Chevrolet Sonic 2012 Body Repair Manual Download Page 692

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Callout

Component Name

Steering Wheel Horn Cap

Procedure

Use flat bladed plastic tool to gently pry horn cap from steering wheel.

Steering Wheel Horn Cap Replacement

Steering

STEERING

0-9

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CHEVROLET SONIC 2012 BODY REPAIR MANUAL

Summary of Contents for Sonic 2012

Page 1: ...CHEVROLET SONIC 2012 CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 2: ... the latest product information available at the time of publication approval General Motors reserves the right to make changes at any time without notice Published by North American Operations General Motors LLC Warren Michigan 48090 2009 GENERAL MOTORS LLC ALL RIGHTS RESERVED The information cutoff date is 09 28 09 LITHO IN U S A No part of this manual may be reproduced stored in any retrieval s...

Page 3: ...RIM 02 BODY REPAIR 03 BODY SYSTEMS 04 ROOF 05 SEATBELTS 06 SEATS 07 08 08 RESTRAINTS 09 STEERING 10 SUSPENSION 11 HVAC SYSTEM PREFACE CHEVROLET SONIC BODY REPAIR MANUAL 2012 BACK TO FOREWORD TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL HATCHBACK SEDAN ...

Page 4: ...odule Voltage after Ignition is Turned Off Warning Servicing the SIR System Warning SIR Inflator Module Handling and Storage Warning SIR Seatbelt Pretensioner Handling Warning SIR Warning Torque to Yield Fastener Warning Brake Fluid Damage to Electrical Connections Caution Brake Fluid Effects on Paint and Electrical Components Caution Catalytic Converter Movement Caution Clearcoat Ultraviolet Scre...

Page 5: ... is not heeded the following consequences may occur Serious bodily injury to the technician Serious bodily injury to other technicians in the workplace area Serious bodily injury to the driver and or passenger s of the vehicle if the vehicle has been improperly repaired CAUTION Defined CAUTIONS call special attention to a necessary action or to a prohibited action If a CAUTION is not heeded the fo...

Page 6: ...umes 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 7: ...ing near a battery observe the following guidelines Always shield your eyes Avoid leaning over the battery whenever possible Do not expose the battery to open flames or sparks Do not allow battery acid to contact the eyes or the skin Flush any contacted areas with water immediately and thoroughly Get medical help 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER I...

Page 8: ...ery power disruption to the VCIM OnStar module Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF Retained accessory power RAP should be allowed to time out or be disabled simply opening the driver door should disable RAP before disconnecting power Disconnecting power to the OnStar module in any way while the ignition is On or ...

Page 9: ...t take the following actions Eye contact rinse thoroughly with water Skin contact wash with soap and water If ingested consult a physician immediately 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 10: ...container Do not use fluid from an open container that may be contaminated with water Improper or contaminated fluid could result in damage to components or loss of braking with possible injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 11: ...ended areas Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 12: ...ut still intact crisscross the window with masking tape in order to reduce the risk of damage or personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 13: ...falls into the defroster outlets it can be blown into the passenger compartment and cause personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 14: ...tart up even when the engine is not running and can injure you Keep hands clothing and tools away from any underhood electric fan 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 15: ...d being burned do not service the exhaust system while it is still hot Service the system when it is cool 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 16: ...glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 17: ...source is present Never drain or store gasoline or diesel fuel in an open container due to the possibility of fire or explosion Have a dry chemical Class B fire extinguisher nearby 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 18: ...ass or sheet metal with exposed or rough edges wear approved safety glasses and gloves in order to reduce the chance of personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 19: ...ng the bulb Leave the lamp switch OFF until the bulb change is complete Always wear eye protection when changing a halogen bulb Handle the bulb only by its base Avoid touching the glass Keep dirt and moisture off the bulb Properly dispose of the used bulb Keep halogen bulbs out of the reach of children 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MOD...

Page 20: ...is being removed or installed provide alternate support to avoid the possibility of damage to the vehicle or personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 21: ...he parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 22: ... gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 23: ...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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 24: ...ased when servicing the fuel lines the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fuel system components with a shop towel before disconnection This will catch any fuel that may leak out Place the towel in an approved container when the disconnection is complete 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER ...

Page 25: ...d not be physically disturbed until after that time Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 26: ...arning Warning Wear safety glasses when using compressed air in order to prevent eye injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 27: ...ses Warning Warning Wear safety glasses in order to avoid eye damage 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 28: ... Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 29: ... horizontally on the mounting surface Point the arrow on the SDM toward the front of the vehicle Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment personal injury or unnecessary SIR system repairs 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO ...

Page 30: ... minute after the ignition has been turned OFF and the fuse has been removed If the airbags and pretensioners are not disconnected do not begin service until one minute has been passed after disconnecting power to the SDM Failure to do so may cause personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPA...

Page 31: ...isted below in order to temporarily disable the SIR system Failure to follow the procedures could result in the following Air bag deployment Personal injury Otherwise unneeded SIR system repairs 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 32: ... away from the surface on which the inflator module rests Provide free space for the air bag to expand in case of an accidental deployment When storing a steering column do not rest the column with the air bag opening facing down and the column vertical Lay the column on its side Failure to observe these guidelines may result in personal injury 2011 General Motors All rights reserved 0 0 Caution N...

Page 33: ...Carry the seat belt pretensioner by the housing keeping hands and fingers away from the seat belt webbing Make sure the opening from which the seat belt webbing extends faces downward and the seat belt webbing hangs freely Failure to observe these guidelines may result in personal injury 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVRO...

Page 34: ...he above conditions observe the following guidelines Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring If you are performing service on or near the SIR components or the SIR wiring disable the SIR system Refer to Disabling the SIR System 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER...

Page 35: ... 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 36: ...faces Use shop cloths suitable containers and fender covers to prevent brake fluid from contacting these areas Always re seal and wipe off brake fluid containers to prevent spills 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 37: ...ause corrosion to electrical components If any brake fluid comes in contact with painted surfaces immediately flush the area with water If any brake fluid comes in contact with electrical connections wiring or cables use a clean shop cloth to wipe away the fluid 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 38: ...alytic 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 39: ... can result in early paint failure The clearcoat contains ultraviolet screeners Do not finesse sand more than what is required to remove the defect 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 40: ...edure Some replacement components may come with these coatings already applied Do not use these coatings on components unless specified These coatings can affect the final torque which may affect the operation of the component Use the correct torque specification when installing components in order to avoid damage 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER ...

Page 41: ...ution Use a plastic flat bladed tool to prevent paint damage when removing an emblem name plate 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 42: ...e the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When using fasteners that are threaded directly into plastic use extreme care not to strip the mating plastic part s Use hand tools only and do not use any kind of impact or power tools Fastener should be hand tightened fully seated and not stripped 2011 Gen...

Page 43: ...ailure 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 44: ...or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Powertrain Control Module PCM or other electronic components 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 45: ...ring installation Do not bend or distort the inlet or outlet hoses to make installation easier Failure to follow these procedures could result in component damage 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 46: ...e 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 47: ...owing components The steering column The steering shaft coupling The intermediate shaft s After disconnecting these components do not rotate the steering wheel or move the front tires and wheels Failure to follow this procedure may cause the SIR coil assembly to become un centered and cause possible damage to the SIR coil If you think the SIR coil has became un centered refer to your specific SIR ...

Page 48: ...not hold the steering wheel in the full turn position longer than 5 seconds as damage to the steering pump may result 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 49: ...g the following components The steering column The intermediate shaft s The steering gear After disconnecting these components do not rotate the steering wheel or move the front tires and wheels Failure to follow this procedure may cause the SIR coil assembly to become un centered and cause possible damage to the SIR coil If you think the SIR coil has became un centered refer to your specific SIR ...

Page 50: ...emoving body panels apply tape to corners of panel and adjacent surfaces to help prevent paint damage 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 51: ...all 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 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 52: ...pment must meet the operational standards of the lifting equipment or jacking equipment manufacturer Perform the vehicle lifting or jacking procedure on a clean hard dry level surface Perform the vehicle lifting or jacking procedure only at the identified lift points DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components Failure to perform the previous step...

Page 53: ...t use spacers when installing a windshield The stress caused by the spacers may damage the windshield 2011 General Motors All rights reserved 0 0 Caution Notices PREFACE BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 54: ... Wheeling Lock Cylinder Coding Ignition Rear Compartment Lid Lock Cylinder Coding Lifting and Jacking the Vehicle 2011 General Motors All rights reserved 0 1 Index GENERAL INFORMATION BACK TO MAIN INDEX Body Waterleak Repair Air Hose Test Water Hose Test Dust Leaks Recommended Materials Waterleak Repair Waterleak Test Preparation Squeaks and Rattles Tracing Powder or Chalk Test Soap Suds or Bubble...

Page 55: ...2 7 Ambient Clean Air Flow or Cool Air Flow 8 Lubrication Point Oil or Fluid 9 Task Related 10 Sectioning 1 3 11 Gas Other Than Ambient Air or Hot Air Flow 12 Lubrication Point Grease or Jelly 13 Multidirectional Arrow 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 56: ...le Camshaft Phasing Variable Intake Module VIM G RPO LDV Engine Diesel 4 Cylinder 1 3L L4 DI DOHC Turbo 55 KW 190NM R RPO LSF Engine Diesel 4 Cylinder 1 3L CRI DOHC Turbo VGT 0 RPO LFJ Engine Flexible Fuel Gas ALc 4 Cylinder 1 6L MFI E100 H RPO L2N Engine Gas 4 Cylinder 1 4L MFI L4 DOHC FAM O 74 KW E20 MAX GME Vehicle Engine and Transmission ID and VIN Location Derivative and Usage The vehicle ide...

Page 57: ...ine ID and VIN Derivative Location Refer to Engine Identification 6T30 6T40 6T45 6T50 MH9 Transmission ID and VIN Derivative Location Refer to Transmission Identification Information D16 MFH MXP Transmission ID and VIN Derivative Location Refer to Transmission Identification Information M20 6 MZ7 Transmission ID and VIN Derivative Location Refer to Transmission Identification Information 2011 Gene...

Page 58: ...located under the radiator opening upper cover 10 Matiz Identification Plate Location Tire Placard The tire placard label is located on the driver side B pillar and displays the following assessments Tire size Tire pressure Front Rear Various loading conditions 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REP...

Page 59: ...oor Panel Brick 4AA Interior Trim Jet Black 4AQ Interior Trim VDK Pewter 5EA Equipment Package CO2 Reduction 9L3 Tire Spare None A33 Window Power Operated Rear DRS A55 Window Power Operated Driver 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 Identificati...

Page 60: ...raint System Seat Inflatable Driver Passenger Single Stage AE2 Latch Rear Compartment Safety Manual Release AG5 Adjuster Passenger Seat Manual 2 Way AH3 Adjuster Front Seat Manual 4 Way Driver AH9 Adjuster Front Seat Manual 2 Way Driver AHU Restraint Provisions Belts Adjuster Height Front AJ3 Restraint System Seat Inflatable Driver Front AJC Restraint Head Front Seat Up Down Adjustment AJD Restrai...

Page 61: ...g AMA Seat Rear Split Back Folding Headrest AN1 Seat Rear Bench AQ2 Net Convenience Package AQP Restraint Head Rear Seat Center AR1 Restraint System None AR7 Seat Front BKT Standard AT7 Restraint System Rear Seat SHLDR RETR 3 Point 3 SHLDR AU3 Lock Control Side Door Electronic AWB Restraint System Rear Seat LH and RH ELR and CTR 2 Point AXG Window Power Operated Express Driver Up Down 0 1 General ...

Page 62: ... Close BA8 Compartment Stowage Front Seat Passenger BAH Equipment Security System Immobilization Step Two BCM Covering Load Compartment Movable BCO Plant Code Bogota Colombia BGY Plant Code Dong Yue China BPF Bumper Provisions Front Lower Spoiler Edge BTT Alarm Remote Panic BTV Remote Start Engine BUP Plant Code Bupyeong 1 Korea BXQ Ornamentation EXTR PLR APLQ Reveal Black C25 Wiper System Rear Wi...

Page 63: ...of Courtesy C95 Lamp INTR Roof Courtesy Dual Reading C99 Switch INFL RST I P MDL MAN Suppression CAI Lamp Tail Stop w o Fog ECE CD4 Wiper System Windshield Pulse Variable Delay CF5 Roof Sun Glass Sliding ELEC D05 Arm Rest Front Seat Driver D31 Mirror I S R V Tilt D6J Mirror I S Front VAN Sunshade w o Mirror Passenger w Mirror D7A Handle O S Door Body Color Chrome Strip D72 Handle O S Door Black 0 ...

Page 64: ...r I S Front VAN Sunshade Driver Passenger w o Mirror DL6 Mirror O S LH RH Remote Control Electric Manual Folding Color DL7 Mirror O S LH RH Remote Control Electric Heated Power Folding Color DNJ Mirror I S Front VAN Sunshade w Mirror w o Cover DLV Mirror I S Front VAN Sunshade Driver Passenger w Mirror Cover DUJ Ashtray Smoker s Package E17 Bumper 2 5mph E19 Bumper 5 0mph E21 Handle I S Door Chrom...

Page 65: ... Final Drive 4 11 FE1 Suspension System Soft Ride FE4 Suspension System Special Ride and Handling FE9 Certification Emission Federal FHA Fuel System Electronic Returnless FHB Ratio Transaxle Final Drive 3 47 FHF Trim Door Hard Touch Paint FHG Trim Door Soft Touch Paint FHN Vehicle Fuel Gasoline E5 FHP Vehicle Fuel Gasoline E20 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CH...

Page 66: ...o Transaxle Final Drive 4 63 FVG Ratio Transaxle Final Drive 4 64 FX1 Ratio Transaxle Final Drive 3 94 FX3 Ride And Handling Automatic Electronic Controlled FXB Ratio Transaxle Final Drive 3 65 FY2 Ratio Transaxle Final Drive 3 74 G83 Ratio Transaxle Final Drive 4 47 GAN Primary Color Exterior Switchblade Silver Met G 636R GAR Primary Color Exterior Carbon Flash Met G 501Q 0 1 General GENERAL INFO...

Page 67: ...Orange MET 502Q GCW Primary Color Exterior Misty Lake Met 683R GEL Primary Color Exterior Dynamic Orange Met 728R GGE Primary Color Exterior Super Red G 717R GIY Primary Color Exterior Galaxy Silver MET 519F GJP Primary Color Exterior Grenada Black 446P GLF Primary Color Exterior Space Blue Metallic 819T GMN Primary Color Exterior Desert Bloom 876S GOB Primary Color Exterior Cherry Red MET G 715J ...

Page 68: ...4 JBD Booster Brake Single Rate JBE Booster Brake Dual Rate JDE Bumper Front Rear Lightweight JPW Brake System Power FRT Disc RR Drum 14 K12 Filter Air Pollutant K33 Cruise Control Automatic Electronic Speed Governor K34 Cruise Control Automatic Electronic K4E Battery LN3 AGM 12V 70AH 760ENCCA K09 Generator 120Amp K60 Generator 100Amp K97 Generator 80Amp 0 1 General GENERAL INFORMATION BACK TO CHA...

Page 69: ... Knob TRANS CONT Lever Leather Satin Silver Chrome KTD Key Primary Rigid Additional Rigid KTF Key Primary Foldable Additional Foldable KTH Lock Control Side Door Lock Unlock KTI Kit Tire Inflator KTJ Lock Control Side Door Lock Unlock Trunk Release KTK Lock Control Side Door Lock Unlock Remote Start KTL Lock Control Side Door Lock Unlock Trunk Release Remote Start 0 1 General GENERAL INFORMATION B...

Page 70: ...I DOHC VVT Variable Camshaft Phasing Variable Intake Module VIM LDV Engine Diesel 4 Cyl 1 3L L4 DI DOHC Turbo 55KW 190NM LED Engine Gas 4Cyl 1 6L MFI DOHC VVT Variable Intake Module VIM E85 MAX LFJ Engine Gas 4 Cyl 1 6L MFI E100 MAX LHD Vehicle Drive Left Hand Drive LSF Engine Diesel 4 Cyl 1 3L CRI DOHC Turbo VGT LUV Engine Gas 4 Cyl 1 4L MFI DOHC Turbo VVT ALUM GME E85 MAX LUW Engine Gas 4 Cyl 1 ...

Page 71: ...Transmission Manual 5Speed GMDAT D16 Intermediate Semi wide 72MM 3 727 1ST 0 763 5TH MZ4 Transmission Manual 6Speed Opel 76 5 MM 3 82 1ST 0 615 6TH M32 WR MZ7 Transmission Manual 6Speed Opel 76 5 MM 4 273 1ST 0 614 6TH M20 N08 Lock Control Fuel Filler Door REM CONT N12 Exhaust System Rear Exit N30 Steering Wheel Deluxe N33 Steering Column Tilt Type N34 Steering Wheel Leather 3Spokes N37 Steering C...

Page 72: ... EEC09 NF7 Emission System Federal NLEV NJ1 Steering Power Non variable Ratio Electric NPH Exhaust System Heavy Duty NQU Emission System Korean ULEV NT3 Emission System EEC00 NT4 Emission System EEC05 NT7 Emission System Federal Tier 2 NU6 Emission System California PZEV NZA Control Steering Wheel Wireless Interface Radio Phone Handsfree Controls ORN Plant Code Orion MI USA 0 1 General GENERAL INF...

Page 73: ...L 91H BW HW3 Q6L Tire All 205 55R16 SL 91H BW HW4 Q8E Jack Mechanical with Tools QB0 Tire All P185 75R14 SL 89H BW ALS QLG Tire All P205 55R16 SL 89H BW AL3 QZF Tire All P195 65R15 SL 89H BW AL2 Low Resistance RHD Vehicle Drive Right Hand Drive RQ4 Tire All 195 65R15 SL 91H BW HW2 Low Resistance RRB Wheel 14x5 5 J Steel Design 1 RRK Wheel 15x6 0 J Aluminum Design 1 0 1 General GENERAL INFORMATION ...

Page 74: ...lar Intensity Low Beam T43 Spoiler Rear T44 Alarm Overspeed Warning Acoustical T4A Headlamps Halogen T67 Battery LN3 FLA 12V 70AH 512ENCCA T83 Headlamps Control Automatic On Off TB1 Lamp Tail and Stop Korea TBU Plant Code 6 October City Egypt TCU License Plate Front Rear Mounting ECE TD1 Reflector Safety Triangle TL6 Grille Radiator Black 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MO...

Page 75: ... Lamp Interior Rear Compartment Courtesy U2K Digital Audio System S Band U58 Radio Faceplate Integrated Center Console U68 Display Driver Information Center U71 Antenna Roof Radio UBA Antenna Roof Radio GPS Phone S Band XM UC1 Speedometer Instrument Miles UC3 Control Steering Wheel Radio Phone Redundant Controls UD7 Sensor Indicator Rear Parking Assist 0 1 General GENERAL INFORMATION BACK TO CHAPT...

Page 76: ...ng LH UH1 Indicator Seat Belt Warning RH UH5 Indicator Seat Belt Warning Rear Seat UH7 Radio AM FM Stereo Seek Scan CD ETR Clock DSP MP3 WMA USB AUX IN Wireless Interface UJ2 Indicator Engine Oil Life UJM Tire Press Indicator Manual Learn UL5 Radio None UM7 Radio AM FM Stereo Seek Scan Clock ETR UPF Wireless Interface Short Range Voice REC UQ9 Speaker System None UQJ Restraint Provisions Child ISO...

