling forward near the bottom of the tray.
Page 613 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Armrest Replacement Callout Component Name Front Seat Armrest Cover Zipper Procedure Open the zipper to access the front seat armrest mounting bolt and to remove the armrest cover...
Page 614 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Head Restraint Replacement Callout Component Name Driver or Passenger Seat Head Restraint Procedure 1. Raise the headrest to the full upward position.
Page 615 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Head Restraint Guide Replacement Callout Component Name Preliminary Procedure Remove the seat head restraint. Refer to Driver or Passenger Seat Head Restraint Replacement...
Page 616 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Belt Anchor Plate Tensioner Cover Replacement (2 Way) Callout Component Name Driver or Passenger Seat Belt Tensioner Cover Procedure Remove the tensioner cover by pushing downward on the rear of the cover while applying light pressure to the front of the cover.
Page 617 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Belt Anchor Plate Tensioner Cover Replacement (4 Way) Callout Component Name Driver or Passenger Seat Belt Tensioner Cover Procedure Remove the tensioner cover by pushing downward on the rear and center of the cover. Then applying light pressure to the front of the cover, push the cover rearward to remove it from the seat frame.
Page 618 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Cushion Frame Replacement Callout Component Name Preliminary Procedures 1. Remove the driver or passenger seat. Refer to Driver or Passenger Seat Replacement 2.
Page 619 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Outer Trim Panel Replacement (4 Way Standard) Callout Component Name Preliminary Procedures 1. Remove the front seat outer recliner upper finish cover. Refer to...
Page 620 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Outer Trim Panel Replacement (4 Way Uplevel) Callout Component Name Preliminary Procedures 1. Remove the front seat outer recliner upper finish cover. Refer to...
Page 621 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Outer Trim Panel Replacement (2 Way Uplevel) Callout Component Name Preliminary Procedures 1. Remove the driver or passenger seat. Refer to Driver or Passenger Seat Replacement 2.
Page 622 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Outer Trim Panel Replacement (2 Way Standard) Callout Component Name Preliminary Procedures 1. Remove the driver or passenger seat. Refer to Driver or Passenger Seat Replacement 2.
Page 623 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Inner Trim Panel Replacement Callout Component Name Driver or Passenger Seat Inner Recliner Finish Cover Cap Procedure Use a flat-bladed tool to release the cap from the recliner cover.
Page 624 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Front Seat Cushion Cover and Pad Replacement Callout Component Name Warning: Refer to SIR Warning SIR Warning . Preliminary Procedures 1. Remove the driver or passenger seat. Refer to Driver or Passenger Seat Replacement 2.
Page 625 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Back Cushion Cover and Pad Replacement Callout Component Name Warning: Refer to SIR Warning Warning: Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal mounted seat side airbag module.
Page 626 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Back Cushion Frame Replacement Callout Component Name Preliminary Procedures 1. Remove the driver or passenger seat. Refer to Driver or Passenger Seat Replacement 2.
Page 627 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Recliner Handle Replacement (4 Way Standard) Callout Component Name Front Seat Recliner Handle Cover Cap Procedure Use a flat-bladed tool to release the handle cover from the handle assembly.
Page 628 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Driver or Passenger Seat Recliner Handle Replacement (2 Way Uplevel) Callout Component Name Front Seat Recliner Handle Cover Cap Procedure Use a flat-bladed tool to release the handle cover from the handle assembly.
Page 629 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Child Seat Back Cushion Cover Replacement Callout Component Name Child Seat Back Cushion Cover Procedure Remove the child seat bracket trim cover using a suitable flat-bladed tool.
Page 630 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Head Restraint Replacement Callout Component Name Rear Seat Head Restraint Preliminary Procedures 1. Depress the large button on the head restraint guide and raise the head restraint to the full up position.
Page 631 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Head Restraint Guide Replacement Callout Component Name Preliminary Procedure Remove the rear seat head restraint. Refer to Rear Seat Head Restraint Replacement Rear Seat Head Restraint Guide...
Page 632 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Pivot Support Replacement Callout Component Name Preliminary Procedure Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement...
Page 633 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Center Head Restraint Replacement Callout Component Name Rear Seat Center Head Restraint Procedure 1. Depress the large button on the head restraint guide and raise the head restraint to the full up position.
