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.
Removal Procedure
Warning:
Refer to
Glass and Sheet Metal Handling Warning
.
1. Disable the SIR System. Refer to
SIR Disabling and Enabling
.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
3. Remove the front side door. Refer to
Front Side Door Replacement
.
4. Remove the front side door outside handle. Refer to
Front Side Door Outside Handle Replacement
.
5. Remove the outside rearview mirror. Refer to
Outside Rearview Mirror Replacement
.
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to
Anti-Corrosion Treatment and
Repair
.
7. Grind the edges of the front side door outer panel (1) to separate the outer door panel from the door shell.
8. Remove the front side door outer door panel (1).
9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to
Anti-Corrosion Treatment and
Repair
.
10. Straighten the edges of the door shell.
Installation Procedure
1. Align the front side door outer panel.
2. Verify the fit of the front side door outer panel.
Collision Repair
BODY REPAIR
0-3
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CHEVROLET SONIC 2012 BODY REPAIR MANUAL