Page 77: ...chanical Double Locking Latch UW4 Speaker System 4 Custom UW6 Speaker System 6 Custom UY0 Battery LN0 FLA 12V 40AH 300ENCCA V22 Grille Radiator Chrome V48 Coolant Engine Maximum Protection V5M Calibration TCM Neutral Idle Control VD1 Provision Options Europe VD8 Provisions First Aid Kit VEE Bumper Front Body Color Front Rear VGC Protector Film Paint Etch Preventive VHY Protector Body Sheet Metal H...

Page 78: ... Chassis Protection Kit Engine Compartment XL7 Frequencies Rating 315 MHZ Long Distance XL8 Frequencies Rating 433 MHZ XX7 Radio Provisions Installation VAR3 YF5 Certification Emission California YG3 Ornamentation EXTR Head Tail Lamps Chrome Bezel YG5 Ornamentation EXTR Head Tail Lamps High Gloss Finish ZAA Tire Spare Compact 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION ...

Page 79: ...l grade For example a grade8 bolt will have 6radial lines on the bolt head Some metric nuts are marked with a single digit strength identification number on the nut face The correct fasteners are available through GM SPO Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States and may exhibit the following Lower st...

Page 80: ...m 27lbin 16mm 4 2N m 37lbin 20mm 7N m 62lbin 24mm 10 5N m 93lbin Nylon Interface Prevailing Torque Fasteners 6mm 0 3N m 3lbin 8mm 0 6N m 5lbin 10mm 1 1N m 10lbin 12mm 1 5N m 13lbin 14mm 2 3N m 20lbin 16mm 3 4N m 30lbin 20mm 5 5N m 49lbin 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 81: ...n 1 2in 2 3N m 20lbin 9 16in 3 2N m 28lbin 5 8in 4N m 36lbin 3 4in 7N m 54lbin Nylon Interface Prevailing Torque Fasteners 1 4in 0 3N m 3lbin 5 16in 0 6N m 5lbin 3 8in 1N m 9lbin 7 16in 1 3N m 12lbin 1 8N m 16lbin English Prevailing Torque Fastener Minimum Torque Development 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 82: ... 9 16in 2 5N m 22lbin 5 8in 3 4N m 30lbin 3 4in 5N m 45lbin 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 83: ...uired depth 2 Drill out the damaged threads Clean out any chips 3 Lubricate the tap with light engine oil Tap the hole Clean the threads 4 Thread the thread insert onto the mandrel of the installer Engage the tang of the insert onto the end of the mandrel Note The insert should be flush to one turn below the surface 5 Lubricate the insert with light engine oil except when installing in aluminum an...

Page 84: ...bution Center for a new coded key based off of the information card After receiving the new key the dealer must program the immobilizer through the TECH 2 Inspect the new key operation in the lock cylinder Ensure the new key operates effectively 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 85: ...ositions 3 5 and 7 following the key code and same process Press the tumblers in place until they are secure 4 Check the correct loading of the tumblers by inserting the key into the cylinder All tumblers should be flush with the lock cylinder body 5 Turn the cylinder so the side with the 4tumbler spring wells faces up This side uses right tumblers 6 Insert the tumbler springs into the 4spring poc...

Page 86: ...buffer is properly seated 16 Install the free wheel pin 11 in the sleeve 4 and clutch 5 and insert the assembly into the case 9 17 With the lock cylinder assembly installed in the case 9 install the retainer 10 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 10 18 Insert the key into the lock and function the ...

Page 87: ...rs key cut positions 3 5 and 7 following the key code and same process Press the tumblers in place until they are secure 4 Check the correct loading of the tumblers by inserting the key into the cylinder All tumblers should be flush with the lock cylinder body 5 Turn the cylinder so the side with the 4tumbler spring wells faces up This side uses right tumblers 6 Insert the tumbler springs into the...

Page 88: ...ing a small punch and hammer to peen the case material onto the exposed ends of the installed retainer 6 13 Insert the key into the lock and function the lock to check for proper assembly and smooth operation 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 89: ...Insert the tumbler spring into each of the spring pockets of the cylinder assembly This side of the cylinder used right tumblers 5 The first tumbler 3 to be loaded will be the second key cut position the second number in the key code Install the first tumbler in the slot over the spring Install the remaining left tumblers following the key code and same process pressing the tumblers in place until...

Page 90: ... and work through until the last tumbler at the base Use the key as a tool by pushing it in step by step to hold the already assembled tumblers in place 2 Check the correct loading of the tumblers by inserting the key into the cylinder All tumblers should be flush with the lock cylinder body 3 Assemble the restoring spring 4 onto the rear of the cylinder 4 Tape the pad 5 onto the housing 6 5 Greas...

Page 91: ... contents The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer Perform the vehicle lifting or jacking procedure on a clean hard dry level surface Perform the vehicle lifting or jacking procedure only at the identified lift points DO NOT allow the lifting equipment or jacking equipment to contact any other vehi...

Page 92: ...the following locations Front of Vehicle Place the service jack pad in the same location as shown for the front lift pads Rear of Vehicle Note Place jackstands ONLY under strong and stable vehicle structures Place the service jack pad in the same location as shown for the rear lift pads 2011 General Motors All rights reserved General GENERAL INFORMATION 0 1 BACK TO CHAPTER INDEX TO MODEL INDEX CHE...

Page 93: ...oise by lowering one window at a time If the location corresponds with the condition in step 2 pull over and make a temporary repair with 51mm 2in wide masking tape 2 Tape over the gaps and the moldings one at a time Test between each taping Taping over the gaps and moldings will correct the condition 3 Temporarily repair the condition with masking tape Adjust the tape when needed 4 Continue testi...

Page 94: ... valves to cause added air pressure within the vehicle 2 Test drive the vehicle and listen for windnoise or a whistle 3 Pull the vehicle over and make the temporary repairs using masking tape If you cannot determine the source of the windnoise perform one or more of the following diagnostic tests Air Pressure Test Soap Suds or Bubble Test Tracing Powder or Chalk Test 2011 General Motors All rights...

Page 95: ...on high speed and in the defrost mode 4 Unlock and close the doors 5 Listen for escaping air along the door and the window seals with a stethoscope or a length of heater hose 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX Air Pressure Test TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 96: ...lector on high speed and in the defrost mode 4 Unlock and close the doors 5 Apply the soap solution to the potential leak areas 6 Look for bubbles revealing escaping air 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX Soap Suds or Bubble Test TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 97: ...esses the weatherstrip firmly against the mating surface 3 Inspect the applied line on the weatherstrip The applied line is marred where contact is good A corresponding imprint is on the mating surfaces 4 Gaps or irregularities in the powder or the chalk line on the mating surfaces indicate the areas with a poor seal 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO C...

Page 98: ...s and rattles To aid in diagnosing use J 39570 chassis ear or J 41416 ultrasonic leak detector Attach the component that squeaks or rattles securely Separate the components that squeak or rattle to prevent contact Insulate the components that squeak or rattle Insulate low uniform friction surfaces to eliminate stickslip motion 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION...

Page 99: ... compartment lid or liftgate area this does not necessarily indicate a bad weatherstrip An adjustment to these areas may resolve the condition 1 Assemble the water test stand as shown 2 Position the stands as shown The water spray from the stands should overlap the vehicle as shown 3 Have an assistant inside of the vehicle during the test in order to locate any leaks 4 The water pressure at the no...

Page 100: ...ck Sealer or equivalent Ventilation Ducts 3M Auto Bedding and Glazing Compound or equivalent Weatherstrips 3M 08011 Weatherstrip Adhesive or equivalent Windshield Rear Window Urethane adhesive caulking kit or equivalent 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX Recommended Materials Waterleak Repair TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 101: ...cle on a dusty road 6 Examine the interior Dust in the shape of a small cone or slit will usually be found at the point of leakage 7 Mark the points of leakage Note Ensure that the interior is darkened when performing this step 8 Shine bright lamps on the underside of the floor and the cowl 9 Have an assistant mark any points inside of the vehicle for any points where the light shines through Insp...

Page 102: ...icle in order to locate the leak 2 Begin testing at the base of the window or the windshield 3 Slowly move the hose upward and across the top of the vehicle 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 103: ...edges Begin at the bottom and gradually move up and across the top Note The compressed air should not exceed 205kPa 30psi 2 Have an assistant inside of the vehicle with an air hose 3 Have the assistant aim the compressed air at the suspected areas Bubbles will form in the soap solution at the location of the leak 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPT...

Page 104: ...nts in order to repair the leak 1 If the floor carpet is wet refer to Floor Carpet Drying 2 Cut out a portion of the adhesive caulking in the leak area from inside or outside of the vehicle 3 Clean and remove all loose particles of the adhesive old caulking from the area 4 Apply joint body and seam sealer where the old adhesive caulking was removed 5 Allow the adhesive caulking to dry for several ...

Page 105: ...Replace the SDM harness connector Replace the SDM Failure to follow these tasks could result in possible air bag deployment personal injury or otherwise unneeded SIR system repairs 1 If the floor carpet is wet refer to Floor Carpet Drying 2 Remove the trim moldings or the headliner in order to repair the leak if needed 3 Determine the source of water entry 4 If water is leaking at the edge of the ...

Page 106: ...on CH 39570 J 39570 Chassis Ear GE 41416 J 41416 Ultrasonic Leak Detector Special Tools 2011 General Motors All rights reserved 0 1 General GENERAL INFORMATION BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 107: ...ings and Headlinings Instrument Panel and Console Trim Interior Trim and Paneling 2011 General Motors All rights reserved 0 2 Idex BODY HARDWARE AND TRIM BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 108: ...or Grille Emblem Nameplate Replacement Liftgate Emblem Nameplate Replacement Hatchback Rear Compartment Lid Nameplate Replacement Sedan Radiator Upper Grille Replacement Radiator Lower Grille Replacement Radiator Grille Opening Cover Replacement Upper Grille Cover Radiator Grille Opening Cover Replacement Lower Grille Cover Roof Panel Joint Finish Molding Replacement Rear End Spoiler Replacement H...

Page 109: ...que Nut 5 0N m 44lbin Rear End Spoiler Nut 5 0N m 44lbin Rear End Spoiler Bolt for Cross Bar Indicator 1 5N m 13lbin Rear End Spoiler Screw 1 5N m 13lbin Fastener Tightening Specifications 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 110: ...s and rear compartment lids where emblem nameplates are to be placed 8 When removing protective liners from adhesive backed emblem nameplates be careful not to touch the adhesive tape or allow the tape to come in contact with dirt or any foreign matter prior to the placement and adhesion 9 Remove the protective liner from the emblem nameplate 10 Position align and press the emblem nameplate to the...

Page 111: ...cking liner from the protective film patch 7 Use the solution to liberally spray the adhesive side of the protective patch the mounting location along with your hands 8 Position the paint protective film patch to the desired location on the vehicle 9 Spray the surface of the film with the alcohol water and soap solution 10 Using a dampened squeegee start at the center of the protective patch worki...

Page 112: ...t or right front door in order to access the backside of the body side upper front applique 1 Body Side Upper Front Applique Body Side Upper Front Applique Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 113: ...1 Liftgate Side Applique Nut Qty 4 Caution Refer to Fastener Caution Tighten 5N m 44lbin 2 Liftgate Side Applique Retainer 3 Liftgate Release Switch Procedure Remove the liftgate release switch Refer to Liftgate Release Switch Replacement 4 Rear License Plate Lamp Qty 2 Procedure Remove the rear license plate lamps Refer to Rear License Plate Lamp Replacement Liftgate Side Applique Replacement Hat...

Page 114: ...Rear Compartment Lid Applique Nut Qty 4 Caution Refer to Fastener Caution Tighten 5N m 44lbin 2 Rear Compartment Lid Retainer 3 Liftgate Release Switch Procedure Remove the liftgate release switch Refer to Liftgate Release Switch Replacement 4 Rear License Plate Lamp Qty 2 Procedure Remove the rear license plate lamps Refer to Rear License Plate Lamp Replacement Rear Compartment Lid Applique Repla...

Page 115: ...ate Bracket Screw Qty 4 Caution Refer to Fastener Caution Tighten 1 5N m 13lbin 2 Front License Plate Bracket Front License Plate Bracket Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 116: ...the front bumper fascia 2 Using needle nose pliers release the v notch hook from the square in the front fascia and remove Front Bumper Fascia Front Tow Eye Access Hole Cover Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 117: ... the rear bumper fascia 2 Using needle nose pliers release the v notch hook from the square in the rear fascia and remove Rear Bumper Fascia Rear Tow Eye Access Hole Cover Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 118: ...ergy absorber Refer to Front Bumper Energy Absorber Replacement 1 Radiator Grille Emblem Nameplate 2 Radiator Grille Emblem Nameplate Screw Qty 2 Radiator Grille Emblem Nameplate Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 119: ...liners from the adhesive tape be careful not to touch tape with hands and do not allow tape to come in contact with dirt or any foreign matter prior to adhesion 4 Using the previous witness marks of the old emblem nameplate or making measurements from another alike vehicle use masking tape to reference the alignment of the new emblem nameplate to the liftgate panel 5 Close the rear liftgate panel ...

Page 120: ...surface dry with a clean lint free towel prior to installing the new nameplate 3 When removing protective liners from the adhesive tape be careful not to touch tape with hands and do not allow tape to come in contact with dirt or any foreign matter prior to adhesion 4 Close the rear compartment lid prior to adhesion 5 Using the palm of the hand wet out the emblem to the rear compartment lid to ens...

Page 121: ...tion 2 Radiator Upper Grille Assembly Procedure Release the outer upper grille locking tabs from the front bumper fascia and push the grille assembly outward away from the front bumper fascia assembly Radiator Upper Grille Replacement 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 122: ...t bumper fascia in order to remove 5 Upon installation index the right center alignment pin to the front bumper fascia first followed by the ten locking tabs on the lower grille assembly to the front bumper fascia 6 Push the locking tabs inward at all ten locations in order to secure the radiator lower front grille to the front bumper fascia 2 Front License Plate Bracket Assembly Procedure Remove ...

Page 123: ...Cover Upper Procedure Release the locking tabs securing the radiator opening grille cover to the radiator upper grille and remove Radiator Grille Opening Cover Replacement Upper Grille Cover 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 124: ...Cover Lower Procedure Release the locking tabs securing the radiator opening grille cover to the radiator lower grille and remove Radiator Grille Opening Cover Replacement Lower Grille Cover 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 125: ...l and clean drinkable water 5 Dry the ditch with a lint free cotton towel 1 Roof Panel Joint Finish Molding Procedure 1 Insert the front edge of the finish molding to the edge of glass 2 Using a roller type tool roll the molding into the ditch front to rear to ensure full adhesion is made 3 Tuck the rear lip of the finish molding to the edge of glass at the rear of the roof panel 4 Inspect the mol...

Page 126: ...oiler Screw Qty 4 Tighten 1 5N m 13lbin 3 Clip Button Tip Upon assembly of the rear spoiler to the liftgate position and secure the clip button to the rear liftgate spoiler to liftgate outer panel first 4 Rear End Spoiler Assembly Rear End Spoiler Replacement Hatchback TTV 2011 General Motors All rights reserved 0 2 Exterior Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLE...

Page 127: ...ow direction in the plenum chamber and drains system Plenum Chamber and Drain Valve Cleaning The plenum chamber is located in front of the windshield and below the air inlet grille panel 1 Remove the air inlet grille panel Refer to Air Inlet Grille Panel Replacement 2 Clean the plenum chamber drains and the air inlet grille panel of debris blockage 3 Flush the plenum chamber drains and the air inl...

Page 128: ...et Replacement Hatchback Headlining Trim Panel Replacement Hatchback with Sunroof Headlining Trim Panel Replacement Hatchback without Sunroof Headlining Trim Panel Replacement Sedan with Sunroof Headlining Trim Panel Replacement Sedan without Sunroof 2011 General Motors All rights reserved 0 2 Index BODY HARDWARE AND TRIM Eliminating Unwanted Odors in Vehicles Specifications BACK TO CHAPTER INDEX ...

Page 129: ...r Eliminator Fluids Refer to Electronic Parts Catalog Adhesives Fluids Lubricants and Sealers 2011 General Motors All rights reserved 0 2 Floor Coverings Headlinings BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 130: ...aks use this product with diagnostic procedures to first eliminate the primary cause of the odor Then use further applications on the residual odor to permanently correct the vehicle condition How to Use this Product Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners Do not use on any interior surface that plain water would deteriorate because th...

Page 131: ...d to a foam padding or attached to a synthetic padding dry the carpet using the method described below For a 2 piece carpet assembly with a synthetic padding dry the assembly using the method described below Drying Method 1 If you observe puddles of liquid on the carpet face use a wet vacuum to remove the excess moisture 2 Blot the face of the carpet with a towel in order to absorb as much moistur...

Page 132: ...to Front Side Door Opening Floor Carpet Retainer Replacement 5 Remove the rear side door opening floor carpet retainer Refer to Rear Side Door Opening Floor Carpet Retainer Replacement 6 Remove the center pillar lower trim panels Refer to Center Pillar Lower Trim Panel Replacement 1 Front Floor Panel Carpet Assembly Floor Panel Carpet Replacement 2011 General Motors All rights reserved 0 2 Floor C...

Page 133: ...nt Side Door Opening Floor Carpet Retainer Clip Qty 3 4 Front Side Door Opening Floor Carpet Retainer Assembly Front Side Door Opening Floor Carpet Retainer Replacement 2011 General Motors All rights reserved 0 2 Floor Coverings Headlinings BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 134: ...on Replacement 1 Rear Side Door Opening Floor Carpet Retainer Assembly Rear Side Door Opening Floor Carpet Retainer Replacement 2011 General Motors All rights reserved 0 2 Floor Coverings Headlinings BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 135: ... Panel Carpet Assembly Rear Compartment Floor Panel Carpet Replacement Sedan 2011 General Motors All rights reserved 0 2 Floor Coverings Headlinings BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 136: ...anel Carpet Assembly Rear Compartment Floor Panel Carpet Replacement Hatchback 2011 General Motors All rights reserved 0 2 Floor Coverings Headlinings BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 137: ...5 Remove the roof rail rear assist handle Refer to Roof Rail Rear Assist Handle Replacement 6 Remove the dome lamp bezel Refer to Dome Lamp Bezel Replacement 7 Remove the roof rail front stowage compartment Refer to Roof Rail Front Stowage Compartment Replacement 8 Remove the windshield side garnish molding Refer to Windshield Side Garnish Molding Replacement 9 Remove the body lock pillar upper tr...

Page 138: ... Refer to Roof Rail Front Assist Handle Replacement 5 Remove the roof rail rear assist handle Refer to Roof Rail Rear Assist Handle Replacement 6 Remove the dome lamp bezel Refer to Dome Lamp Bezel Replacement 7 Remove the roof rail front stowage compartment Refer to Roof Rail Front Stowage Compartment Replacement 8 Remove the windshield side garnish molding Refer to Windshield Side Garnish Moldin...