Page 634 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Cushion Cover and Pad Replacement Callout Component Name Preliminary Procedure Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement Rear Seat Cushion Cover Procedure 1.
Page 635 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Cushion Replacement Callout Component Name Rear Seat Cushion Replacement Preliminary Procedures 1. Release the rear seat center seat belts. 2. Lift up on the front of the seat cushion at the latch locations to disengage the cushion retainers from the floor.
Page 636 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Latch Replacement Callout Component Name Preliminary Procedures 1. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 2. Remove the rear seat back cushion cover and pad. Refer to...
Page 637 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Replacement (AN1 Fixed Bench) Callout Component Name Preliminary Procedure Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement Rear Seat Back Cushion Bolt (Qty: 3)
Page 638 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Replacement (AMA 40% w/Split Back) Callout Component Name Procedure Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement Rear Seat Back Cushion Pivot Support Procedure 1.
Page 639 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Replacement (AMA 60% w/Split Back) Callout Component Name Procedure Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement Rear Seat Back Cushion Pivot Support Procedure 1.
Page 640 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Replacement (AM7 Non Split Folding) Callout Component Name Rear Seat Back Cushion Pivot Support Procedure 1. Remove the rear outboard shoulder belts from the shoulder belt bezel and position it out of the way, if equipped.
Page 641 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Shoulder Belt Guide Opening Bezel Replacement Callout Component Name Rear Seat Shoulder Belt Opening Bezel Procedure Push inward and upward from the front of the bezel to release from the seat back.
Page 642 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Panel Replacement Callout Component Name Preliminary Procedure 1. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 2.
Page 643 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Cover and Pad Replacement (AMA 40% w/Split Back) Callout Component Name Preliminary Procedures 1. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 2.
Page 644 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Cover and Pad Replacement (AMA 60% w/Split Back) Callout Component Name Preliminary Procedure 1. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 2.
Page 645 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Cover and Pad Replacement (AN1 Fixed Bench) Callout Component Name Preliminary Procedure Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement...
Page 646 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Cover and Pad Replacement (AM7 Non Split Folding) Callout Component Name Preliminary Procedures 1. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 2.
Page 647 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Hinge Replacement Callout Component Name Preliminary Procedure 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement 2. Remove the rear seat back cushion. Refer to Rear Seat Back Cushion Replacement 3.
Page 648 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Rear Seat Back Cushion Latch Release Knob Bezel Replacement Callout Component Name Rear Seat Back Cushion Latch Release Handle Bezel Procedure Use a flat-bladed tool to tilt the rear of the handle upward, then lifting and pulling the bezel rearward to disengage the front hooks.
Page 649 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SEATS Seats Manual Seats Description Note: Do not attempt to change the designed seat position by altering the designed seat adjuster-to-floor pan anchor provisions or the seat adjuster-to-seat frame anchor provisions. Changing the seat position could affect the performance of the seat system.
Page 650 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Index Specifications Driver or Passenger Seat Side Inflatable Restraint Module Replacement Component Locator Inflatable Restraint Instrument Panel Compartment Module Disable Switch SIR Disabling and Enabling Replacement...
Page 651 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Fastener Tightening Specifications Specification Application Metric English 7.5 N·m 66 lb in Driver or Passenger Seat Belt Tensioner Cover Fastener 45 N·m 33 lb ft...
Page 652 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Component Locator Center Front Impact Sensor—Located under the hood at the center of the vehicle Passenger Instrument Panel Air Bag—Located at the top right under the instrument panel Right Roof Rail Air Bag—Located under the...
Page 653 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle.
Page 654 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints • Passenger presence module and/or occupant sensor Disabling Procedure – Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
Page 655: Restraints 08
BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints SIR Service Precautions General Service Instructions Warning: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling .
Page 656 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Front End Inflatable Restraint Discriminating Sensor Replacement Callout Component Name Warning: Refer to SIR Warning Warning: Refer to SIR Inflator Module Handling and Storage Warning Warning: Following the deployment of a side impact air bag, inspect the following parts for damage.
Page 657 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Inflatable Restraint Side Impact Sensor Replacement Callout Component Name Warning: Refer to SIR Warning Warning: Refer to SIR Inflator Module Handling and Storage Warning Warning: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: •...
Page 658 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Inflatable Restraint Sensing and Diagnostic Module Replacement Callout Component Name Warning: Refer to SIR Warning Warning: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle.
Page 659 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Steering Wheel Inflatable Restraint Module Replacement Removal Procedure Warning: Refer to SIR Inflator Module Handling and Storage Warning Warning: Refer to SIR Warning 1. Disable the SIR system. Refer to SIR Disabling and Enabling 2.
Page 660 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints 2. Align the steering wheel module fasteners to the steering column fastener holes. 3. Push the steering wheel module (1) firmly into the steering column in order to engage the fasteners.
Page 661 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Steering Wheel Airbag Coil Replacement Callout Component Name Preliminary Procedures 1. Remove the steering wheel. Refer to Steering Wheel Replacement 2. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement 3.
Page 662 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction.
Page 663 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Instrument Panel Inflatable Restraint Module Replacement Callout Component Name Warning: Refer to SIR Inflator Module Handling and Storage Warning Warning: Refer to SIR Warning Preliminary Procedure 1.
Page 664 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Driver or Passenger Seat Side Inflatable Restraint Module Replacement Callout Component Name Warning: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: •...
Page 665 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Inflatable Restraint Instrument Panel Compartment Module Disable Switch Replacement Callout Component Name Warning: Refer to SIR Warning Preliminary Procedure 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling 2.
Page 666 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Roof Side Rail Inflatable Restraint Module Replacement (AYC) Callout Component Name Warning: In order to prevent SIR deployment, personal injury, or unnecessary SIR system repairs, do not strike the door or the door pillar in the area of the side impact sensor (SIS).
Page 667 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Front Seat Belt Anchor Plate Tensioner Replacement Callout Component Name Warning: Refer to SIR Warning Warning: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste.
Page 668 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Procedure Remove the seat belt with latch from front seat belt tensioner. Driver or Passenger Seat Belt Tensioner Fastener Tighten 45 N·m (33 lb ft)
Page 669 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Driver or Passenger Seat Shoulder Belt Replacement (with A69) Callout Component Name Warning: Refer to SIR Warning Warning: Refer to SIR Inflator Module Handling and Storage Warning...
Page 670 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Driver or Passenger Shoulder Belt Retractor Fastener Tighten 45 N·m (33 lb ft) Driver or Passenger Seat Belt Push On Retainer Procedure Use a flat-bladed tool to remove locking pin in retainer.
Page 671 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Driver or Passenger Seat Shoulder Belt Replacement (without A69) Callout Component Name Warning: Refer to SIR Warning Warning: Refer to SIR Seatbelt Pretensioner Handling Warning Warning: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste.
Page 672 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Repairs and Inspections Required After a Collision Accident With or Without Air Bag Deployment – Component Inspections Warning: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration.
Page 673 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Impact Sensor Replacement Guidelines The impact sensor replacement policy requires replacing sensors in the area of the accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision.
Page 674 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Inflatable Restraint Module Handling and Scrapping Air Bag Module Deployment – Inside of Vehicle Warning: When deploying an airbag inside the vehicle, make sure the vehicle doors are closed and the side windows are fully open.
Page 675 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints 3. Deploy the air bag module. 4. Perform the Air Bag Module Deployment procedure as follows. 5. Cut the yellow wires to the air bag module/pretensioner.
Page 676 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Pretensioner Handling and Scrapping Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) pretensioner.
Page 677 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. 5. When carrying a pretensioner to the deployment area keep the open end of pretensioner pointed away from the body.
Page 678 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Object Number: 483848 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the pretensioner (1) to the adapter (2) on the deployment harness (3).
Page 679 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Note: When the seat belt pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner.
Page 680 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints SIR System Description and Operation SIR System Overview The supplemental inflatable restraint (SIR) system supplements the protection offered by the seat belts. The SIR system contains an inflatable restraint sensing and diagnostic module (SDM), air bags, seat belt pretensioners (anchor and retractor), and impact sensors.
Page 681 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints off. The vehicle has a PASSENGER AIR BAG ON/OFF indicator to tell the customer when the passenger air bag is on or off based on the disable switch position.
Page 682 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX RESTRAINTS Restraints Special Tools Illustration Tool Number/ Description EL 38826 J 38826 KM 799-3 SIR Deployment Harness EL 39401-B J 39401-B SIR Deployment Fixture © 2011 General Motors. All rights reserved.