Page 139: ...t 5 Remove the roof rail rear assist handle Refer to Roof Rail Rear Assist Handle Replacement 6 Remove the dome lamp bezel Refer to Dome Lamp Bezel Replacement 7 Remove the roof rail front stowage compartment Refer to Roof Rail Front Stowage Compartment Replacement 8 Remove the windshield side garnish molding Refer to Windshield Side Garnish Molding Replacement 9 Remove the body lock pillar upper ...

Page 140: ...le Refer to Roof Rail Front Assist Handle Replacement 5 Remove the roof rail rear assist handle Refer to Roof Rail Rear Assist Handle Replacement 6 Remove the dome lamp bezel Refer to Dome Lamp Bezel Replacement 7 Remove the roof rail front stowage compartment Refer to Roof Rail Front Stowage Compartment Replacement 8 Remove the windshield side garnish molding Refer to Windshield Side Garnish Mold...

Page 141: ... Compartment Replacement Instrument Panel Compartment Door Latch Replacement Instrument Panel Compartment Door Dampener Replacement Instrument Panel Center Molding Replacement With U58 Instrument Panel Center Molding Replacement Without U58 Instrument Panel Assembly Replacement Instrument Panel Tie Bar Replacement Front Floor Console Cover Replacement Automatic Transmission Front Floor Console Cov...

Page 142: ... Bar Lower Support Bracket to Front Floor Tunnel Bolts 22N m 16lbft Instrument Panel Tie Bar to Brake Pedal Bracket Bolts 9N m 80lbin Instrument Panel Tie Bar to Brake Pedal Mounting Bracket Bolt 22N m 16lbft Instrument Panel Tie Bar to Cowl Nut 22N m 16lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK ...

Page 143: ...on Refer to Fastener Caution 2 Instrument Panel Insulator Instrument Panel Insulator Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 144: ...ate Qty 2 Procedures 1 Use a flat bladed plastic trim tool in order to disengage the retainers securing the accessory upper trim plates to the instrument panel assembly 2 When replacing the accessory trim plates transfer all necessary components Instrument Panel Accessory Upper Trim Plate Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0...

Page 145: ...engage the retainers securing the center trim plates to the instrument panel accessory upper trim plates Instrument Panel Center Trim Panel Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 146: ...flat bladed plastic trim tool in order to disengage the retainers securing the center upper trim molding to the instrument panel assembly 2 Disconnect electrical connections Instrument Panel Center Upper Molding Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUA...

Page 147: ...acement 7 Remove the right instrument panel outer air outlet Refer to Instrument Panel Outer Air Outlet Replacement Right Side 1 Instrument Panel Inflatable Restraint Module Fasteners Qty 2 Caution Refer to Fastener Caution Tighten 10N m89lbin 2 Instrument Panel Upper Trim Panel Fastener Qty 3 3 Instrument Panel Upper Trim Panel Procedures 1 Use a flat bladed plastic trim tool in order to disengag...

Page 148: ...m Cover Replacement 6 Remove the right instrument panel outer air outlet Refer to Instrument Panel Outer Air Outlet Replacement Right Side 1 Instrument Panel Upper Trim Panel Fastener Qty 3 Caution Refer to Fastener Caution 2 Instrument Panel Upper Trim Panel Procedures 1 Use a flat bladed plastic trim tool in order to disengage the retainers securing the upper trim panel to the instrument panel a...

Page 149: ...ft instrument panel outer trim cover Refer to Instrument Panel Outer Trim Cover Replacement 1 Instrument Panel Upper Trim Panel Fastener Caution Refer to Fastener Caution 2 Instrument Panel Upper Trim Panel Procedures 1 Use a flat bladed plastic trim tool in order to disengage the retainers securing the upper trim panel to the instrument panel assembly 2 When replacing the instrument panel upper t...

Page 150: ...ward disengaging the retainers securing the fuse block cover to the instrument panel compartment housing Instrument Panel Fuse Block Access Hole Cover Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 151: ...bladed plastic trim tool in order to disengage the retainers securing the instrument panel outer trim covers to the instrument panel assembly 2 Disconnect the electrical connections 3 When replacing the instrument panel outer trim cover transfer all necessary components Instrument Panel Outer Trim Cover Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARD...

Page 152: ...engage the retainers securing the instrument panel cluster upper bezel to the instrument cluster assembly Instrument Cluster Upper Bezel Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 153: ... retainers securing the lower trim pad to the instrument panel assembly 2 Disconnect the electrical connectors 3 When replacing the instrument panel lower trim pad transfer all necessary components Instrument Panel Lower Trim Pad Cover Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONI...

Page 154: ...rtment door 2 Unsnap the instrument compartment door latch from the door assembly Instrument Panel Upper Compartment Door Latch Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 155: ...er to Fastener Caution 2 Instrument Panel Compartment Housing Procedure Grasp the housing and pull downward disengaging the retainer clips securing the housing to the instrument panel Instrument Panel Compartment Housing Replacement RHD 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY...

Page 156: ...ner Qty 6 Caution Refer to Fastener Caution 2 Instrument Panel Compartment Procedure When replacing the instrument panel compartment transfer all necessary components if applicable Instrument Panel Compartment Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 157: ...des of the compartment assembly and allow the compartment to move past the compartment stops 2 Unsnap the compartment assembly from the instrument panel assembly 3 When replacing the instrument panel lower compartment transfer all necessary components Instrument Panel Lower Compartment Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 ...

Page 158: ... Fastener Caution 2 Instrument Panel Compartment Door Latch Assembly Instrument Panel Compartment Door Latch Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 159: ...ument Panel Compartment Door Dampener Procedure Unsnap the dampener assembly from the instrument panel compartment housing Instrument Panel Compartment Door Dampener Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 160: ...he center molding to the instrument panel assembly 2 When replacing the center molding assembly transfer all necessary components Instrument Panel Center Molding Replacement With U58 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 161: ... center molding to the instrument panel assembly 2 When replacing the center molding assembly transfer all necessary components Instrument Panel Center Molding Replacement Without U58 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 162: ...ument Panel Lower Trim Pad Cover Replacement 7 Remove the instrument panel insulator Refer to Instrument Panel Insulator Replacement 8 Note location and routing of the instrument panel electrical harness assembly in order to ensure proper installation 1 Instrument Panel Fastener Qty 9 Caution Refer to Fastener Caution 2 Instrument Panel Assembly Procedures 1 With the aid of an assistant lift the i...

Page 163: ...t 4 Unsnap the instrument panel fuse block 1 from the instrument panel tie bar assembly and position out of the way 5 Remove the push pin fastener 1 securing the left floor air outlet duct 2 to the instrument panel tie bar assembly 6 Remove the left floor air outlet duct 2 from the vehicle 7 Remove the nut 1 securing the instrument panel tie bar assembly to the cowl panel Instrument Panel and Cons...

Page 164: ...trument panel tie bar to the brake pedal mounting bracket 10 Remove the bolts 1 securing the right and left instrument panel tie bar lower support brackets 2 to the front floor tunnel panel Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 165: ...id of an assistant remove the instrument panel tie bar assembly 2 from the vehicle Installation Procedure 1 With the aid of an assistant position the instrument panel tie bar assembly 2 into the vehicle 2 Install the instrument panel wiring harness assembly to its in vehicle position as it was noted in the removal procedure 3 Loosely install the bolts 1 securing the instrument panel tie bar assemb...

Page 166: ...the right and left instrument panel tie bar lower support brackets 2 to the front floor tunnel panel 6 Loosely install the nut 1 securing the instrument panel tie bar to the brake pedal mounting bracket Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 167: ...cket to front floor tunnel panel bolts to 22N m 16lbft 12 Tighten the instrument panel tie bar to brake pedal mounting bracket nut to 22N m 16lbft 13 Tighten the instrument panel tie bar assembly to the brake pedal bracket bolts to 9N m 80lbin 14 Tighten the instrument panel tie bar assembly to the cowl panel nut to 22N m 16lbft 15 Install the left floor air outlet duct 2 into the vehicle 16 Insta...

Page 168: ...ment 19 Install the steering column and wheel from the vehicle Refer to Steering Column Replacement 20 Install the Instrument panel assembly Refer to Instrument Panel Assembly Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 169: ...he retainers securing the console cover to the console assembly 4 Disconnect the electrical connections 5 When replacing the console cover transfer all necessary components Front Floor Console Cover Replacement Automatic Transmission 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY RE...

Page 170: ...y 1 and release the retainer tabs securing the transmission shift lever boot 2 to the console cover assembly 3 Feed the transmission control lever boot assembly thru the opening in the console cover assembly 1 4 Remove the console cover assembly 1 from the vehicle 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL IND...

Page 171: ...g in the console cover assembly 1 3 Snap the transmission control lever boot assembly 2 to the console cover 1 ensuring the retainer tabs lock the boot assembly to the cover 4 Install the cover assembly to the console Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 172: ...loor Console Cup Holder Fasteners Qty 6 Caution Refer to Fastener Caution 2 Front Floor Console Cup Holder Assembly Front Floor Console Cup Holder Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 173: ...ing Cover Assembly Procedure Release the retainer clips securing the transmission control indicator to the front floor console cover Automatic Transmission Control Indicator Opening Cover Replacement 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 174: ...rder to release the retainers securing the extension to the console assembly Front Floor Console Extension Replacement Right Side 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 175: ...rder to release the retainers securing the extension to the console assembly Front Floor Console Extension Replacement Left Side 2011 General Motors All rights reserved Instrument Panel and Console Trim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 176: ...ront Floor Console Fasteners Qty 6 Caution Refer to Fastener Caution Procedure Move the front seats to the full forward position to access the front floor console rear fasteners 2 Front Floor Console Procedures 1 Disconnect the electrical connections 2 When replacing the console transfer all necessary components Front Floor Console Replacement 2011 General Motors All rights reserved 0 2 Instrument...

Page 177: ...eners Qty 3 Caution Refer to Fastener Caution 2 Instrument Cluster Assembly Procedure 1 Disconnect the electrical connector 2 Refer to Control Module References for programming and set up information Instrument Cluster Replacement 2011 General Motors All rights reserved 0 2 Instrument Panel and Console Trim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX 0 2 Instrument Panel and Console Trim BODY HAR...

Page 178: ...y Lock Pillar Upper Trim Panel Replacement Sedan Body Lock Pillar Upper Trim Panel Replacement Hatchback Quarter Inner Trim Finish Panel Replacement Hatchback Body Side Trim Panel Replacement Sedan Rear Window Panel Trim Replacement Sedan Rear Compartment Stowage Shelf Replacement Hatchback Rear Side Door Trim Replacement Hatchback Rear Side Door Trim Replacement Sedan Luggage Shade Replacement Ha...

Page 179: ...tener 6N m 53lbin Roof Rail Front Stowage Compartment Fastener 6N m 53lbin Roof Rail Rear Assist Handle Fastener 6N m 53lbin Fastener Tightening Specifications 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 180: ... Door Window Switch Bezel Screw Qty 8 Caution Refer to Fastener Caution 2 Front Side Door Window Switch Bezel Assembly Front Side Door Window Switch Bezel Replacement Left Side 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 181: ...Door Window Switch Bezel Screw Qty 8 Caution Refer to Fastener Caution 2 Front Side Door Window Switch Bezel Assembly Front Side Door Window Switch Bezel Replacement Right Side 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 182: ...astener Qty 2 Caution Refer to Fastener Caution 2 Rear Side Door Window Switch Bezel Fastener Qty 5 3 Rear Side Door Window Switch Bezel Assembly Rear Side Door Window Switch Bezel Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 183: ...Use the appropriate plastic trim tool to aid in the removal of the door trim Front Side Door Upper Front Trim Panel Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 184: ...rim integral cap to access the fastener 4 Front Side Door Trim Assembly Procedure 1 Use the appropriate plastic trim tool to aid in the removal of the door trim 2 Pull upwards on the door lock retainer cable to disengage 3 Disconnect the electrical connector Front Side Door Trim Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MOD...

Page 185: ... Pull the door upper rear trim panel away from the rear side door Rear Side Door Upper Rear Trim Panel Replacement Hatchback 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 186: ...and hold 2 Use a small flat bladed tool to release the cover to access the fastener Tighten 6N m 53lbin 2 Roof Rail Front Stowage Compartment Assembly Roof Rail Front Stowage Compartment Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 187: ...d hold 2 Use a small flat bladed tool to open the assist handle covers to access the screws Tighten 6N m 53lbin 2 Roof Rail Front Assist Handle Assembly Roof Rail Front Assist Handle Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 188: ...nd hold 2 Use a small flat bladed tool to open the assist handle covers to access the screws Tighten 6N m 53lbin 2 Roof Rail Rear Assist Handle Assembly Roof Rail Rear Assist Handle Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 189: ...shade Fastener Qty 2 Caution Refer to Fastener Caution 2 Sunshade Assembly Procedure 1 Squeeze the tabs at the base of the sunshade assembly to remove from the headliner 2 Disconnect the electrical connector Sunshade Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 190: ...downward to access the fastener 2 Sunshade Support Assembly Procedure Unclip the sunshade from the support and reposition Sunshade Support Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 191: ...rior to retainers 2 Tabs to be fully seated in the instrument panel I P trim panel retainer and valance panel 3 Disconnect the electrical connectors 4 Ensure the tether is reattached when installed Windshield Side Garnish Molding Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 192: ...eplacement 1 Body Rear Seat Back Trim Panel Retainer Qty 5 2 Body Rear Seat Back Trim Panel Assembly Body Rear Seat Back Trim Panel Replacement Sedan with AN1 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 193: ...e top of the rear seat back cushion and fold the rear seat back cushion forward 2 Body Rear Seat Back Trim Panel Assembly Body Rear Seat Back Trim Panel Replacement Sedan with AMA 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 194: ...iver or Passenger Seat Shoulder Belt Replacement 1 Center Pillar Upper Trim Panel Assembly Procedure When replacing the center pillar upper trim panel feed the seat belt through the panel Center Pillar Upper Trim Panel Replacement With AHU 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 195: ...Driver or Passenger Seat Shoulder Belt Replacement 1 Center Pillar Upper Trim Panel Assembly Procedure When replacing the center pillar upper trim panel feed the seat belt through the panel Center Pillar Upper Trim Panel Replacement Without AHU 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUA...

Page 196: ...r Refer to Rear Side Door Opening Floor Carpet Retainer Replacement 3 Move seat to full forward position 1 Center Pillar Lower Trim Panel Assembly Procedure Ensure the seat belt webbing does not become trapped during installation Center Pillar Lower Trim Panel Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET ...

Page 197: ...o Body Side Trim Panel Replacement 1 Body Lock Pillar Upper Trim Panel Assembly Procedure Pull outward from the top front to disengage clips Body Lock Pillar Upper Trim Panel Replacement Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 198: ...stener Caution 3 Body Lock Pillar Upper Trim Panel Assembly Procedure 1 Grasp the molding and pull outward to disengage the integral retainers 2 Disconnect the electrical connector if equipped Body Lock Pillar Upper Trim Panel Replacement Hatchback 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR M...

Page 199: ...towage Shelf Replacement 6 Remove the rear compartment sill trim plate Refer to Rear Compartment Sill Trim Plate Replacement 7 Remove the rear shoulder belt Refer to Shoulder Belt Replacement Rear 1 Quarter Inner Trim Finish Panel Assembly Procedure Use a trim tool or equivalent to aid in removal Note After installation of the quarter inner trim panel ensure the rear seat belt is not trapped under...

Page 200: ... Replacement 3 Remove lower rear shoulder belt fastener Refer to Shoulder Belt Replacement Rear 1 Body Side Trim Panel Push In Retainer 2 Body Side Trim Panel Assembly Note Ensure seat belt assembly is routed over and through opening in panel assembly Body Side Trim Panel Replacement Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODE...

Page 201: ...y Rear Seat Back Trim Panel Replacement 1 Rear Window Panel Trim Fastener Qty 2 2 Rear Window Panel Trim Assembly Procedure When replacing the rear window panel trim assembly transfer all necessary components Rear Window Panel Trim Replacement Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR ...

Page 202: ...tment Stowage Shelf Assembly Rear Compartment Stowage Shelf Replacement Hatchback 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 203: ...de Door Trim Fastener Procedure Use a small flat bladed tool to open the rear side door trim integral cap to access the fastener 4 Rear Side Door Trim Assembly Procedure 1 Use the appropriate plastic trim tool to aid in the removal of the door trim 2 Pull upwards on the door lock retainer cable to disengage 3 Disconnect the electrical connector Rear Side Door Trim Replacement Hatchback 2011 Genera...

Page 204: ...o open the rear side door trim integral cap to access the fastener 4 Rear Side Door Trim Assembly Procedure 1 Use the appropriate plastic trim tool to aid in the removal of the door trim 2 Pull upwards on the door lock retainer cable to disengage 3 Disconnect the electrical connector Rear Side Door Trim Replacement Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TR...

Page 205: ...bly Procedure Detach luggage shade from upper support Luggage Shade Replacement Hatchback 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 206: ...anel Retainer Qty 8 3 Liftgate Trim Finish Panel Assembly Procedure Use a trim tool or equivalent to aid in removal Liftgate Trim Finish Panel Replacement Hatchback 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 207: ...ent Lid Weatherstrip Replacement 1 Rear Compartment Sill Trim Plate Retainer Qty 4 2 Rear Compartment Sill Trim Plate Assembly Rear Compartment Sill Trim Plate Replacement 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 208: ... Retainer Qty 13 Procedure Use a trim removal tool to aid in the removal of the rear compartment trim panel 2 Rear Compartment Lid Inner Panel Trim Rear Compartment Lid Inner Panel Trim Replacement Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 209: ...ar compartment sill trim plate Refer to Rear Compartment Sill Trim Plate Replacement 1 Rear Compartment Side Trim Retainer Qty 4 2 Rear Compartment Side Trim Rear Compartment Side Trim Replacement Left Side Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 210: ...r compartment sill trim plate Refer to Rear Compartment Sill Trim Plate Replacement 1 Rear Compartment Side Trim Retainer Qty 4 2 Rear Compartment Side Trim Rear Compartment Side Trim Replacement Right Side Sedan 2011 General Motors All rights reserved 0 2 InteriorTrim BODY HARDWARE AND TRIM BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 211: ...a Refer to Rear Bumper Fascia Replacement 1 Pressure Relief Valve Quarter Outer Panel Pressure Relief Valve Replacement 2011 General Motors All rights reserved InteriorTrim BODY HARDWARE AND TRIM 0 2 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 212: ...pers and Fascias Collision Repair Frame and Underbody Paint and Coatings Plastic Panel Information and Repair 2011 General Motors All rights reserved Index BODY REPAIR 0 3 BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 213: ...ent Fuel Tank Filler Door Replacement Fuel Tank Filler Door Latch Housing Replacement Hood Hold Open Rod Replacement Rear Compartment Lid Hinge Torque Rod Replacement Hood Side Seal Replacement Hood Rear Seal Replacement Hood Rear Weatherstrip Replacement Radiator Grille Bumper Replacement Radiator Opening Upper Cover Replacement Liftgate Strut Replacement Front Side Door Weatherstrip Replacement ...

Page 214: ...k Nut 9N m 80lbin Front Side Door Lower Hinge to Body Bolt 32N m 24lbft Front Side Door Lower Hinge to Door Bolt 25N m 18lbft Front Side Door Upper Hinge to Body Bolt 32N m 24lbft Front Side Door Upper Hinge to Door Bolt 25N m 18lbft Hood Hinge Bolts 22N m 16lbft Hood Hinge Nuts 22N m 16lbft Hood Primary and Secondary Latch Bolts 22N m 16lbft Bolted Exterior Body Panels and Closures BODY REPAIR 0 ...