Page 683: Steering
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Index Specifications Steering Wheel Horn Cap Replacement Intermediate Steering Shaft Replacement (NJ1) Steering Wheel Replacement Intermediate Steering Shaft Replacement (N40) Steering Column Replacement (NJ1) Steering Column Upper Trim Cover Replacement...
Page 684 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Fastener Tightening Specifications Specification Application Metric English 49 N·m 36 lb ft Intermediate Steering Shaft Lower Bolt 49 N·m 36 lb ft Intermediate Steering Shaft Upper Bolt Steering Column Lower Support Bracket Bolts 22 N·m...
Page 685 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Intermediate Steering Shaft Replacement (NJ1) Callout Component Name Preliminary Procedure Remove the steering column and the intermediate steering shaft as an assembly. Refer to Steering Column Replacement...
Page 686 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Intermediate Steering Shaft Replacement (N40) Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system.
Page 687 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering 11. Disconnect the intermediate steering shaft from the steering column shaft. 12. Remove the intermediate steering shaft from the vehicle. Installation Procedure 1. If you are replacing the intermediate steering shaft, copy the match marks from the old shaft to the new shaft.
Page 688 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Column Upper Trim Cover Replacement Callout Component Name Instrument Panel Steering Column Upper Trim Cover Fasteners (Qty: 2) Caution: Refer to Fastener Caution Procedure Turn the steering wheel to the right and to the left in order to gain access to the fasteners.
Page 689 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Column Lower Trim Cover Replacement Callout Component Name Preliminary Procedure Remove the instrument panel steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement...
Page 690 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Turn Signal Switch Bracket Replacement Callout Component Name Preliminary Procedure Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Airbag Coil Replacement...
Page 691 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Turn Signal Multifunction Switch Replacement Callout Component Name Preliminary Procedure Remove the upper trim cover and the lower trim cover from the steering column. Refer to...
Page 692 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Wheel Horn Cap Replacement Callout Component Name Steering Wheel Horn Cap Procedure Use flat bladed plastic tool to gently pry horn cap from steering wheel.
Page 693 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Wheel Replacement Callout Component Name Preliminary Procedure 1. If equipped with the supplemental inflatable restraint system, remove the steering wheel module. Refer to Steering Wheel Inflatable Restraint Module Replacement .
Page 694 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Column Replacement (NJ1) Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system.
Page 695 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering 10. Remove the 2 steering column lower support bracket bolts (1, 2). 11. Remove the 2 steering column upper support bracket nuts (1, 2). Caution: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on the end could collapse the steering shaft or loosen the plastic injections, which maintain column rigidity.
Page 696 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Installation Procedure 1. If you are replacing the steering column or the intermediate steering shaft, copy the match marks from the old parts to the new parts.
Page 697 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering 5. Install, but do not tighten, the 2 steering column lower support bracket bolts (1, 2). Caution: Refer to Fastener Caution 6. Install the intermediate steering shaft lower bolt (2) and tighten to 49 N·m (36 lb ft).
Page 698 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Column Replacement (N40) Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system.
Page 699 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering 10. Remove the 2 steering column upper support bracket nuts (1, 2). Caution: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on the end could collapse the steering shaft or loosen the plastic injections, which maintain column rigidity.
Page 700 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Warning: In order to ensure the intended function of the steering column in a vehicle during a crash and in order to avoid personal injury to the driver, perform the following: •...
Page 701 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Angle Sensor Replacement Callout Component Name Preliminary Procedure Remove the steering wheel airbag coil. Refer to Steering Wheel Airbag Coil Replacement Steering Angle Sensor Procedure 1.
Page 702 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX STEERING Steering Steering Wheel and Column Description and Operation Warning: Refer to Safety Glasses Warning Warning: In order to ensure the intended function of the steering column in a vehicle during a crash and in order to avoid personal injury to the driver, perform the following: •...
Page 703: Suspension
BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Index Front Suspension Tires and Wheels Rear Suspension © 2011 General Motors. All rights reserved.
Page 704 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Specifications Strut and Shock Absorber Inspection (Strut) Stabilizer Shaft Replacement Strut Assembly Removal and Installation Stabilizer Shaft Link Replacement Shock Absorber Disposal Front Wheel Bearing and Hub Replacement...
Page 705 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Fastener Tightening Specifications Specification Application Metric English 9 N·m 80 lb in Front Brake Dust Shield Front Lower Control Arm Ball Joint Nut 30 N·m 22 lb ft •...
Page 706 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Stabilizer Shaft Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation 3.
Page 707 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 7. Remove the stabilizer shaft insulator bolts (1). Note: It maybe necessary to maneuver the front stabilizer shaft in such away as to remove it from the front suspension frame.
Page 708 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Installation Procedure 1. Position the front stabilizer shaft (1) in the front suspension frame. Caution: Refer to Fastener Caution 2. Install the front stabilizer shaft insulator bolts and tighten to 22 N·m (16 lb ft).
Page 709 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 5. Install the stabilizer shaft link to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement 6. Install the exhaust pipe insulators (1). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation 8.
Page 710 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Stabilizer Shaft Link Replacement Callout Component Name Preliminary Procedure 1. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle 2. Remove the tire and wheel assembly. Refer to...
Page 711 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Front Wheel Bearing and Hub Replacement Special Tools CH-50559 Wheel Hub/Bearing Remover Kit For equivalent regional tools, refer to Special Tools Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2.
Page 712 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 7. Using the appropriate tool, remove the retaining ring (1) from the steering knuckle. 8. Position the CH-50559–1 wheel hub/bearing removal/installation bridge assembly (1) and the CH–50559–3 wheel bearing removal adapter (2) on the steering knuckle.
Page 713 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 2. Position the CH-50559–4 (1) wheel hub/bearing installation adapter and the appropriate extension to the inside of the bearing and position the CH-50559–2 wheel hub removal/installation adapter and the appropriate extension on the wheel hub.
Page 714 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Lower Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Note: DO NOT reuse the ball joint nut.
Page 715 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Note: DO NOT reuse the rear lower control arm nut. The nut is NOT reusable. 5. Remove the front lower control arm rear nut (1) and bolt (2).
Page 716 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Note: Install the front lower control arm rear bolt and nut hand tight to hold the lower control arm in place while tightening the front lower control arm bolt.
Page 717 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 4. Install the NEW lower ball joint bolt (2) and nut (1) and tighten the to nut (1): • First Pass: 30 N·m (22 lb ft) •...
Page 718 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Steering Linkage Outer Tie Rod Replacement Callout Component Name Preliminary Procedures 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2.
Page 719 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Procedure 1. Use paint in order to place match marks on the steering linkage inner tie rod nut and on the steering linkage inner tie rod.
Page 720 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Strut and Shock Absorber Inspection (Strut) Note: The strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure.
Page 721 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Strut Assembly Removal and Installation Special Tools CH 35669 Strut Rod Nut Socket For equivalent regional tools, refer to Special Tools Removal Procedure 1. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement 2.
Page 722 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 10. Using the CH 35669 socket (2) and the proper size allen wrench, loosen the front strut nut. 11. Remove the front strut nut (1) and the retaining plate (2). Discard the nut and replace with NEW only.
Page 723 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Installation Procedure 1. Position the front strut assembly (1) in the vehicle. 2. Install the NEW front strut nut (1) and the retaining plate (2).
Page 724 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 4. Install the NEW front strut nut (1) and the bolt (2) from the front strut and tighten the nut to 110 N·m (82 lb ft).
Page 725 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Shock Absorber Disposal Warning: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube.
Page 726 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Strut, Strut Component, or Spring Replacement Disassembly Procedure 1. Remove the front suspension strut from the vehicle. Refer to Strut Assembly Removal and Installation 2.
Page 727 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 6. Remove the front suspension strut mount (1), front spring insulator (2), front spring (3), front suspension strut bumper (4), and the front strut (5) from the spring compressor.
Page 728 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension 2. Using the spring compressor (1), compress the front spring assembly (2) install the front strut spring mount nut. 3. Hand tighten the front suspension strut nut.
Page 729 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Front Suspension Description and Operation The front suspension has 2 primary purposes: • Isolate the driver from irregularities in the road surface. • Define the ride and handling characteristics of the vehicle.
Page 730 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Front Suspension Special Tools Illustration Tool Number/ Description CH 49375 Strut Rod Nut Socket CH 43631 Ball Joint Remover CH 50559 Wheel Hub/Bearing Remover/Installer Kit © 2011 General Motors. All rights reserved.