Page 215: ...2N m 16lbin Rear Side Door Check Link Nut 9N m 80lbin Rear Side Door Lower Hinge to Body Bolts 32N m 24lbft Rear Side Door Lower Hinge to Door Bolts 25N m 18lbft Rear Side Door Upper Hinge to Body Bolts 32N m 24lbft Rear Side Door Upper Hinge to Door Bolts 25N m 18lbft 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL IN...

Page 216: ...nflatable restraint discriminating sensor Refer to Front End Inflatable Restraint Discriminating Sensor Replacement 1 Front End Upper Tie Bar Bolt Qty 4 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Front End Upper Tie Bar Lower Bolt Qty 4 Tighten 22N m 16lbft 3 Front Bumper Impact Bar Bolt Qty 2 Tighten 100N m 74lbft 4 Front End Upper Tie Bar Procedure 1 Disconnect the electrical connec...

Page 217: ...ease Cable Retainer Procedure Disconnect the hood release cable retainers from the hood release cable 3 Hood Primary Latch Release Cable Grommet 4 Hood Primary Latch Release Cable Procedure Disconnect the hood primary latch release cable handle from the hood latch cable Refer to Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Replacement 2011 General Motors All...

Page 218: ...l and the front fender and so that the front side door is flush with the roof the rear door the rocker panel and the front fender Adjustment Front side door to roof a 4 5mm 1 0mm 0 18in 0 04in Front side door to rear door b 3 5mm 0 75mm 0 14in 0 03in Front side door to rocker panel c 5 0mm 1 0mm 0 20in 0 04in Front side door to front fender d 3 5mm 0 75mm 0 14in 0 03in Tighten 25N m 19lbft Front S...

Page 219: ...moved ensure that the dome lamp is off If the dome lamp is on remove the fuse Tighten 22N m 16lbft 2 Front Side Door Upper Hinge Bolt to Door Qty 2 Tighten 25N m 18lbft 3 Front Side Door Lower Hinge Bolt to Door Qty 2 Tighten 25N m 18lbft 4 Front Side Door Assembly Front Side Door Replacement 2011 General Motors All rights reserved Procedure 1 When replacing the door it is necessary to transfer al...

Page 220: ...ear side door to quarter outer panel b 3 8mm 0 75mm 0 15in 0 03in Rear side door to rocker panel c 5 0mm 1 0mm 0 20in 0 04in Rear side door to front side door d 3 5mm 0 75mm 0 14in 0 03in Adjustment Rear side door to roof a 4 5mm 1 0mm 0 18in 0 04in Rear side door to quarter outer panel b 3 8mm 0 75mm 0 15in 0 03in Rear side door to rocker panel c 5 0mm 1 0mm 0 20in 0 04in Rear side door to front ...

Page 221: ... been removed ensure that the dome lamp is off If the dome lamp is on remove the fuse Tighten 22N m 16lbft 2 Rear Side Door Hinge Bolt to Door Qty 2 Tighten 32N m 24lbft 3 Rear Side Door Hinge Bolt to Door Qty 2 Tighten 32N m 24lbft 4 Rear Side Door Assembly Rear Side Door Replacement 2011 General Motors All rights reserved Procedure 1 When replacing the door it is necessary to transfer all of the...

Page 222: ...e front bumper fascia guide Refer to Front Bumper Fascia Guide Replacement 1 Front Fender Bolt Qty 3 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Front Fender Nut Tighten 9N m 80lbin 3 Front Fender Bolt Qty 2 Tighten 9N m 80lbin 4 Front Fender Bolt Qty 2 Tighten 9N m 80lbin 5 Front Fender Front Fender Replacement 2011 General Motors All rights reserved Procedure 1 Disconnect the electri...

Page 223: ...sh with the roof the quarter outer panel the tail lamp and rear bumper fascia Adjustment Liftgate to roof a 5 5mm 1 0mm 0 22in 0 04in Liftgate to quarter outer panel b 4 0mm 1 0mm 0 16in 0 04in Liftgate to tail lamp c 3 5mm 1 0mm 0 14in 0 04in Liftgate to rear bumper fascia d 5 0mm 1 0mm 0 20in 0 04in Tighten 22N m 16lbft Liftgate Adjustment 2011 General Motors All rights reserved Bolted Exterior ...

Page 224: ...lar Upper Trim Panel Replacement 1 Liftgate Hinge Bolt Qty 4 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Liftgate Procedure 1 Transfer parts as needed 2 Adjust the liftgate if needed Refer to Liftgate Adjustment Liftgate Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012...

Page 225: ...s the release cable handle upward to release the retainers from the instrument panel bracket 2 Hood Primary Latch Release Cable Procedure Disconnect the hood release cable from the hood release handle Hood Primary Latch Release Cable Handle Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SON...

Page 226: ...hten 32N m 24lbft 2 Front Side Door Upper Hinge to Door Bolt Qty 2 Tighten 25N m 18lbft 3 Front Side Door Upper Hinge 4 Front Side Door Lower Hinge to Body Bolt Qty 2 Tighten 32N m 24lbft 5 Front Side Door Lower Hinge to Door Bolt Qty 2 Tighten 25N m 18lbft Front Side Door Upper Hinge and Lower Hinge Replacement 2011 General Motors All rights reserved 6 Front Side Door Lower Hinge Procedure If the...

Page 227: ...od Hinge Bolt Qty 2 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Hood Hinge Procedure Adjust the hood and hinge if needed Refer to Hood Adjustment Hood Hinge Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 228: ...pencil to mark the liftgate hinge position to the body prior to removal 1 Liftgate Hinge Nut Qty 2 Caution Refer to Fastener Caution Tighten 40N m 30lbft 2 Liftgate Hinge Qty 2 Procedure Adjust the liftgate if needed Liftgate Hinge Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 B...

Page 229: ...Torque Rod Replacement 1 Rear Compartment Lid Rear Hinge Bolt Qty 2 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Rear Compartment Lid Rear Hinge Procedures 1 Transfer parts as needed 2 Adjust the rear compartment lid if needed Refer to Rear Compartment Lid Adjustment Rear Compartment Lid Rear Hinge Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closu...

Page 230: ...er Hinge to Door Bolts Qty 2 Tighten 25N m 18lbft 3 Rear Side Door Upper Hinge 4 Rear Side Door Lower Hinge to Body Bolts Qty 2 Tighten 32N m 24lbft 5 Rear Side Door Lower Hinge to Door Bolts Qty 2 Tighten 25N m 18lbft 6 Rear Side Door Lower Hinge Rear Side Door Upper Hinge and Lower Hinge Replacement 2011 General Motors All rights reserved Procedure If the door striker needs adjust Refer to Rear ...

Page 231: ...od is flush with both fenders on the front edge the front bumper fascia and the headlamps Adjustment Hood to front fender a 3 0mm 0 75mm 0 12in 0 03in Hood to headlamp b 3 0mm 1 0mm 0 12in 0 04in Hood to front bumper fascia c 3 0mm 1 0mm 0 12in 0 04in Tighten 22N m 16lbft Hood Adjustment 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTE...

Page 232: ... of the hinge to the hood with a grease pencil to aid in alignment Tighten 22N m 16lbft 2 Hood Procedure 1 Transfer parts as needed 2 Adjust the hood if needed Refer to Hood Adjustment Hood Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 233: ...Insulator Procedure Ensure the 3 integral tabs are secured to the hood Hood Insulator Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 234: ...ft 2 Hood Primary and Secondary Latch Procedure Disconnect the release cable from the hood primary latch Hood Primary and Secondary Latch Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 235: ...ia Adjustment Rear compartment lid to quarter outer panel a 3 0mm 0 75mm 0 12in 0 03in Tail lamp to rear compartment lid b 3 0mm 1 0mm 0 12in 0 04in Rear compartment lid to rear bumper fascia c 5 5 mm 1 5mm 0 22in 0 06in Adjustment Rear compartment lid to quarter outer panel a 3 0mm 0 75mm 0 12in 0 03in Tail lamp to rear compartment lid b 3 0mm 1 0mm 0 12in 0 04in Rear compartment lid to rear bump...

Page 236: ...on Tighten 9N m 80lbft 2 Rear Compartment Lid Procedure 1 Disconnect the electrical connector 2 Adjust the rear compartment lid as needed Refer to Rear Compartment Lid Adjustment 3 Transfer components as necessary Rear Compartment Lid Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 201...

Page 237: ... Place the door window in the full open position Tighten 22N m 16lbft 2 Front Side Door Check Link Nut Qty 2 Procedure Remove the water deflector Tighten 9N m 80lbin 3 Front Side Door Check Link Front Side Door Check Link Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 238: ... Body Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Rear Side Door Check Link Nut Qty 2 Procedure Remove the water deflector Tighten 9N m 80lbin 3 Rear Side Door Check Link Assembly Rear Side Door Check Link Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MA...

Page 239: ...g light outward sliding pressure on the filler door release the retainer on the fuel tank filler door from the hinge Fuel Tank Filler Door Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 240: ...iner Qty 4 Procedure Release the 4 filler door latch housing retainers on the back of the housing 2 Fuel Tank Filler Door Latch Housing Procedure Press the fuel tank filler housing outward from the fuel filler pipe and the quarter panel Fuel Tank Filler Door Latch Housing Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER IN...

Page 241: ...t to avoid the possibility of damage to the vehicle or personal injury Procedure Open the retainer and remove the hood hold open rod Hood Hold Open Rod Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 242: ...ht Side Note Only use the special tool to remove and install the rear compartment lid hinge torque rod 2 Rear Compartment Lid Hinge Torque Rod Left Side Note Only use the special tool to remove and install the rear compartment lid hinge torque rod Rear Compartment Lid Hinge Torque Rod Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK ...

Page 243: ... Push In Retainer Qty 6 2 Hood Side Seal Hood Side Seal Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 244: ...t gun to a minimum prior to the hood rear outer seal installation 3 Do NOT touch the adhesive surface when tape is removed Peel the tape liner off and install the outer rear hood seal 4 Position the end of the seal into the end of the hood rear weatherstrip Hood Rear Seal Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER IN...

Page 245: ...rt of the air inlet grille Carefully pull the weatherstrip to the right left to release from the retainers on the air inlet grille Hood Rear Weatherstrip Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 246: ...efer to Fastener Caution 2 Radiator Grille Bumper Procedure Pull gently on each side of the radiator grille bumper to disengage from the front bumper fascia Radiator Grille Bumper Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 247: ...r Bolt Qty 4 Tighten 9N m 80lbin 3 Radiator Opening Upper Cover Push In Retainer Qty 6 4 Radiator Opening Upper Cover Radiator Opening Upper Cover Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 248: ...e removing or attaching Do NOT apply pressure to the middle of the rod because damage or bending will result Procedure 1 Release the locking tabs on the strut 2 Ensure the clip is fully seated when the strut is reinstalled If the clip cannot be fully seated a new strut should be installed Liftgate Strut Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BO...

Page 249: ...om the upper rear corner of the door 4 Pull the weatherstrip out of the door retainer 2 Front Side Door Weatherstrip Retainers Qty 21 3 Front Side Door Weatherstrip Procedure 1 Ensure that the weatherstrip is fully seated in the door frame retainer 2 Verify proper door operation Front Side Door Weatherstrip Replacement Door Side 2011 General Motors All rights reserved Bolted Exterior Body Panels a...

Page 250: ...nary Procedure 1 Starting in the center bottom of the weatherstrip pull the weatherstrip upward and away from the pinch weld flange 2 Start in the center bottom of the pinch weld flange 3 Ensure that the weatherstrip and retainers are fully seated on the flange before installing the front carpet retainer 4 Inspect the door for proper operation Front Side Door Weatherstrip Replacement Body Side 201...

Page 251: ...le solvent with a mixture of 50percent isopropyl alcohol and 50percent water by volume or high flash naphtha Liftgate Weatherstrip Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 252: ...mounted Use a suitable solvent with a mixture of 50percent isopropyl alcohol and 50percent water by volume or high flash naphtha Rear Compartment Lid Weatherstrip Replacement 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 253: ... Door Side It is only necessary to remove the upper second of the weatherstrip from the door to replace the weatherstrip retainer 2 Starting in the center top of the weatherstrip pull the weatherstrip upward and away from the door retainer 3 Inspect the door for proper operation and sealing Rear Side Door Upper Front Auxiliary Weatherstrip Retainer Replacement 2011 General Motors All rights reserv...

Page 254: ...tainers from the corners of the door 4 Pull the weatherstrip out of the door retainer 2 Rear Side Door Weatherstrip Retainers Qty 21 3 Rear Side Door Weatherstrip Procedure 1 Ensure that the weatherstrip is fully seated in the door frame retainer 2 Verify proper door operation Rear Side Door Weatherstrip Replacement Door Side 2011 General Motors All rights reserved Bolted Exterior Body Panels and ...

Page 255: ...nary Procedure 1 Starting in the center bottom of the weatherstrip pull the weatherstrip upward and away from the pinch weld flange 2 Start in the center bottom of the pinch weld flange 3 Ensure that the weatherstrip and retainers are fully seated on the flange before installing the front carpet retainer 4 Inspect the door for proper operation Rear Side Door Weatherstrip Replacement Body Side 2011...

Page 256: ... high When the hood is open the switch is closed and the voltage is pulled low The BCM uses the hood ajar switch as a content theft deterrent alarm trigger Hood Ajar Indicator Message When the hood is ajar a message is displayed on the DIC or the hood ajar indicator will be illuminated 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER ...

Page 257: ...scription BO 125 KM 125 Torque Rod Lifter Special Tools 2011 General Motors All rights reserved Bolted Exterior Body Panels and Closures BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 258: ...Front Air Deflector Replacement Front Bumper Fascia Air Deflector Replacement Rear Bumper Fascia Replacement Sedan Rear Bumper Fascia Replacement Hatchback Rear Bumper Fascia Outer Guide Replacement Sedan Rear Bumper Fascia Outer Guide Replacement Hatchback Rear Bumper Impact Bar Replacement Hatchback 2011 General Motors All rights reserved Index BODY REPAIR 0 3 Front Bumper Energy Absorber Replac...

Page 259: ...ing Lower Cover Screws 2 5N m 22lbin Front Bumper Fascia Screws 2 5N m 22lbin Front Bumper Impact Bar Bolts 100N m 74lbin Front Bumper Impact Bar Lower Bracket Screws 2 5N m 22lbin Front Bumper Lower Impact Bracket Bolts 22N m 16lbft Headlamp Bolt 2 5N m 22lbin Rear Bumper Impact Bar Bolts 40N m 30lbft Rear Bumper Impact Bar Nuts 40N m 30lbft Rear Fascia Screws 2 5N m 22lbin Fastener Tightening Sp...

Page 260: ...ergy Upper Absorber Push On Retainer Qty 2 2 Front Bumper Energy Upper Absorber Procedure Reposition the electrical harness from the absorber Front Bumper Energy Absorber Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 261: ...fer to Fastener Caution Tighten 100N m 74lbft 2 Front Bumper Impact Bar Procedure 1 Disconnect the electrical connectors harnesses as needed 2 Transfer any parts as needed Front Bumper Upper Impact Bar Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 262: ... Bumper Lower Impact Bar Bracket Bolt Qty 6 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Front Bumper Lower Impact Bar Front Bumper Lower Impact Bar Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 263: ...ion Refer to Fastener Caution Tighten 8N m 71lbin 2 Front Bumper Impact Bar Lower Bracket Procedure Lift up the front of the lower bracket enough to release the front guide tab from the front fascia Front Bumper Impact Bar Lower Bracket Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUA...

Page 264: ... m 53lbin 3 Front Bumper Fascia Procedure 1 Carefully push a small nylon wedge between the fascia and the bracket Insert a small flat bladed tool into the fascia slot and depress the tabs one at a time and pull the fascia wings off in the forward direction rather than outboard to gradually remove the fascia from the bracket 2 Disconnect the electrical connectors 3 On reassembly of the front fascia...

Page 265: ... Front Bumper Fascia Guide Rivet Qty 2 Special Tools BO 594 A Hand Rivet Tongs For equivalent regional tools refer to Special Tools 3 Front Bumper Fascia Guide Procedure Slide the guide forward to release the front retainer from the fender 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 Front Bumper Fascia Guide Replacement BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET...

Page 266: ... Fascia Center Support Bolt Qty 2 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Front Bumper Fascia Center Support Front Bumper Fascia Center Support Bracket Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 267: ...tener Caution Tighten 22N m 16lbft 3 Front Bumper Fascia Opening Lower Cover Screw Qty 3 Tighten 2 5N m 22lbin 4 Front Bumper Fascia Opening Lower Cover Front Bumper Fascia Opening Lower Cover Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 268: ...er Fascia Center Support Bracket Replacement 1 Front Bumper Fascia Bracket Bolt Qty 4 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Front Bumper Fascia Bracket Note Transfer any parts as needed Front Bumper Fascia Bracket Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 269: ...dlamp Replacement 1 Front Air Deflector Retainers Qty 2 2 Front Air Deflector Bolts Qty 2 Caution Refer to Fastener Caution Tighten 8N m 71lbin 3 Front Air Deflector Front Air Deflector Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 270: ...eplacement 1 Front Bumper Fascia Air Deflector Screw Qty 4 Caution Refer to Fastener Caution Tighten 8N m 71lbin 2 Front Bumper Fascia Air Deflector Front Bumper Fascia Air Deflector Replacement 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 271: ...tainer Qty 2 3 Rear Fascia Procedure 1 Carefully push a small nylon wedge between the fascia and the rear fascia guide Insert a small flat bladed tool into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove the fascia from the rear fascia guide 2 Transfer parts as needed Rear Bumper Fascia Replacement Sedan 2011 General Motors All rights...

Page 272: ...efully push a small nylon wedge between the fascia and the rear fascia guide Insert a small flat bladed tool into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove the fascia from the rear fascia guide 2 Transfer parts as needed Rear Bumper Fascia Replacement Hatchback 2011 General Motors All rights reserved Bumpers and Fascias BODY REP...

Page 273: ...umper Fascia Outer Guide Rivet Qty 7 Special Tools BO 594 A Hand Rivet Tongs For equivalent regional tools refer to Special Tools 2 Rear Bumper Fascia Outer Guide Rear Bumper Fascia Outer Guide Replacement Sedan 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 274: ...per Fascia Outer Guide Rivet Qty 5 Special Tools BO 594 A Hand Rivet Tongs For equivalent regional tools refer to Special Tools 2 Rear Bumper Fascia Outer Guide Rear Bumper Fascia Outer Guide Replacement Hatchback 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 275: ...fer to Fastener Caution Tighten 40N m 30lbft 2 Rear Bumper Impact Bar Nut Qty 2 Tighten 40N m 30lbft 3 Rear Bumper Impact Bar Procedure Transfer any parts as needed Rear Bumper Impact Bar Replacement Hatchback 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 276: ...Refer to Fastener Caution Tighten 40N m 30lbft 2 Rear Bumper Impact Bar Nut Qty 2 Tighten 40N m 30lbft 3 Rear Bumper Impact Bar Procedure Transfer any parts as needed Rear Bumper Impact Bar Replacement Sedan 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 277: ...ool Number Description BO 594 A Hand Rivet Tongs Special Tools 2011 General Motors All rights reserved Bumpers and Fascias BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 278: ...placement Rear Compartment Floor Panel Replacement Quarter Outer Panel Sectioning 5HB Quarter Outer Panel Sectioning 4NB Quarter Inner Panel Replacement 4NB Quarter Inner Panel Sectioning 5HB Center Pillar Inner Panel Replacement Center Pillar Reinforcement Replacement Center Pillar Sectioning Outer Rear Rail Sectioning Underbody Rear Side Rail Extension Replacement Rear End Panel Replacement Tail...