Page 731 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Rear Spring Insulator and Jounce Bumper Replacement Specifications Strut and Shock Absorber Inspection Description and Operation Shock Absorber Replacement Special Tools © 2011 General Motors. All rights reserved.
Page 732 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Fastener Tightening Specifications Specification Application Metric English 175 N·m 129 lb ft Rear Axle to Body Bolts 58 N·m 43 lb ft Rear Wheel Bearing and Hub Bolts Shock Absorber-to-Axle Bolt–...
Page 733 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Strut and Shock Absorber Inspection (Shock Absorber) Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure.
Page 734 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Shock Absorber Replacement Callout Component Name Preliminary Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2. Remove the tire and wheel assembly. Refer to...
Page 736 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Rear Spring, Insulator, and Jounce Bumper Replacement Callout Component Name Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle...
Page 737 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Rear Suspension Description and Operation This vehicle has a beam rear suspension system consisting of the following components: • An axle with integral trailing arms •...
Page 738 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Rear Suspension Special Tools Illustration Tool Number/ Description CH 43631 Ball Joint Remover © 2011 General Motors. All rights reserved.
Page 739 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Specifications Aluminum Wheel Refinishing Tire and Wheel Removal and Installation Aluminum Wheel Porosity Repair © 2011 General Motors. All rights reserved.
Page 740 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Fastener Tightening Specifications Specification Application Metric English 140 N·m 103 lb ft Wheel Nuts © 2011 General Motors. All rights reserved.
Page 741 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Aluminum Wheel Porosity Repair 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation 3.
Page 742 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Note: • If the wheels are chrome-plated, do not re-plate or refinish the wheels. • If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines.
Page 743 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Tire and Wheel Removal and Installation Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle 2. If rotating the tires, refer to Tire Rotation 3.
Page 744 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SUSPENSION Tyres and Wheels Installation Procedure Note: Only apply a small amount the lubricant to the pilot hole of the wheel and NOT the wheel bearing flange. DO NOT apply it to the entire pilot hole of the wheel.
Page 745 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Index Specifications Heater Inlet Hose Replacement (1.2L or 1.4L) Refrigerant Recovery and Recharging Heater Inlet Hose Replacement (Diesel) Flushing Side Window Defogger Outlet Grille Replacement Instrument Panel Outer Air Outlet Replacement - Left Side Air Conditioning Compressor Replacement (1.6L or 1.8L)
Page 746 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Fastener Tightening Specifications Specification Application Metric English 14 N·m 16 lb ft Air Conditioning Compressor Clutch Bolt 4 N·m 35 lb in...
Page 747 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac 7 N·m 62 lb in Thermal Expansion Valve Bolt...
Page 748 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Refrigerant System Specifications Specification Application Metric English PAG Oil ISU 105 Compressor Replacement The service compressor for all Engines for T300 is precharged with 70 ml (2.5 oz) of PAG oil.
Page 749 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Refrigerant Recovery and Recharging Special Tools GE-45037 A/C Oil Injector For equivalent regional tools, refer to Special Tools Warning: To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area.
Page 750 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Flushing Special Tools • BO 42220 Universal 12V Leak Detection Lamp • GE 41447 R-134A A/C Tracer Dye Box of 24 •...
Page 751 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac 9. Install the TXV block fitting nut and tighten to 22 N·m (16 lb ft). 10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement 11.
Page 752 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor Replacement (1.6L or 1.8L) Callout Component Name Preliminary Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 753 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor Replacement (1.2L or 1.4L) Callout Component Name Preliminary Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 754 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor Replacement (Diesel) Callout Component Name Preliminary Procedures 1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection 2.
Page 755 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor Bracket Replacement (Diesel) Callout Component Name Preliminary Procedures Remove air conditioning compressor. Refer to Air Conditioning Compressor Replacement...
Page 756 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor and Condenser Hose Replacement (1.6L or 1.8L) Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 757 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure Note: Use NEW system seals. Refer to Air Conditioning System Seal Replacement 1. Install air conditioning compressor and condenser hose.
Page 758 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor and Condenser Hose Replacement (1.2L or 1.4L) Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 759 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure Note: Use NEW system seals. Refer to Air Conditioning System Seal Replacement 1. Install air conditioning compressor and condenser hose.
Page 760 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Compressor and Condenser Hose Replacement (Diesel) Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement 3.