Page 279: ...Dimensions Body 5HB Dimensions Body 4NB 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 280: ...tram bar pointers set at equal lengths All die marks holes slots and fasteners are measured to the center All dimensions are symmetrical unless otherwise specified Point to Point Measurements Front End Engine Compartment Front End Lower Rear End Lower Rear End Side 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BOD...

Page 282: ...e Compartment 1 1201mm 2 944mm 3 599mm 4 1300mm 5 1409mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 283: ... 1 928mm 2 1122mm 3 1110mm 4 633mm 5 910mm 6 440mm 7 852mm 8 584mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 284: ...Rear End Lower 1 1233mm 2 1259mm 3 627mm 4 966mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 286: ... 1319mm 3 955mm 4 981mm 5 611mm 6 946mm 7 1005mm 8 1277mm 9 772mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 287: ...tram bar pointers set at equal lengths All die marks holes slots and fasteners are measured to the center All dimensions are symmetrical unless otherwise specified Point to Point Measurements Front End Engine Compartment Front End Lower Rear End Lower Rear End Side 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BOD...

Page 289: ...e Compartment 1 1201mm 2 944mm 3 599mm 4 1300mm 5 1409mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 290: ... 1 928mm 2 1122mm 3 1110mm 4 633mm 5 910mm 6 440mm 7 852mm 8 584mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 291: ...3mm 2 1259mm 3 627mm 4 966mm 5 1035mm 6 1504mm 7 1052mm 8 417mm 9 965mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 293: ...2 1319mm 3 955mm 4 981mm 5 611mm 6 946mm 7 886mm 8 1155mm 9 776mm 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 294: ...ty of the vehicle 4 Repair as much of the damage as possible 5 Locate mark and drill out all factory welds 1 Note the number and location of welds for installation of the service assembly 6 Remove the front wheelhouse from the vehicle Installation Procedure Note If the location of the original plug weld holes cannot be determined or if structural weld thru adhesive is present space the plug weld h...

Page 295: ...lers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 9 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling and Enabling Collision Repair...

Page 296: ... materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the front wheelhouse panel reinforcement 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the front wheelhouse panel reinforcement Installation Procedure 1 Drill 8mm 5 16in holes for plug we...

Page 297: ...rials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabling Collision Repair BODY REPAIR 0 3 BACK TO CHAP...

Page 298: ...corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the front compartment side rail 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the front compartment side rail Installation Procedure 1 Drill 8mm 5 16in holes for plug welding alo...

Page 299: ...epair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabling Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO M...

Page 300: ...he damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair Note Sectioning can be done anywhere in the straight area along the rocker panel 6 Create cut lines 1 on the front hinge pillar body Note Do not damage any inner panels or reinforcements 7 Cut the panel where sectioning ...

Page 301: ...rocedure 1 Cut the front hinge pillar body in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to overlap the remaining original panel by 25mm 1in at each joint location 1 2 Prepare all mating surfaces as necessary Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 302: ...ortion make 25mm 1in stitch welds along the seam with 25mm 1in gaps between them Then go back and complete the stitch weld 10 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 11 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 12 Install all related panels and components 13 Connect the negative battery cabl...

Page 303: ...e sealers and anti corrosion materials from the repair area Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the front hinge pillar body 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the damaged front hinge pillar body reinforcement 1 Installation Procedure 1 Prepare all mating su...

Page 304: ...rcement into position 8 Plug weld accordingly 1 9 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 10 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 11 Install all related panels and components 12 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 13 Enable the...

Page 305: ...sually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Cut the adhesive with an appropriate tool 9 Remove the dama...

Page 306: ...n and prepare the attaching surfaces for welding 3 Apply one part windshield urethane adhesive as noted from the original panel 1 4 Position the roof panel 1 on the vehicle 5 Verify the fit of the panel 6 Clamp the panel into position Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 307: ... Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling and Enabling 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 308: ...sually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Cut the adhesive with an appropriate tool 9 Remove the dama...

Page 309: ...n and prepare the attaching surfaces for welding 3 Apply one part windshield urethane adhesive 1 as noted from the original panel 4 Position the roof panel 1 on the vehicle 5 Verify the fit of the panel 6 Clamp the panel into position Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 310: ... Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling and Enabling 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 311: ...y cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Repair as much of the damage as possible to factory specifications Refer to Dimensions Body 5 Remove the sealers and anti corrosion materials from the repair area Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the numbe...

Page 312: ...y 1 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enablin...

Page 313: ...sions Body 5 Remove the sealers and anti corrosion materials from the repair area Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the damaged rear header panel 1 Installation Procedure Drill 8mm 5 16in holes for plug welding along the edges of the ser...

Page 314: ...i Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabling 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX ...

Page 315: ...r to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Repair as much of the damage as possible to factory specifications Refer to Dimensions Body 5 Remove the sealers and anti corrosion materials from the repair area Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the rocker inner panel 7 Drill all fa...

Page 316: ...y 1 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enablin...

Page 317: ... Cable Disconnection and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Create cut lines on the rocker outer panel 1 Note Do not damage any inner panels or reinforcements 7 Cut the panel wher...

Page 318: ...ocker outer panel 1 Installation Procedure 1 Cut the rocker outer panel in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to overlap the remaining original panel by 25mm 1inch at each joint location 1 2 Prepare all mating surfaces as necessary Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR M...

Page 319: ...e seam with 25mm 1in gaps between them Then go back and complete the stitch weld 10 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 11 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 12 Install all related panels and components 13 Connect the negative battery cable Refer to Battery Negative Cable Disconne...

Page 320: ...egative Cable Disconnection and Connection 3 Remove all related panels and components 4 Repair as much of the damage as possible to factory specifications Refer to Dimensions Body 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the body side frame rocker reinforceme...

Page 321: ...lug the weld accordingly 1 8 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 9 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to S...

Page 322: ...er 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 out...

Page 323: ... 8 Install the front side door outside handle Refer to Front Side Door Outside Handle Replacement 9 Install the front side door Refer to Front Side Door Replacement 10 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 11 Install all related panels and components 12 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 13 Enable the SIR syst...

Page 324: ...oor outside handle Refer to Rear Side Door Outside Handle Replacement 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Grind the edges of the rear side door outer panel 1 to separate the outer door panel from the door shell 7 Remove the rear side door outer door panel 1 8 Remove the sealers and anti corrosion materia...

Page 325: ...side door outside handle Refer to Rear Side Door Outside Handle Replacement 8 Install the rear side door Refer to Rear Side Door Replacement 9 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling...

Page 326: ...as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the rear compartment floor panel 7 Note the number and location of weld studs for installation of the service assembly 8 Drill all factory welds 1 Note the number and location of welds for installation of t...

Page 327: ...loor panel rear reinforcement the spare wheel carrier bracket the shipping device and the floor panel reinforcement as noted from the original panel 1 9 Clean and prepare the attaching surfaces for welding 10 Position the floor panel rear reinforcement the spare wheel carrier bracket the shipping device and the floor panel reinforcement on the vehicle 11 Verify the fit of the floor panel rear rein...

Page 328: ... Repair 15 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 16 Install all related panels and components 17 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 18 Enable the SIR system Refer to SIR Disabling and Enabling Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 329: ...tem Refer to SIR Disabling and Enabling 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Create cut lin...

Page 330: ... the quarter outer panel 10 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 11 Remove the damaged quarter outer panel 1 Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 331: ...nt location 1 2 Prepare all mating surfaces as necessary 3 Drill 8mm 5 16in holes for plug welding along the edges of the quarter outer panel as noted from the original panel 1 4 Clean and prepare the attaching surfaces for welding 5 Apply one part windshield urethane adhesive 1 as noted from the original panel Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2...

Page 332: ...ool kit 12 Finish closing the wheelhouse flanging 13 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 14 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 15 Install all related panels and components 16 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 17 Enable ...

Page 333: ...connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Create cut lines on the quarter outer panel 1 Note Do not d...

Page 334: ... the quarter outer panel 10 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 11 Remove the damaged quarter outer panel 1 Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 335: ...t location 1 2 Prepare all mating surfaces as necessary 3 Drill a 8mm 5 16in holes for plug welding along the edges of the quarter outer panel as noted from the original panel 1 4 Clean and prepare the attaching surfaces for welding 5 Apply one part windshield urethane adhesive 1 as noted from the original panel Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC ...

Page 336: ...ol kit 12 Finish closing the wheelhouse flanging 13 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 14 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 15 Install all related panels and components 16 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 17 Enable t...

Page 337: ...s much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the rear wheelhouse outer panel 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the damaged rear wheelhouse outer pan...

Page 338: ...accordingly 1 9 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 10 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 11 Install all related panels and components 12 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 13 Enable the SIR system Refer to SIR Disabling...

Page 339: ...ed panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Create cut lines on the body lock pillar inner reinforcement 1 Note Do not damage any inner panels or reinforcements 7 Cut the panel where sectioning is to be performed 1 8 ...

Page 340: ...ock pillar inner reinforcement 1 11 Locate and mark all the necessary factory welds of the rear wheelhouse outer panel 12 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 341: ...elhouse outer panel as noted from the original panel 1 2 Clean and prepare the attaching surfaces for welding 3 Position the rear wheelhouse outer panel 1 4 Verify the fit of the panel 5 Clamp the rear wheelhouse outer panel into position Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 342: ...ng original part Locate these holes 13mm 1 2in from the edge of part and spaced 40mm 1 1 2in apart 10 Prepare all mating surfaces as necessary 11 Fit the backing plates halfway into the sectioning joints clamp in place and plug weld to the vehicle 12 Align the body lock pillar inner reinforcement 13 Drill 8mm 5 1in holes for plug welding along the edges of the body lock pillar inner reinforcement ...

Page 343: ...r to Anti Corrosion Treatment and Repair 20 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 21 Install all related panels and components 22 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 23 Enable the SIR system Refer to SIR Disabling and Enabling 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAP...

Page 344: ...inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove the damaged center pillar inner panel 1 Installation Proced...

Page 345: ...elds along the seam with 25mm 1in gaps between them Then go back and complete the stitch weld 10 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 11 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 12 Install all related panels and components 13 Connect the negative battery cable Refer to Battery Negative C...

Page 346: ...on and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the center pillar reinforcement 7 Drill all factory welds 1 Note the number and locati...

Page 347: ... accordingly 1 9 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 10 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 11 Install all related panels and components 12 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 13 Enable the SIR system Refer to SIR Disablin...

Page 348: ... the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Remove the weather strip observe the flange in the center pillar a...

Page 349: ...ning procedures as needed depending on damage to vehicle Refer to Rocker Outer Panel Sectioning or Front Hinge Pillar Body Sectioning 11 Locate and drill out all factory welds 1 Note the number and location of welds for installation of the service part Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 350: ...nal panel by 25 mm 1 in at each joint location 1 2 Drill 8 mm 5 16 in holes for plug welding in the service part 1 as necessary in the corresponding locations noted on the original panel and along sectioned joint 3 Clean and prepare the attaching surfaces for welding Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 351: ...ly the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 9 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 10 Install all related panels and components 11 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling and Enabling 2011 G...

Page 352: ...nels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Create cut lines on the rear side rail 1 Note Do not damage any other panels or reinforcements 7 Cut the panel where sectioning is to be performed 1 8 Locate and mark all the nec...

Page 353: ...original cutting line on the service part rear rail 2 Align a sliding square or similar tool to the original cutting line and scribe a line across the rail 3 Use the same tool to transfer this scribed line onto the sides and the weld flanges of the rail 4 Place a mark forward 25mm 1in from the scribed line on all 3 sides of the service rail 5 Use the tool to scribe a line on all 3 sides and weld f...

Page 354: ...ervice part back to the first scribe line and remove the small corners 10 Bend the bottom side of the service part at the sectioning location inward slightly by aligning a vice grip flanging tool or similar tool at the first scribed line 11 Clean and prepare the attaching surfaces for welding 12 Position the rear side rail 1 on the vehicle Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO ...

Page 355: ...e welded surfaces 18 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 19 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 20 Install all related panels and components 21 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 22 Enable the SIR system Refer to SIR Disa...

Page 356: ...on 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all factory welds 7 Drill all factory welds 1 Note the number and location of welds for installation of the service assembly 8 Remove th...

Page 357: ... weld accordingly 1 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disab...

Page 358: ... 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair Note Note the number and location of welds for installa...

Page 359: ...5 Clamp the body rear end panel into position 6 Plug weld accordingly 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Conn...

Page 360: ...ated panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the body rear end panel 7 Drill all factory welds 1 Note the number and location of welds for installation of the servic...

Page 361: ...gly 1 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabl...

Page 362: ...ated panels and components 4 Visually inspect the damage Repair as much of the damage as possible 5 Remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair 6 Locate and mark all the necessary factory welds of the body rear end panel 7 Drill all factory welds 1 Note the number and location of welds for installation of the servic...

Page 363: ...gly 1 7 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repaired area Refer to Basecoat Clearcoat Paint Systems 9 Install all related panels and components 10 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabl...

Page 364: ... Alloy Steel Mild Steel Ultra High Strength Dual Phase Steel Ultra High Strength Steel 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 365: ...less the damage includes kinks If the damage includes kinks the part should be replaced Sectioning or partial replacement of this type of steel is recommended only at approved locations in a specific sectioning procedure This type of steel can be used as a sleeve or backer plate when recommended in a specific sectioning procedure Squeeze resistance spot welding can be used to replace factory spot ...

Page 366: ...d use of heat can be used to repair damage if the heat does not exceed 650 C 1200 F The heat should be applied a maximum of 2times for up to 90seconds Sectioning or partial replacement of this type of steel is recommended only at approved locations in a specific sectioning procedure This type of steel can be used as a sleeve or backer plate during sectioning procedures Squeeze resistance spot weld...

Page 367: ...ed Controlled use of heat can be used to repair damage if the heat does not exceed 650 C 1200 F The heat should be applied a maximum of 2times for up to 90seconds Sectioning or partial replacement of this type of steel is recommended only at approved locations in a specific sectioning procedure This type of steel can be used as a sleeve or backer plate when recommended in a specific sectioning pro...

Page 368: ...artial replacement is not recommended The use of heat to repair damage is not recommended for this type of steel Stitch welding is not recommended for this type of steel This classification of steel cannot be used as a backing reinforcement or a sleeve for a sectioning joint unless a specific procedure is available Recommended Repairs Squeeze resistance spot welding can be used to replace factory ...

Page 369: ... joints only Sectioning or partial replacement is not recommended The use of heat to repair damage is not recommended for this type of steel Stitch welding is not recommended for this type of steel This type of steel can not be used as a backing reinforcement or a sleeve for a sectioning joint Recommended Repairs Squeeze resistance spot welding can be used to replace factory spot welds where appli...

Page 370: ...ion BO 6392 MKM 6392 Flanging Tool Kit BO 6396 MKM 6396 Bonding Pliers Special Tools 2011 General Motors All rights reserved Collision Repair BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 371: ...er Replacement Hatchback Left Rear Wheelhouse Panel Liner Replacement Hatchback Right Rear Wheelhouse Panel Liner Replacement Sedan Left Rear Wheelhouse Panel Liner Extension Replacement Front Compartment Front Insulator Cover Replacement 2011 General Motors All rights reserved Index BODY REPAIR 0 3 Drivetrain and Front Suspension Frame Skid Plate Replacement Specifications Special Tools BACK TO C...

Page 372: ...tension Screws 3N m 27lbin Front Wheelhouse Liner Screw Front 3N m 27lbin Front Wheelhouse Rear Liner Nut 3N m 27lbin Front Wheelhouse Rear Liner Screw 3N m 27lbin Power Steering Fluid Cooling Pipe Bolt if equipped 9N m 80lbin Power Steering Inlet and Outlet Hose Bolt if equipped 9N m 80lbin Rear Wheelhouse Panel Liner Nut 2N m 18lbin Rear Wheelhouse Panel Liner Screw 3N m 27lbin Skid Plate Fasten...

Page 373: ...od Nut 65N m 48lbft Transmission Rear Mount Bracket Bolts 100N m 74lbft 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 374: ...late 3 Remove the front suspension frame skid plate 2 Installation Procedure 1 Position the front suspension frame skid plate 2 on the frame Caution Refer to Fastener Caution 2 Install the front suspension frame skid plate mounting bolts 2 and tighten to 22N m 16lbft 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 201...

Page 375: ...act Bar Lower Bracket Replacement 7 Disconnect the steering linkage tie rod end from the steering knuckle Refer to Steering Linkage Outer Tie Rod Replacement 8 Disconnect the lower ball joints from the steering knuckles Refer to Lower Control Arm Replacement 9 Disconnect the stabilizer links from the strut assemblies 10 Remove the steering rack retaining bolts 1 and discard 11 Using mechanics wire...

Page 376: ... The power brake booster pump if equipped Refer to Power Brake Booster Pump Replacement The front bumper lower impact bar Refer to Front Bumper Lower Impact Bar Replacement The stabilizer shaft Refer to Stabilizer Shaft Replacement The lower control arms Refer to Lower Control Arm Replacement 2 Install the frame 3 into the vehicle 3 Using the CH 50619 front suspension frame adjusting pins have an ...

Page 377: ...to the strut assemblies Refer to Stabilizer Shaft Link Replacement 15 Connect the steering linkage tie rod end to the steering knuckle Refer to Steering Linkage Outer Tie Rod Replacement 16 Install the front bumper impact bar lower bracket Refer to Front Bumper Impact Bar Lower Bracket Replacement 17 Install the left and right front wheel house liner inner front extensions Refer to Front Wheelhous...