Page 761 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure Note: Use NEW O-ring seals. Refer to Air Conditioning O-Ring Seal Replacement 1. Install air conditioning compressor and condenser hose.
Page 762 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Evaporator Hose Assembly Replacement Callout Component Name Preliminary Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 763 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Air Conditioning Condenser Replacement Callout Component Name Preliminary Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement 3.
Page 764 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater and Air Conditioning Evaporator and Blower Module Replacement Callout Component Name Preliminary Procedures 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging 2.
Page 765 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater Inlet Hose Replacement (1.6L or 1.8L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools Removal Procedure 1.
Page 766 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure 1. Install the heater inlet hose to the vehicle. 2. Install the heater inlet hose (2) to the engine.
Page 767 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater Outlet Hose Replacement (1.6L or 1.8L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools Removal Procedure 1.
Page 768 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure 1. Install the heater outlet hose to the vehicle. 2. Install the heater outlet hose (2) to the engine.
Page 769 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater Outlet Hose Replacement (1.2L or 1.4L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1.
Page 770 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure 1. Install the heater outlet hose to the vehicle. 2. Install the heater outlet hose (2) to the engine.
Page 771 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater Inlet Hose Replacement (1.2L or 1.4L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1.
Page 772 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure 1. Install the heater inlet hose to the vehicle. 2. Install the heater inlet hose (2) to the engine.
Page 773 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater Inlet Hose Replacement (Deisel) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1.
Page 774 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Installation Procedure 1. Install the heater inlet hose to the vehicle. 2. Install the heater inlet hose (2) to the engine.
Page 775 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Side Window Defogger Outlet Grille Replacement Callout Component Name Side Window Defroster Outlet Grille (Qty: 2) Procedure Use a flat bladed plastic trim tool to aid in the removal of the grille assemblies from the instrument panel.
Page 776 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Instrument Panel Outer Air Outlet Replacement - Left Side Callout Component Name Instrument Panel Outer Air Outlet Assembly Procedure Use a flat bladed plastic trim tool to aid in the removal of the air outlet assembly from the instrument panel.
Page 777 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Instrument Panel Center Air Outlet Replacement Callout Component Name Preliminary Procedure Remove the instrument panel center molding. Refer to Instrument Panel Center Molding Replacement...
Page 778 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Instrument Panel Outer Air Outlet Replacement - Right Side Callout Component Name Instrument Panel Outer Air Outlet Assembly Procedure Use a flat bladed plastic trim tool to aid in the removal of the air outlet assembly from the instrument panel.
Page 779 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Instrument Panel Outer Air Outlet Duct Replacement Callout Component Name Preliminary Procedures 1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement 2.
Page 780 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Floor Air Outlet Duct Replacement - Left Side (RHD) Callout Component Name Preliminary Procedure Remove the instrument panel compartment housing. Refer to...
Page 781 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Floor Air Outlet Duct Replacement - Right Side (RHD) Callout Component Name Preliminary Procedure 1. Remove the instrument panel insulator, if equipped.
Page 782 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Floor Rear Air Outlet Duct Replacement - Left Side Callout Component Name Preliminary Procedure Remove the floor panel carpet . Refer to...
Page 783 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Floor Rear Air Outlet Duct Replacement - Right Side Callout Component Name Preliminary Procedure Remove the front floor l carpet. Refer to...
Page 784 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heater and Air Conditioning Control Replacement Callout Component Name Preliminary Procedures 1. Remove I/P center bezel. Refer to Instrument Panel Center Molding Replacement 2.
Page 785 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Heating and Air Conditioning System Description and Operation Engine Coolant Engine coolant is the key element of the heating system. The engine thermostat controls the normal engine operating coolant temperature.
Page 786 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac Special Tools Illustration Tool Number/ Description A/C Filling Device BO-38185 J-38185 Hose Clamp Pliers GE-39400 J-39400 GE-50078 Electric Halogen Leak Detector...
Page 787 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac BO-42220 J-42220 Universal 12V Leak Detection Lamp GE-43872 J-43872 Florescent Dye Cleaner GE-45037 J-45037 A/C Oil Injector GE-45268 J-45268 A/C Flushing Adapter Kit...