Page 378: ...ty 2 Caution Refer to Fastener Caution Tighten 3N m 27lbin 2 Front Wheelhouse Liner Inner Front Extension Push In Retainer Qty 2 3 Front Wheelhouse Liner Inner Front Extension Front Wheelhouse Liner Inner Front Extension Replacement 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 379: ... Refer to Fastener Caution Tighten 2 5N m 22lbin 2 Front Wheelhouse Liner Push In Retainer Front Qty 2 3 Front Wheelhouse Liner Front Procedure Disengage the upper interlocking retainers Front Wheelhouse Liner Replacement Front 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 380: ...ighten 3N m 27lbin 2 Front Wheelhouse Rear Liner Nut Qty 3 Tighten 3N m 27lbin 3 Front Wheelhouse Rear Liner Push In Retainer Qty 2 4 Front Wheelhouse Rear Liner Procedure Disengage the upper interlocking retainers Front Wheelhouse Liner Replacement Rear 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 381: ...er to Fastener Caution Tighten 3N m 27lbin 2 Rear Wheelhouse Panel Liner Nut Qty 4 Tighten 2N m 18lbin 3 Rear Wheelhouse Panel Liner Push In Retainer 4 Rear Wheelhouse Panel Liner Rear Wheelhouse Panel Liner Replacement Sedan Right 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 382: ...r Nut Caution Refer to Fastener Caution Tighten 2N m 18lbin 2 Rear Wheelhouse Panel Liner Screw Qty 5 Tighten 3N m 27lbin 3 Rear Wheelhouse Panel Liner Rear Wheelhouse Panel Liner Replacement Hatchback Left 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 383: ... to Fastener Caution Tighten 3N m 27lbin 2 Rear Wheelhouse Panel Liner Nut Qty 4 Tighten 2N m 18lbin 3 Rear Wheelhouse Panel Liner Push In Retainer 4 Rear Wheelhouse Panel Liner Rear Wheelhouse Panel Liner Replacement Hatchback Right 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 384: ... Liner Screw Qty 4 Caution Refer to Fastener Caution Tighten 3N m 27lbin 2 Rear Wheelhouse Panel Liner Push In Retainer 3 Rear Wheelhouse Panel Liner Rear Wheelhouse Panel Liner Replacement Sedan Left 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 385: ...n 1 Rear Wheelhouse Panel Liner Extension Nut Qty 2 Caution Refer to Fastener Caution 2 Rear Wheelhouse Panel Liner Extension Rear Wheelhouse Panel Liner Extension Replacement 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 386: ...22lbin 2 Front Compartment Front Insulator Cover Bolt Qty 4 Tighten 22N m 16lbft 3 Front Compartment Front Insulator Cover Front Compartment Front Insulator Cover Replacement 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 387: ... 45059 J 45059 Angle Meter CH 50619 Front Suspension Frame Adjusting Pins Special Tools 2011 General Motors All rights reserved Frame and Underbody BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 388: ...2011 General Motors All rights reserved Paint and Coatings BODY REPAIR 0 3 Clearcoat Repair without Repainting Environmental Fallout Acid Rain Paint Gauges Clearcoat Thickness Rail Dust Damage Repair BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 389: ...to identify the paint systems you may use that have been engineered to meet GM standards The GM Approved Refinish Materials book supplies all approved products including volatile organic compound VOC compliant regulations recommended by the individual manufacturer and detailed procedures for materials used in their paint system The latest revision of the GM Approved Refinish Materials booklet is l...

Page 390: ...book which identifies the paint systems you may use The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www gmgoodwrench com Anti corrosion compounds are light bodied materials designed to penetrate between metal to metal surfaces such as pinch weld joints hem flanges and integral panel attaching points where metal surfaces are difficult to coa...

Page 391: ...er to close a gap should be sealed using a heavy bodied caulking material Follow the label directions for the material selected Color application may be required in order to restore repaired areas such as hood fenders doors quarters lid roof engine compartment underbody and inner panels to original appearance When this is necessary conventional refinishing preparation undercoat buildup and color a...

Page 392: ...lout Acid Rain or Rail Dust Damage Repair Important Follow all of the instructions from the manufacturer of the polishing material 3 Use a paint gauge before during and after sanding and or polishing to avoid removing too much clearcoat Refer to Paint Gauges 2011 General Motors All rights reserved Paint and Coatings BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REP...

Page 393: ...g Refer to Basecoat Clearcoat Paint Systems Surface Level Contamination Repair 1 Thoroughly wash and dry the contaminated area with a GM approved Liquid Wash and Wax kit 2 Clean the affected area with silicone wax and grease remover 3 Remove and neutralize acidic residue by cleaning the contaminated areas with a mixture of baking soda and water 1 tablespoon of baking soda per 1liter or 1quart of w...

Page 394: ...d to checking either ferrous metal steel non ferrous metal or aluminum panel At this time there are no viable gauges for reading film thickness on composite SCM doors RIM fenders panels The more sophisticated ETG electronic paint thickness gauges digital type gauges are able to read film thickness on both ferrous and non ferrous metal panel Digital ETG gauges may have an accuracy range of 1percent...

Page 395: ... 0020in thick The clearcoat contains ultraviolet screeners Removing more than 0 5mils 0 019in of the clearcoat may result in early paint failure 2011 General Motors All rights reserved Paint and Coatings BODY REPAIR 0 3 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 396: ...d ensure the vehicle surfaces are cool during the removal process 2 Thoroughly wash the repair area with a GM approved Liquid Wash and Wax kit 3 Wipe the area dry 4 Clean the affected area with silicone wax and grease remover 5 Perform the removal process according to the manufacturer s directions of the type of repair material used Gel Type Oxalic Acid or Clay Type Non Acid Based If upon inspecti...

Page 397: ...ll types of thermoset plastic Follow the manufacturer s application and curing recommendations Do not intermix systems Use the supplies and the repair materials from the same manufacturer Clean the inner and outer surfaces of the repair area with a soap impregnated scouring pad in order to remove any dirt or mold release agent Clean the area with a wax and grease remover using only enough of the r...

Page 398: ...t is thermoplastic polyolefin or thermoset non polyolefin Float Test 1 Cut a shaving of plastic from the back of the part The shaving should be free of mold release agents and paint 2 Place the shaving in a container of water Thermoplastic polyolefin floats Thermoset non polyolefin sinks Abrasion Test Sand a spot near the damaged area with Grade36 Roloc Disc Thermoplastic polyolefin material melts...

Page 399: ...s Exterior Finish Trim Panels Nylon Capron Zytel Rilsan Minion Vydyne Welland Rigid PA PAG PAGG Polyamide Exterior Finish Trim Panel Headlamp Bezel Quarter Panel Extension Capron Minlon Nylon Rilsan Vydyne Wellamid Zytel Rigid Thermoset PA PPE Polymide Polypheneylene Ether Exterior Trim Fender GTX Rigid Thermoset PBT TEEE PBTP EEBC Polybutylene Terephthalate Ether Ester Block Compound Fascia Rocke...

Page 400: ...l Vinylite Flexible Vinyl SAN SA Styrene Acrylonitrite Center Console Glove Box Door Interior Trim Panel Foracryl Lustran Tyril Rigid TEO EP EPM TPO Ethylene Propylene Rubber Air Dam Bumper Fascia Valance Panel EPI EPII TPO TPR Thermoplastic Rubber Flexible Thermoplastic TPO Thermal Plastic Oletin Bumper Covers TPO Flexible Thermoplastic TPU TPUR Polyurethane Polyolefin Bumper Fascia Gravel Deflec...

Page 401: ... Moveable Windows Horns Lighting Mirrors Vehicle Access Wipers and Washers 2011 General Motors All rights reserved Index BODY SYSTEMS 0 4 BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 402: ...egulator Motor Replacement Front Side Door Window Regulator Handle Replacement Rear Side Door Window Regulator Handle Replacement Front Side Door Window Rear Guide Replacement Rear Side Door Window Rear Guide Replacement Front Side Door Window Outer Sealing Strip Replacement Rear Side Door Window Outer Sealing Strip Replacement Sedan Rear Side Door Window Outer Sealing Strip Replacement Hatchback ...

Page 403: ...11N m 96lbin Front Side Door Window Regulator Power Manual Screws 11N m 97lbin Rear Side Door Window Rear Guide Bolts 11N m 97lbin Rear Side Door Window Regulator Motor Bolts 5N m 44lbin Rear Side Door Window Weatherstrip Lower Screw 9N m 80lbin Rear Side Door Window Weatherstrip Upper Screw 3N m 27lbin Fastener Tightening Specifications 2011 General Motors All rights reserved Fixed and Movable Wi...

Page 404: ... parts from broken glass Upper dash pad Defroster outlets and A C outlets Seats and carpeting Warning Refer to Glass and Sheet Metal Handling Warning Note Before cutting out a stationary window apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim 7 Using the appropriate tool carefully cut the windshield reveal molding 1 in order to access the auto...

Page 405: ...ling Installation Procedure 1 Install the windshield into the opening Refer to Adhesive Installation of Windshields 2 Install the rearview mirror Refer to Inside Rearview Mirror Replacement 3 Install the interior windshield garnish moldings Refer to Windshield Side Garnish Molding Replacement 4 Install the air inlet grille Refer to Air Inlet Grille Panel Replacement 5 Install the windshield wipers...

Page 406: ... 2 Place the window on a clean and dry surface 3 Use a suitable plastic tool use care when releasing the reveal molding not to pry on the window 4 Clean around the edges and surface of the window and molding with a 50 50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth Windshield Upper Reveal Molding Replacement 2011 General Motors All rights reserved Fixed and Movabl...

Page 407: ...at the window can be removed from the guides 4 In order to remove the window out of the frame carefully grasp and tilt the window as you guide the window up and forward Tighten 11N m 97lbin 2 Front Side Door Window Procedure 1 Lower the window to align the guide nuts with the access holes in the inner door panel 2 Do not operate the regulator motor without supporting the window Ensure that the win...

Page 408: ...ed 4 In order to remove the window out of the frame carefully grasp and tilt the window as you guide the window up and forward Tighten 11N m 97lbin 2 Rear Side Door Window Procedure 1 Align the window guide with the access holes in the inner door panel 2 Install the window to the guide 3 Do not operate the regulator motor without supporting the window Ensure that the window remains in the guide wh...

Page 409: ... 4 In order to remove the window out of the frame carefully grasp and tilt the window as you guide the window up and forward Tighten 11N m 97lbin 2 Rear Side Door Window Procedure 1 Align the window guide with the access holes in the inner door panel 2 Install the window to the guide 3 Do not operate the regulator motor without supporting the window Ensure that the window remains in the guide when...

Page 410: ...ove the weatherstrip from the front and rear lower guides 3 Grasp both upper corners pull forward releasing assembly from the door frame Tighten 3N m 27lbin 3 Rear Side Door Window Weatherstrip Procedures 1 Insert the weatherstrip downward in the guide until fully seated 2 Carefully move the regulator upward for short slow intervals while ensuring that the window remains in the guides 3 Inspect th...

Page 411: ...ect the rear window radio antenna connector Warning If broken glass falls into the defroster outlets it can be blown into the passenger compartment and cause personal injury 5 Cover to protect the following parts from broken glass Upper dash pad Defroster outlets and A C outlets Seats and carpeting Note Keep the cutting edge of the appropriate tool against the window There are window locating pins...

Page 412: ...ers 1 are still attached to the window before installing Installation Procedure 1 Install the rear window into the opening Refer to Adhesive Installation of Rear Windows 2 Connect the rear window defogger electrical connectors 3 Install the rear window radio antenna connector 4 Connect the OnStar antenna if equipped Check the radio and OnStar system to verify reception 5 Close the rear compartment...

Page 413: ...ling 2 Place the window on a clean and dry surface 3 Use a suitable plastic tool use care when releasing the reveal molding not to pry on the window 4 Clean around the edges and surface of the window and molding with a 50 50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth Rear Window Reveal Molding Replacement 2011 General Motors All rights reserved Fixed and Movable...

Page 414: ...er to Rear End Spoiler Replacement Warning Refer to Defroster Outlet Warning 6 Cover the following parts to protect from broken glass Upper dash pad Defroster outlets and A C outlets Seats and carpeting Note Keep the cutting edge of the appropriate tool against the window There are window locating pins one in each upper corner of the window Use care Not to remove or cut them off when removing the ...

Page 415: ...Installation of Liftgate Windows 2 Install the rear spoiler Refer to Rear End Spoiler Replacement 3 Install the rear window wiper arm Refer to Rear Window Wiper Arm Replacement 4 Connect the liftgate window defogger electrical connectors to the bus bar 5 Install the liftgate trim Refer to Liftgate Trim Finish Panel Replacement 6 Remove the double layer of masking tape around the perimeter of the p...

Page 416: ...Door Window Switch Assembly Procedure 1 Disconnect the electrical connectors 2 Refer to Control Module References for programming and set up procedures Front Side Door Window Switch Replacement Left Side 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 417: ...oor Window Switch Assembly Procedure 1 Disconnect the electrical connectors 2 Refer to Control Module References for programming and set up procedures Front Side Door Window Switch Replacement Right Side 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 418: ...ide Door Window Switch Assembly Procedure 1 Disconnect the electrical connectors 2 Refer to Control Module References for programming and set up procedures Rear Side Door Window Switch Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 419: ...ater deflector 2 Loosen the window guide nuts Do Not remove the nuts from the guide 3 Disconnect the electric connector from the regulator motor Tighten 11N m 97lbin 2 Front Side Door Window Regulator Procedure 1 Transfer the front side door window regulator motor Refer to Front Side Door Window Regulator Motor Replacement 2 Inspect the door window for proper operation before installing the door t...

Page 420: ...and the window should perform the express up and express down functions Window Motor Relearn Procedure A relearn procedure may need to be performed for any Local Interconnect Network LIN window motor for the following conditions When the window glass is out of alignment When the window glass has been replaced When the door has been replaced When the window regulator has been replaced Note Prior to...

Page 421: ...rocedure 1 Remove the front side door water deflector 2 Disconnect the electric connector from the regulator motor Tighten 5N m 44lbin 2 Front Side Door Window Regulator Motor Procedure Inspect the door window for proper operation before installing the door trim panel Front Side Door Window Regulator Motor Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0...

Page 422: ...e door electrical connector 4 Remove the rear side door window from the guide Refer to Rear Side Door Window Rear Guide Replacement Do Not remove the window from the vehicle raise the window to the fully up position tape in place Tighten 11N m 97lbin 2 Rear Side Door Window Regulator Procedure 1 Transfer the rear side door window regulator motor Refer to Rear Side Door Window Regulator Motor Repla...

Page 423: ... the door electrical connector 4 Remove the rear side door window from the guide Refer to Rear Side Door Window Rear Guide Replacement Do not remove the window from the vehicle raise the window to the fully up position tape in place Tighten 11N m 97lbin 2 Rear Side Door Window Regulator Procedure 1 Transfer the rear side door window regulator motor Refer to Rear Side Door Window Regulator Motor Re...

Page 424: ...e door window from the guide Do Not remove the window from the vehicle raise the window to the fully up position tape in place 3 Disconnect the electrical connector from the window regulator motor Tighten 5N m 44lbin 2 Rear Side Door Window Regulator Motor Procedure Inspect the door window for proper operation before installing the door trim panel Rear Side Door Window Regulator Motor Replacement ...

Page 425: ...opriate tool remove the clip from handle 2 Front Side Door Window Regulator Handle Front Side Door Window Regulator Handle Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 426: ...opriate tool remove the clip from handle 2 Rear Side Door Window Regulator Handle Rear Side Door Window Regulator Handle Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 427: ...e the window from the vehicle raise the window to the fully up position 3 Pull the weatherstrip out from the inner channel of the guide Tighten 11N m 97lbin 2 Front Side Door Window Rear Guide Tip Inspect the window for proper operation before installing the trim panel Front Side Door Window Rear Guide Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 B...

Page 428: ...window from the vehicle raise the window to the fully up position 3 Pull the weatherstrip out from the inner channel of the guide Tighten 11N m 97lbin 2 Rear Side Door Window Rear Guide Tip Inspect the door window for proper operation before installing the door trim panel Rear Side Door Window Rear Guide Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4...

Page 429: ...d pull upward and away from the door flange 3 Press firmly to insert the front side door window sealing strip back on the door flange 4 Inspect the door window for proper operation Front Side Door Window Outer Sealing Strip Replacement 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 430: ...priate tool lift one end up and pull away from the door flange to remove Rear Side Door Window Outer Sealing Strip Replacement Sedan 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 431: ... Press firmly to insert the rear side door window sealing strip back on the door flange 3 Inspect the door window for proper operation before installing the door trim panel Rear Side Door Window Outer Sealing Strip Replacement Hatchback 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 432: ...the door frame 4 Insert the weatherstrip downward in the front and rear channel until fully seated 5 Position the window weatherstrip in the upper rear corner of the frame work the weatherstrip around the door frame 6 Carefully move the regulator upward for short slow intervals while ensuring that the window remains in the channels 7 Inspect the door window for proper operation before installing t...

Page 433: ...iner to expose the screw 2 Remove the weatherstrip from the front and rear lower guides 3 Grasp both upper corners pull downward releasing the weatherstrip from the door frame Tighten 3N m 27lbin 3 Rear Side Door Window Weatherstrip Procedure 1 Insert the weatherstrip downward in the guide until fully seated 2 Carefully move the regulator upward for short slow intervals while ensuring that the win...

Page 434: ...ng the weatherstrip from the door frame 4 Insert the weatherstrip downward in the window guides until fully seated 5 Carefully move the regulator upward for short slow intervals while ensuring that the window remains in the guides 6 Inspect the door window for proper operation before installing the door trim panel Rear Side Door Window Weatherstrip Replacement Hatchback 2011 General Motors All rig...

Page 435: ... and 5130 PPGDP90LF SPIES HECKER3688 8590 3688 5150 4070 5090 STANDOX11158 13320 14653 14980 products are approved for this application 5 After repairing the opening as indicated perform the following steps 5 1 Remove all traces of broken glass from the outer cowl panel seats floor and defroster ducts 5 2 Clean around the edge of the inside surface of the window with a 50 50 mixture of isopropyl a...

Page 436: ...ructions by the manufacturer s 14 Apply the auto adhesive primer application 2 around the perimeter of the window 1 per auto adhesive instructions by the manufacturer s 15 Apply the glass primer black to the same areas 2 that glass prep clear was applied 16 Allow the glass primer to dry per auto adhesive instructions by the manufacturer s Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER ...

Page 437: ...smooth continuous bead Cut the applicator nozzle to provided a V cut to apply the auto adhesive 19 Use the edge of the window as a guide for the nozzle in order to apply the urethane adhesive 1 to the inner surface of the window 3 Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 438: ...wer the window 2 to touch the auto adhesive 21 Gently depress the window on the auto adhesive bead until the window reveal molding is seated 22 Tape the window to the body in order to minimize movement and until the auto adhesive cures per auto adhesive instructions by the manufacturer s 23 Ensure all excess urethane adhesive is cleaned from the body before water test Fixed and Movable Windows BOD...

Page 439: ...ent relative humidity Allow at least 24hours for the complete curing of the urethane adhesive For the chemical curing type of urethane adhesive allow a minimum of 1hour Do NOT physically disturb the repair area until after these minimum times have elapsed 28 Maintain the following conditions in order to properly cure the urethane adhesive Partially lower a door window in order to prevent pressure ...

Page 440: ...n Williams PSE4600 and NP70 and Martin Semour 5120 and 5130 PPGDP90LF SPIES HECKER3688 8590 3688 5150 4070 5090 STANDOX11158 13320 14653 14980 products are approved for this application 5 After repairing the opening as indicated perform the following steps 5 1 Remove all traces of broken glass from the outer cowl panel seats floor and defroster ducts 5 2 Clean around the edge of the inside surface...

Page 441: ...facturer s 13 Apply the auto adhesive primer application 2 around the perimeter of the window 1 per auto adhesive instructions by the manufacturer s 14 Apply the glass primer black to the same areas 2 that glass prep clear was applied 15 Allow the glass primer to dry per auto adhesive instructions by the manufacturer s 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS ...

Page 442: ...der to apply a smooth continuous bead Cut the applicator nozzle to provided a V cut to apply the auto adhesive 18 Use the edge of the window as a guide for the nozzle in order to apply the urethane adhesive 1 to the inner surface of the window 3 Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 443: ...window 2 to touch the auto adhesive 20 If the locating pins were damaged align the masking tape 1 lines on the window 2 and the body 21 Gently depress the window on the auto adhesive bead until the window reveal molding is seated 22 Tape the window to the body in order to minimize movement and until the auto adhesive cures per auto adhesive instructions by the manufacturer s Fixed and Movable Wind...

Page 444: ...m of 6hours at 21 C 70 F or greater and with at least 30 percent relative humidity Allow at least 24hours for the complete curing of the urethane adhesive For the chemical curing type of urethane adhesive allow a minimum of 1hour Do NOT physically disturb the repair area until after these minimum times have elapsed 28 Maintain the following conditions in order to properly cure the urethane adhesiv...

Page 445: ...20 and 5130 PPGDP90LF SPIES HECKER3688 8590 3688 5150 4070 5090 STANDOX11158 13320 14653 14980 products are approved for this application 5 After repairing the opening as indicated perform the following steps 5 1 Remove all traces of broken glass from the outer cowl panel seats floor and defroster ducts 5 2 Clean around the edge of the inside surface of the window with a 50 50 mixture of isopropyl...

Page 446: ...ructions by the manufacturer s 14 Apply the auto adhesive primer application 2 around the perimeter of the window 1 per auto adhesive instructions by the manufacturer s 15 Apply the glass primer black to the same areas 2 that glass prep clear was applied 16 Allow the glass primer to dry per auto adhesive instructions by the manufacturer s Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER ...

Page 447: ...sive 1 to the inner surface of the window 3 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 20 With an assistant align the window locating pins 2 to the slots located in each corner of the pinch weld flange Lower the window 1 to touch the auto adhesive Fixed and Movable Window...

Page 448: ...veal molding is seated 23 Tape the window to the body in order to minimize movement and until the auto adhesive cures per auto adhesive instructions by the manufacturer s 24 Ensure all excess urethane adhesive is cleaned from the body before water test Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 449: ...ent relative humidity Allow at least 24hours for the complete curing of the urethane adhesive For the chemical curing type of urethane adhesive allow a minimum of 1hour Do NOT physically disturb the repair area until after these minimum times have elapsed 29 Maintain the following conditions in order to properly cure the urethane adhesive Partially lower a door window in order to prevent pressure ...

Page 450: ...n Rear Window Defogger Description and Operation Stationary Window Description Urethane Adhesive Description 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 451: ...e mix the application and the drying times After repairing the opening as indicated shake the pinch weld primer black 3 well Using a new dauber apply the primer to the primed surface of the flange in the bonding area Allow the primer to dry for 10minutes Use only the full cut method also known in the field as full strip method when installing windows This method includes the following The replacem...

Page 452: ...ircuit is spliced into the driver window switch voltage supply circuit within the IP Fuse Block Ground for all three of the passenger door switches is also supplied by the driver window switch Driver Express Up and Express Down Power Window Motor If Equipped The driver door may be equipped with a smart window motor that will detect excessive resistance while performing the express up function and ...

Page 453: ...ff internally in the BCM to the supply voltage circuit of the rear window defogger indicator The rear defogger relay is energized and the rear window defogger indicator is illuminated With the relay energized battery positive voltage is allowed from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger grid When you start the engine and ...

Page 454: ...ity The reinstallation of the windows with adhesive requires complete replacement of the adhesive bead and is known as the full cut method All stationary windows must use a adhesive systems which meet GM Specification GM3651G 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 455: ...se these materials based on specific manufacturer Do NOT intermix primers or adhesives from one manufacturer to another Always follow the system manufacturer s instructions for application handling and curing 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 456: ... A Glass Sealant Cold Knife Remover BO 39032 J 39032 Stationary Glass Removal Tool Special Tools 2011 General Motors All rights reserved Fixed and Movable Windows BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 457: ...n Contact Replacement 2011 General Motors All rights reserved Index BODY SYSTEMS 0 4 Horn Replacement Specifications Description and Operation BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 458: ...orn Nut 17N m 13lbft Steering Wheel Horn Contact Bolts 5 5N m 49lbin Fastener Tightening Specifications 2011 General Motors All rights reserved Horns BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 459: ...heelhouse Liner Replacement 1 Horn Nut Caution Refer to Fastener Caution Tighten 17N m 13lbft 2 Horn Procedure Disconnect the electrical connector Horn Replacement 2011 General Motors All rights reserved Horns BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 460: ...ing Wheel Horn Contact Spring Retainer Bolt Qty 3 Caution Refer to Fastener Caution Tighten 5 5N m 49lbin 2 Steering Wheel Horn Contact Assembly Procedure Disconnect the electrical connectors Steering Wheel Horn Contact Replacement 2011 General Motors All rights reserved Horns BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 461: ...e has been locked The notification feature may be enabled or disabled through personalization For further information refer to Keyless Entry System Description and Operation Circuit Operation The BCM controls the horn operation when the horn switch is pressed it closes a switch pulling the horn signal circuit low When the BCM detects the drop in voltage in the horn switch signal circuit it energiz...

Page 462: ...t Stop Lamp Replacement Hatchback Cargo Center Courtesy Lamp Bulb Replacement Hatchback Cargo Center Courtesy Lamp Bulb Replacement Sedan Backup Lamp Bulb Replacement Sedan Rear License Plate Lamp Replacement Sedan Rear License Plate Lamp Replacement Hatchback Rear License Plate Lamp Bulb Replacement Sedan Rear License Plate Lamp Bulb Replacement Hatchback Tail Lamp Replacement Sedan Tail Lamp Rep...

Page 463: ...Headlamp Bolt 2 5N m 22lbin High Mount Stop Lamp Bolt 2 5N m 22lbin Rear License Plate Lamp Bolt 1 0N m 9lbin Tail Lamp Bolt 2 5N m 22lbin Fastener Tightening Specifications Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 464: ...tion sensor home value This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data Calibration Procedure 1 Apply the parking brake 2 Place the transmission in the PARK position for automatic transmission or NEUTRAL position for manual transmission 3 Install a scan tool 4 Clear all BCM DTCs b...

Page 465: ...d over the brake pedal post 1 Install the brake pedal position sensor to the brake pedal bracket Caution Refer to Fastener Caution 2 Install the brake pedal position sensor bolt 1 and tighten to 3N m 27lbin 3 Connect the brake pedal position sensor electrical connector 4 Calibrate the brake pedal position sensor Refer to Brake Pedal Position Sensor Calibration 5 Install the instrument panel lower ...

Page 466: ...r Replacement 1 Headlamp Switch Procedure 1 Gently depress tabs to remove the switch assembly from the instrument panel lower cover 2 Disconnect the electrical connector Headlamp Switch Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 467: ...trol Replacement 1 Hazard Warning Switch Bolts Qty 2 Caution Refer to Fastener Caution 2 Hazard Warning Switch Procedure Disconnect the electrical connector Hazard Warning Switch Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 468: ...wnward to release the retainer clips securing the bezel assembly to the headliner 2 Disconnect the electrical connections Dome Lamp Bezel Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 469: ...ard to release the retainer clips securing the courtesy lamp assembly to the dome lamp bezel 2 Disconnect the electrical connections Windshield Header Courtesy Lamp Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 470: ...eld header courtesy lamp Refer to Windshield Header Courtesy Lamp Replacement 1 Dome Lamp Bulb Dome Lamp Bulb Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 471: ...er Caution Tighten 2 5N m 22lbin 2 Headlamp Assembly Procedure 1 Disconnect the electrical connector bulb harness and remove the headlamp assembly 2 Aim the headlamps after replacement Refer to Headlamp Aiming Headlamp Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 472: ...rom the bulb socket 2 Rotate the bulb socket and remove from the headlamp housing 3 Headlamp Bulb High Beam Procedure 1 Disconnect the electrical connector from the bulb socket 2 Rotate the bulb socket a quarter turn and remove from the headlamp housing Headlamp Bulb Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2...

Page 473: ... 2 Caution Refer to Fastener Caution Tighten 2 5N m 22lbin 2 Headlamp Housing Bracket Procedure Release the tabs on the housing bracket from the front bumper fascia and remove Headlamp Housing Bracket Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 474: ... aiming screen is not available the screen may consist of a vertical wall having a clear uninterrupted area approximately 1 83m 6 ft high and 3 66m 12 ft wide The surface should be finished with a washable non gloss white paint After the aiming screen has been set up in a permanent location paint a reference line on the floor directly under the lens of the lamps to indicate the proper location of ...

Page 475: ...of the high intensity zone should fall within the specifications Headlamp Aiming Procedure 1 Open the hood 2 Measure from the floor to the center of the headlamp bulb Some headlamps have an aim dot marked on the headlamp lens 3 At the screen measure from the floor and place the horizontal tape at the measured distance 4 Measure from the reference line on the floor to the left headlamp bulb centerl...

Page 476: ... by the arrow of the headlamps to the specifications required by the state and the local authorities or as shown in step number8 10 Repeat the aiming procedure for the passenger side headlamp while blocking the light from projecting onto the screen from the driver side headlamp 11 Turn the headlamps OFF 12 Close the hood Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONI...

Page 477: ...bulb socket 1 Front Fog Lamp Screw Qty 3 Caution Refer to Fastener Caution Remove the three fog lamp mounting screws from the front bumper fascia 2 Front Fog Lamp Procedure Aim the front fog lamps after replacement Refer to Fog Lamp Aiming Front Fog Lamp Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPA...

Page 478: ... the electrical connector to the fog lamp bulb 1 Front Fog Lamp Bulb Warning Refer to Halogen Bulb Warning Turn the fog lamp bulb socket counter clockwise and remove from the fog lamp housing Front Fog Lamp Bulb Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 479: ...t 1 Front Fog Lamp Front Cover Procedure Release the tabs securing the front fog lamp front cover to the front bumper fascia and remove Front Fog Lamp Cover Replacement Without T3U 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 480: ...nt 1 Front Fog Lamp Front Cover Procedure Release the tabs securing the front fog lamp front cover to the front bumper fascia and remove Front Fog Lamp Cover Replacement With T3U 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 481: ...he proper pressure 8 Ensure that the driver or a similar weight approximately 75kg 165lb is in the vehicle driver seat Aiming Procedure 1 Park the vehicle 7 6m 25ft away from the target screen 2 Measure from the center of the fog lamp to the ground line Using this measurement mark the horizontal centerline 2 of the fog lamp on the target screen directly in front of the vehicle 3 Turn ON the fog la...

Page 482: ...n order to rotate the lamp from the opening in the fender 3 Rotate forward the lamp housing from the fender opening 4 Rotate the electrical bulb socket counter clockwise and remove from the housing 1 Front Side Turn Signal Lamp Assembly Tip Remove the masking tape from the fender after the lamp has been removed Front Side Turn Signal Lamp Replacement 2011 General Motors All rights reserved Lightin...

Page 483: ...de Turn Signal Lamp Socket 2 Front Side Turn Signal Lamp Bulb Procedure Hold the bulb socket and pull the turn signal lamp bulb straight from the bulb socket Front Side Turn Signal Lamp Bulb Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 484: ...p bulb socket 1 Parking and Turn Signal Lamp Bulb Socket Procedure Rotate the bulb socket counter clockwise and remove from the headlamp housing 2 Parking and Turn Signal Lamp Bulb Procedure Push inward and rotate the parking and turn signal bulb counter clockwise in order to remove Parking and Turn Signal Lamp Bulb Replacement 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK...

Page 485: ...ss and remove the high mount stop lamp screws 1 High Mount Stop Lamp Screw Qty 2 Caution Refer to Fastener Caution 2 High Mount Stop Lamp Tip The high mount stop lamp is LED Light Emitting Diode and is serviced as an assembly High Mount Stop Lamp Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 486: ...amp Cover Procedure Remove the cover and the four screws from the high mount stop lamp 3 High Mount Stop Lamp Assembly Procedure Release the electrical connector and LED Light Emitted Diode lamp from the cover High Mount Stop Lamp Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 487: ...r to Rear Compartment Courtesy Lamp Replacement 2 Cargo Lamp Bulb Cargo Center Courtesy Lamp Bulb Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 488: ...fer to Rear Compartment Courtesy Lamp Replacement 2 Cargo Lamp Bulb Cargo Center Courtesy Lamp Bulb Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 489: ...p bulb socket counter clockwise and remove from the tail lamp housing 2 Back Up Lamp Bulb Procedure Push inward while rotating counter clockwise on the bulb and remove from the lamp socket Backup Lamp Bulb Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 490: ...housing down far enough to access the lamp socket and electrical harness 1 Rear License Plate Lamp Socket Procedure Rotate the lamp socket a quarter turn and remove 2 Rear License Plate Lamp Rear License Plate Lamp Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 491: ...lique 3 Pull and rotate the housing downward far enough to remove and access the lamp socket and electrical harness 1 Rear License Plate Lamp Socket Procedure Rotate the lamp socket counter clockwise and remove from the lamp housing 2 Rear License Plate Lamp Rear License Plate Lamp Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODE...

Page 492: ...ate Lamp Replacement 1 License Plate Lamp Socket 2 License Plate Lamp Bulb Tip Pull the bulb straight out of the lamp socket Rear License Plate Lamp Bulb Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 493: ...the electrical lamp socket a quarter turn counter clockwise and remove from the lamp housing 2 License Plate Lamp Bulb Procedure Pull the bulb straight out of the electrical lamp socket Rear License Plate Lamp Bulb Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 494: ... Refer to Fastener Caution Tighten 2 5N m 22lbin 2 Tail Lamp Electrical Harness Procedure Remove all three tail lamp bulb sockets with bulbs 3 Tail Lamp Tail Lamp Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 495: ...arward in order to disengage the two locator pins from the bodyside outer panel 2 Rotate all three bulb sockets and remove from the tail lamp housing being careful not to damage the exposed bulbs 3 Disengage the tail lamp bulb electrical harness from the retainer clips on the tail lamp housing Tail Lamp Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO...

Page 496: ...ise and remove the socket from the lamp housing 2 Park and Stop Lamp Bulb Procedure Push the bulb inward while rotating counter clockwise to remove 3 Turn Signal Bulb 4 Back Up Bulb Stop and Turn Signal Lamp Bulb Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 497: ... remove the socket from the lamp housing 2 Park and Stop Lamp Bulb Procedure Pull the bulb straight from the lamp harness socket 3 Turn Signal Bulb 4 Back Up Bulb 5 Tail Lamp Housing Assembly Stop and Turn Signal Lamp Bulb Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 498: ...l in order to release the lamp assembly from the rear quarter trim panel 2 Disconnect the electrical connection Rear Compartment Courtesy Lamp Replacement Hatchback 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 499: ...ool in order to release the lamp assembly from the rear quarter trim panel 2 Disconnect the electrical connection Rear Compartment Courtesy Lamp Replacement Sedan 2011 General Motors All rights reserved Lighting BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 500: ... When the lever is released it will return to horizontal and the turn signals will cancel Side Marker Lamps For the North American application the side marker lamps are located in the front and rear bumper fascias and work in conjunction with the exterior lighting system When the parking lamps or headlamps are turned on the side marker lamps will illuminate to mark the front and the rear end of th...

Page 501: ...sition the lamp will stay ON until it is turned OFF In the OFF position the lamp will not come ON even when a door is opened Luggage Compartment Lamp The luggage compartment lamp is located under the deck lid sill plate on the notchback The lamp is located on the left side wheelhouse trim panel on the hatchback It will come ON whenever the luggage compartment is opened 2011 General Motors All righ...

Page 502: ...w Mirror Switch Replacement Outside Rearview Mirror Housing Replacement 2011 General Motors All rights reserved Index BODY SYSTEMS 0 4 Outside Rearview Mirror Motor Replacement Outside Rearview Mirror Glass Replacement Specifications Inside Rearview Mirror Replacement Description and Operation BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 503: ...18lbin Outside Rearview Mirror Motor Fastener 5N m 44lbin Outside Rearview Mirror Fastener 10N m 89lbin Fastener Tightening Specifications 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 504: ...ide Mirror Adhesive Kit Adhesive Refer to Electronic Parts Catalog Adhesives Fluids Lubricants and Sealers 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 505: ...1 Outside Rearview Mirror Fastener Qty 3 Caution Refer to Fastener Caution Procedure Disconnect the electrical connector Tighten 10N m 89lbin 2 Outside Rearview Mirror Procedure Inspect the outside mirror for proper operation before installing the door trim panel Outside Rearview Mirror Replacement Power 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODE...

Page 506: ...1 Outside Rearview Mirror Fastener Qty 3 Caution Refer to Fastener Caution Tighten 10N m 89lbin 2 Outside Rearview Mirror Procedure 1 Transfer the outside rearview mirror knob 2 Inspect the outside mirror for proper operation before installing the door trim panel Outside Rearview Mirror Replacement Manual 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MOD...

Page 507: ...1 After the mirror glass has been removed the retainers can be accessed to release 2 Align the housing cover with the slots in the mirror housing push downward locking retainers in place Outside Rearview Mirror Housing Rear Cover Replacement 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 508: ...e Control Rearview Mirror Switch Assembly Procedure 1 Disconnect the electrical connector 2 Refer to Control Module References for programming and set up procedures Outside Remote Control Rearview Mirror Switch Replacement 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 509: ... to Fastener Caution Procedure Disconnect the outside mirror motor electrical connector Tighten 5N m 44lbin 3 Outside Rearview Mirror Motor Procedure Inspect the outside mirror for proper operation before installing the door trim panel Outside Rearview Mirror Motor Replacement 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012...

Page 510: ...he mirror glass firmly lift it up and pull rearward until the mirror glass releases the motor ring Installation Procedure 1 Place the mirror glass on the lower motor ring retainers 2 Place one hand on the back of the mirror housing using the flat palm of the other hand press inward locking the mirror glass to the motor ring 3 Remove the masking tape from the mirror glass 4 Inspect the outside mirr...

Page 511: ...tor Replacement 1 Outside Rearview Mirror Housing Fastener Qty 4 Caution Refer to Fastener Caution Tighten 5N m 44lbin 2 Outside Rearview Mirror Housing Procedure Inspect the outside mirror for proper operation before installing the door trim panel Outside Rearview Mirror Housing Replacement 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVR...

Page 512: ...tion Refer to Fastener Caution Procedure 1 Adjust the mirror to the full upward position loosen the screw at the base in order to remove the mirror from the button 2 Slide the mirror in an upward motion in order to remove Tighten 2N m 18lbin 3 Inside Rearview Mirror Inside Rearview Mirror Replacement 2011 General Motors All rights reserved Mirrors BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL IN...

Page 513: ...it and ground through the left mirror motor common control circuit If the down switch is pressed battery voltage will be supplied to the left outside rearview mirror vertical motor through the left mirror motor common control circuit and ground through the left mirror motor vertical control circuit The remainder of the mirror functions operate in the same manner as described above Placing the powe...

Page 514: ...oor Outside Handle Rod Adjustment Front Side Door Outside Handle Rod Replacement Rear Side Door Locking Rod Replacement Sedan Rear Side Door Locking Rod Replacement Hatchback Rear Side Door Locking Rod Bellcrank Replacement Rear Side Door Outside Handle Rod Adjustment Rear Side Door Outside Handle Rod Replacement Sedan Rear Side Door Outside Handle Rod Replacement Hatchback Front Side Door Lock St...