Page 788 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX HEATING VENTILATION AND AIR CONDITIONING Hvac GE-46297 J-46297 A/C Dye Injector Kit GE-46297-12 J-46297-12 Replacement Dye Cartridges DT-48280 Clutch Plate Holder © 2011 General Motors. All rights reserved.
Page 789 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radio Replacement (With US8) Callout Component Name Preliminary Procedure Remove the instrument panel center molding. Refer to Instrument Panel Center Molding Replacement Radio Bolts (Qty: 4)
Page 790 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radio Replacement (Without US8) Callout Component Name Preliminary Procedure Remove the instrument panel center molding. Refer to Instrument Panel Center Molding Replacement Radio Bolts (Qty: 4)
Page 791 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Replacement (Gasoline) Callout Component Name Preliminary Procedures 1. Drain the coolant. Refer to Cooling System Draining and Filling 2. Remove the engine coolant temperature sensor.
Page 792 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Cooling System Draining and Filling Draining Procedure Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
Page 793 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC 6. Allow 30 seconds for the coolant level to stabilize and continue to fill the coolant filler neck until the level stabilizes for at least 2 minutes.
Page 794 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Engine Coolant Fan Shroud Replacement (Gasoline) Callout Component Name Preliminary Procedure 1. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement 2. Unclip transmission cooler lines from shroud if equipped.
Page 795 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Inlet Hose Replacement (1.6L or 1.8L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling 2.
Page 796 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the radiator inlet hose to the vehicle. 2. Install the radiator inlet hose (2) to the radiator. 3. Install the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers .
Page 797 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Inlet Hose Replacement (1.2L or 1.4L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling 2.
Page 798 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the radiator inlet hose to the vehicle. 2. Install the radiator inlet hose (2) to the radiator. 3. Install the radiator inlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers .
Page 799 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Inlet Hose Replacement (Diesel) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools Removal Procedure Warning: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure.
Page 800 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the radiator inlet hose (3). 2. Install the radiator inlet hose clamp (4) to the radiator (5) using the BO-38185 pliers .
Page 801 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Outlet Hose Replacement (1.6L or 1.8L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools . Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling 2.
Page 802 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose (2) to the radiator. 3. Install the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers .
Page 803 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Outlet Hose Replacement (1.2L or 1.4L) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, Refer to Special Tools Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling 2.
Page 804 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose (2) to the radiator. 3. Install the radiator outlet hose clamp (1) at the radiator using BO-38185 Hose Clamp Pliers .
Page 805 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Outlet Hose Replacement (Diesel) Special Tools BO-38185 Hose Clamp Pliers For equivalent regional tools, refer to Special Tools Removal Procedure Warning: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure.
Page 806 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Radiator Upper Bracket Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Radiator Support Bracket Bolt Caution: Refer to...
Page 807 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Battery Negative Cable Disconnection and Connection (LCU,LDE) Removal Procedure 1. Turn on the radio and record all of the customer radio station presets. 2. Ensure that all lamps and accessories are turned off.
Page 808 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Battery Negative Cable Disconnection and Connection (LSF,LDV) Callout Component Name Preliminary Procedures 1. Turn on the radio and record all of the radio pre-set stations. 2. Ensure that all lamps and accessories are turned off.
Page 809 BACK TO MAIN INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Drive Belt Replacement Special Tools EN 6349 Locking Pin For equivalent regional tools, refer to Special Tools Removal Procedure 1. Remove the power steering pump belt, if equipped. Refer to Power Steering Pump Belt Replacement 2.
Page 810 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Installation Procedure 1. Install the drive belt (1). 2. Release tension to the tensioner by rotating counterclockwise (1). Note: Allow tensioner to slide back slowly. 3. Remove EN 6349 pin (2).
Page 811 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Power Steering Pump Belt Replacement Special Tools CH 49800 Installer Power Steering Pump Belt For equivalent regional tools, refer to Special Tools Removal Procedure 1. Cut the power steering pump belt (2) with a appropriate cutting tool at position (1).
Page 812 BACK TO CHAPTER INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL TO MODEL INDEX SONIC Air Conditioning Compressor Belt Replacement Removal Procedure 1. Remove the front wheelhouse liner inner front extension. Refer to Front Wheelhouse Liner Inner Front Extension Replacement 2. Cut the air conditioning (A/C) belt (1) with a appropriate cutting tool as shown.

Chevrolet Sonic 2012 Body Repair Manual

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