Page 515: ... Bolts 22N m 16lbft Rear Compartment Lid Latch Screw 9N m 80lbin Rear Compartment Lid Latch Striker Bolts 22N m 16lbft Rear Side Door Lock Cylinder Clamp Screw 5N m 44lbin Rear Side Door Lock Screws 10N m 89lbin Rear Side Door Outside Handle Bracket Screw 5N m 44lbin Rear Side Door Striker Screws 22N m 16lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Vehicle Access...

Page 516: ...Side Door Inside Handle Cable Cover Tip Open the inside handle cable cover to access the release 2 Front Side Door Inside Handle Cable Front Side Door Inside Handle Cable Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 517: ...ide Door Inside Handle Cable Cover Tip Open the inside handle cable cover to access the release 2 Rear Side Door Inside Handle Cable Rear Side Door Inside Handle Cable Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 518: ...oor handle or housing to replace the lock cylinder Tighten 5N m 44lbin 3 Front Side Door Lock Cylinder Cover Procedure Remove the lock cylinder cover Refer to Front Side Door Lock Cylinder Opening Cover Replacement 4 Front Side Door Lock Cylinder Procedure 1 Ensure that the lock cylinder gasket is in place when installing the lock cylinder to the handle 2 Inspect the lock cylinder for proper opera...

Page 519: ...e cylinder screw completely from the housing unscrew the screw to a hard stop remove the cylinder Tighten 5N m 44lbin 3 Rear Side Door Lock Cylinder Procedure Remove the lock cylinder cover Refer to Rear Side Door Lock Cylinder Opening Cover Replacement Rear Door Lock Cylinder Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX C...

Page 520: ...d stay in the open position 7 Remove the lock cylinder gently pull it straight out 8 Remove the outside door handle by sliding rearwards and then out in a swinging motion 9 Inspect the door locking system for proper operation before installing the trim panel Tip While screwing in the screw for the lock cylinder hold the handle in the open position this will avoid the door handle from snapping once...

Page 521: ...ector Tighten 5N m 44lbin 2 Front Side Door Outside Handle Bracket Procedure 1 Release front side door outside handle rod mechanism at shift linkage lever clip 2 Release the front side door latch cylinder rod from the door latch 3 Transfer components as necessary 4 Inspect the door latch system for proper operation before installing the door trim panel Front Side Door Outside Handle Bracket Replac...

Page 522: ...ctor Tighten 5N m 44lbin 2 Rear Side Door Outside Handle Bracket Procedure 1 Release rear side door outside handle rod mechanism at shift linkage lever clip 2 Release the rear side door latch cylinder rod from the door latch 3 Transfer components as necessary 4 Inspect the door latch system for proper operation before installing the door trim panel Rear Side Door Outside Handle Bracket Replacement...

Page 523: ...er 1 Liftgate Latch Screw Qty 2 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Liftgate Latch Assembly Procedure 1 Disconnect the electrical connector 2 Adjust the liftgate if needed Liftgate Latch Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 524: ...op 5 Release the handle by now the handle should stay in the open position 6 Remove the lock cylinder gently pull it straight out 7 Remove the outside door handle by sliding rearwards and then out in a swinging motion 8 Inspect the door locking system for proper operation before installing the trim panel Tip While screwing in the screw for the lock cylinder hold the handle in the open position thi...

Page 525: ...the retainers are broken when removing they Must be replaced 4 Rear Side Door Outside Handle Procedure In order to prevent outside handle lever pre load lock outside handle shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Rear Side Door Outside Handle Rod A...

Page 526: ...ide door window rear guide Refer to Front Side Door Window Rear Guide Replacement Tighten 10N m 89lbin 2 Front Side Door Lock Assembly Procedure 1 Disconnect the front side door lock electrical connector 2 Transfer the front side door lock rods 3 Front outside door handle rod adjustment Refer to Front Side Door Outside Handle Rod Adjustment Front Side Door Latch Replacement 2011 General Motors All...

Page 527: ...y 2 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Rear Compartment Latch Procedure 1 Disconnect the electrical connection 2 Slide the latch to the right and up to remove from the compartment lid Rear Compartment Lid Latch Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 528: ...side door window rear guide Refer to Rear Side Door Window Rear Guide Replacement Tighten 10N m 89lbin 2 Rear Side Door Lock Assembly Procedure 1 Disconnect the rear side door lock electrical connector 2 Transfer the rear side door lock rods 3 Rear outside door handle rod adjustment Refer to Rear Side Door Outside Handle Rod Adjustment Rear Side Door Latch Replacement 2011 General Motors All right...

Page 529: ...t remove the lock cylinder screw completely from the housing Unscrew the screw to a hard stop remove the cylinder Tip Use a small flat bladed tool to release the lock cylinder bezel retainers location on both sides Front Side Door Lock Cylinder Opening Cover Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012...

Page 530: ...emove the lock cylinder screw completely from the housing Unscrew the screw to a hard stop remove the cylinder Tip Use a small flat bladed tool to release the lock cylinder bezel retainers location on both sides Rear Side Door Lock Cylinder Opening Cover Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BOD...

Page 531: ...ents as necessary 4 In order to prevent outside handle lever pre load lock outside handle handle bracket and cover cap shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Front Side Door Outside Handle Rod Adjustment Tip Inspect the door lock system for proper...

Page 532: ...pre load lock outside handle handle bracket and cover cap shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Front Side Door Outside Handle Rod Adjustment Tip Inspect the door lock system for proper operation before installing the door trim panel Front Side D...

Page 533: ...e outside door handle 2 Adjust the travel of the handle by removing the threaded rod from the retainer 3 Install the retainer cover closed over the threaded front side door outside handle rod 4 Inspect the door lock system for proper operation before installing the trim panel Tip Use a flat head tool to open the retainer from the threaded rod connecting the lock to the outside handle Front Side Do...

Page 534: ...ver pre load lock outside handle handle bracket and cover cap shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Front Side Door Outside Handle Rod Adjustment Tip Inspect the door lock system for proper operation before installing the door trim panel Front Si...

Page 535: ...ever pre load lock outside handle handle bracket and cover cap shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Rear Side Door Outside Handle Rod Adjustment Tip Inspect the door lock system for proper operation before installing the door trim panel Rear Sid...

Page 536: ... Procedure Remove the water deflector Tip Inspect the door lock system for proper operation before installing the door trim panel Rear Side Door Locking Rod Replacement Hatchback 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 537: ...a small flat bladed tool to release the retainer from the center of the bellcrank 2 Rear Side Door Lock Rod Bellcrank Center 3 Rear Side Door Lock Rod Bellcrank Retainer to Door Note Inspect the door lock system for proper operation before installing the door trim panel Rear Side Door Locking Rod Bellcrank Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO ...

Page 538: ...tside door handle 2 Adjust the travel of the handle by removing the threaded rod from the retainer 3 Install the retainer cover closed over the threaded front side door outside handle rod 4 Inspect the door locking system for proper operation before installing the trim panel Tip Use a flat head tool to open the retainer from the threaded rod connecting the lock to the outside handle Rear Side Door...

Page 539: ...de door water deflector 2 Open the handle rod clip 3 Inspect the door locking system for proper operation before installing the trim panel Refer to Rear Side Door Outside Handle Rod Adjustment Rear Side Door Outside Handle Rod Replacement Sedan 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 540: ...r handle 3 Adjust the travel of the handle by removing the threaded rod from the retainer 4 In order to prevent outside handle lever pre load lock the outside handle shall be fully secured to the door prior to securing integral lock clip to outside handle rod Integral lock clip shall be in the full up position while securing to outside handle rod Refer to Rear Side Door Outside Handle Rod Adjustme...

Page 541: ... reference of the original position Loosen the striker 4 Move the striker to eliminate drag on the striker and door lock and to achieve the proper door position within the door opening Start with the up down position then position the striker to achieve proper alignment to the door opening Set the in out adjustment for the proper door seal engagement making sure the door closing efforts are correc...

Page 542: ...bft 2 Front Door Lock Striker Procedure Ensure the alignment of the striker Refer to Front Side Door Lock Striker Adjustment Front Side Door Lock Striker Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 543: ...Trim Plate Replacement 1 Liftgate Latch Striker Bolt Qty 2 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Liftgate Latch Striker Liftgate Latch Striker Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 544: ...te Replacement 1 Latch Striker Bolt Qty 2 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Rear Compartment Lid Latch Striker Rear Compartment Lid Latch Striker Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 545: ... reference of the original position Loosen the striker 4 Move the striker to eliminate drag on the striker and door lock and to achieve the proper door position within the door opening Start with the up down position then position the striker to achieve proper alignment to the door opening Set the in out adjustment for the proper door seal engagement making sure the door closing efforts are correc...

Page 546: ... Lock Striker Procedures 1 Ensure the spacer is in place 2 Ensure proper alignment after installation Refer to Rear Side Door Lock Striker Adjustment Rear Side Door Lock Striker Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 547: ...ment 1 Liftgate Release Switch Procedure Depress the retainers on the back side of the switch and push the switch out from the applique Liftgate Release Switch Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 548: ...g Control Replacement 1 Door Lock Switch Bolts Qty 2 Caution Refer to Fastener Caution 2 Door Lock Switch Procedure Disconnect the electrical connector Door Lock Switch Replacement 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 549: ...ggage Compartment Description and Operation Power Door Locks Description and Operation Trunk Liftgate Ajar Indicator Description and Operation 2011 General Motors All rights reserved Vehicle Access BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 550: ... supplies a 12V signal to each of the door latches these latches contain an ajar switch which is normally open when the door is closed When a door is ajar or open the contacts of the ajar switch will close causing the voltage in the signal circuit to drop to zero volts The BCM will detect the voltage drop and will send a message to the instrument panel cluster The instrument panel cluster upon rec...

Page 551: ...ol circuit The BCM upon receipt of a lock switch lock or unlock signal will supply battery voltage to the door lock actuator lock or unlock control circuits Since the opposite side of the lock actuator is connected to ground through the other lock actuator control circuit the driver door latch assembly and the fuel door release actuator will then lock or unlock as commanded 2011 General Motors All...

Page 552: ...se command from the release switch the BCM applies brief pulse of voltage to the release relay control circuit which energizes the coil side of the relay The switch side of the release relay then momentarily closes supplying a brief pulse of battery positive voltage to the rear compartment latch The rear compartment latch is continuously grounded and when it receives the voltage pulse it will beco...

Page 553: ...ircuits The BCM upon receipt of a lock switch lock or unlock signal will supply battery voltage to the door lock actuator lock or unlock control circuits Since the opposite side of the lock actuator is connected to ground through the other lock actuator control circuit the doors will then lock or unlock as commanded The following three circuits are used to operate the lock Driver door unlock Passe...

Page 554: ...r or open a switch within the latch assembly closes providing a path to ground for the liftgate ajar signal circuit The voltage within the signal circuit will then drop to 0 volts the BCM will then detect the voltage drop and will send a serial data message to the instrument panel cluster IPC The IPC will then display the door ajar icon 2011 General Motors All rights reserved Vehicle Access BODY S...

Page 555: ... Window Wiper Arm Replacement Windshield Wiper Blade Replacement Rear Window Wiper Blade Replacement Windshield Wiper Motor Replacement Rear Window Wiper Motor Replacement Hatchback Windshield Wiper System Module Replacement Rear Window Wiper Motor Grommet Replacement Windshield Glass Cleaning Wiper Blade Element Cleaning 2011 General Motors All rights reserved Index BODY SYSTEMS 0 4 Wiper Chatter...

Page 556: ...eld Washer Solvent Container Nut 5N m 44lbin Windshield Wiper Arm Nut 25N m 18lb ft Windshield Wiper Motor Bracket Screw 8 5N m 75lbin Windshield Wiper System Module Bolt 18N m 13lb ft Fastener Tightening Specifications 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 557: ...d Washer Switch Procedure 1 Disconnect any electrical connectors as necessary 2 Release the plastic retaining tabs and remove the windshield wiper and washer switch from the turn signal switch bracket Windshield Wiper and Washer Switch Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL...

Page 558: ...hose 2 Disconnect the windshield washer hose retainer at the hood hinge 3 Disconnect all three washer hose retainers from the underside of the hood assembly 4 Disconnect the windshield washer hose at both windshield washer nozzle spouts 5 Remove the windshield washer hose from the vehicle Windshield Washer Nozzle Hose Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYST...

Page 559: ...two fingers squeeze the locking tabs on the underside of the hood on the washer nozzle 3 Push the washer nozzle outward from the hood while rotating the washer nozzle to the right 4 Remove the windshield washer nozzle from the hood assembly Windshield Washer Nozzle Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET...

Page 560: ...ehind the high mounted stop lamp 2 Disconnect the washer hose from the spout 3 Pinch the two tabs on the rear window washer nozzle and push the nozzle up through the liftgate hole 4 Remove the rear window washer nozzle from the vehicle Rear Window Washer Nozzle Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SON...

Page 561: ...r solvent from inside the hose 4 Disconnect the windshield washer pump hose from the windshield washer nozzle hose near the front fender front bracket 5 Disengage the windshield washer pump hose from the two retention clips on the windshield washer container 6 Remove the windshield washer pump hose from the vehicle Windshield Washer Solvent Container Hose Replacement 2011 General Motors All rights...

Page 562: ...d 1 Windshield Washer Solvent Container Filler Tube Procedure 1 Inspect the seal on the filler tube replace as needed 2 Remove and transfer the windshield washer solvent container cap 3 Upon installation of the windshield washer solvent container filler tube back into the windshield washer solvent container ensure to twist the filler tube 1 8 turn clockwise and lock the filler tube into the contai...

Page 563: ...hose from the washer pump spout and the windshield washer container retention tabs 2 Windshield Washer Solvent Container Nut Qty 3 Caution Refer to Fastener Caution Tighten 5 0N m 44lbin 3 Windshield Washer Solvent Container Procedure 1 Remove the windshield washer solvent container from the three studs on the front compartment front outer side rail and battery tray support 2 Remove the windshield...

Page 564: ...tor to the windshield washer pump 2 Using two flat bladed tools place the blades on each side of the washer pump under the windshield washer pump grommet 3 Twist the two flat blades in opposite directions to lift the washer pump from the windshield washer solvent container 4 Disengage the washer pump from the windshield washer container 5 Remove the windshield washer pump and discard the windshiel...

Page 565: ...rom the air inlet grille panel 2 Remove the air inlet grille panel screw Tighten 2 5N m 22lbin 3 Air Inlet Grille Panel Procedure 1 Lift the front edge of the grille panel off the front edge of the dash upper extension panel opening cover 2 Slide the grille panel forward from both hood hinges 3 Remove the grille panel from the vehicle 4 Remove the hood rear weather strip Refer to Hood Rear Weather...

Page 566: ... 1 Use the BO 49385 puller in order to assist in the removal of the wiper arm from the wiper module pivot shaft 2 Remove the wiper arm from the pivot shaft 3 Clean the pivot shaft knurls with a soft wire brush before installing a new wiper arm Special Tools BO 49385 Wiper Arm Puller For equivalent regional tools refer to Special Tools Windshield Wiper Arm Replacement 2011 General Motors All rights...

Page 567: ...ndow Wiper Arm Nut Caution Refer to Fastener Caution Tighten 10N m 89lbin 2 Rear Window Wiper Arm Tip Align and hold the rear window wiper arm blade to the edge of the blackout on the rear liftgate window while tightening Rear Window Wiper Arm Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAI...

Page 568: ...lade downward away from the wiper arm 4 Detach the wiper blade from the hook end of the windshield wiper arm 5 Carefully return the windshield wiper arm back to the glass until the new wiper blade is installed 1 Windshield Wiper Blade Assembly Windshield Wiper Blade Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLE...

Page 569: ...indow and release the rear window wiper blade from the rear window wiper arm 1 Rear Window Wiper Blade Rear Window Wiper Blade Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 570: ...imilar tool separate the transmission drive link from the wiper motor crank arm ball stud 2 Use a wiper linkage installer or similar tool install the transmission drive link onto the wiper motor crank arm ball stud Tip Apply a small amount of grease to the inner cup on the transmission link to aid in installation Windshield Wiper Motor Replacement 2011 General Motors All rights reserved Wipers and...

Page 571: ...per Motor Bolt Qty 3 Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Rear Window Wiper Motor Procedure 1 Pull the rear window wiper motor inward from the rear liftgate 2 Release the wiper motor pivot shaft from the rear window wiper motor window grommet 3 Carefully remove the rear window wiper motor from the liftgate inner panel assembly Rear Window Wiper Motor Replacement Hatchback 2011 G...

Page 572: ...ighten 18N m 13lbft 2 Windshield Wiper System Module Procedure 1 Lift the wiper system module from the plenum brackets 2 Disconnect the electrical connector from the windshield wiper motor 3 Remove the windshield wiper system module from the plenum Windshield Wiper System Module Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL I...

Page 573: ...er Motor Grommet Tip Apply some lubricant to the outside of the grommet upon installation to aid in installation through the liftgate glass opening Rear Window Wiper Motor Grommet Replacement 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 574: ...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 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 575: ...nd clean the element with a cloth saturated with full strength washer solvent Then rinse the blade assemblies with clear water 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 576: ...dition ALL of the items listed should be tested and repaired as necessary Clean the windshield glass Refer to Windshield Glass Cleaning Clean the wiper blade elements Refer to Wiper Blade Element Cleaning Inspect the wiper blade element set 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 577: ...mbly When the wiper blades are not in the park position the wiper park switch is open and the circuit is pulled up to battery by the BCM When the wiper blades are in the park position at the bottom of the glass the wiper park switch closes to ground pulling the park signal circuit low To initiate low speed operation the BCM only energizes the front wiper motor on off relay This allows battery volt...

Page 578: ...Motor Relay and one controls the Rear Wiper Relay Rear Wiper System On vehicles equipped with a Rear Wiper the BCM determines of the Rear Wipe Wash System Mode of Operation by monitoring the multiplexed output of the Rear Wipe Wash Switch The Rear Wipe Wash Switch uses a reference ground signal from the BCM The BCM provides a switched Battery pull up for the Rear Wiper Washer Switch output signal ...

Page 579: ...escription BO 49385 BO 6626 KM 6626 S0201912 Wiper Arm Puller Special Tools 2011 General Motors All rights reserved Wipers and Washers BODY SYSTEMS 0 4 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 580: ...ization Teach Process Sunroof Actuator Motor Replacement Sunroof Sunshade Replacement Sunroof Window Seal Replacement Sunroof Switch Replacement Sunroof Window Height and Opening Fit Adjustment Sunroof Window Replacement 2011 General Motors All rights reserved Index ROOF 0 5 Specifications Description and Operation BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 581: ...olts 9N m 80lbin Sunshade Motor Actuator Screws 6N m 53lbin Sunroof Window Screws 5N m 44lbin Fastener Tightening Specifications 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 582: ...unroof Module Assembly Replacement 1 Sunroof Air Deflector Tip Cycle the sunroof window to the full rearward position Sunroof Air Deflector Replacement 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 583: ...anel Replacement 1 Sunroof Housing Front Drain Hose Retainers Qty 4 2 Sunroof Housing Front Drain Hose Procedure 1 Remove the sunroof housing front drain hose and grommet from plenum 2 Water test the vehicle before installing the headliner to ensure no water leaks Sunroof Housing Front Drain Hose Replacement 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX...

Page 584: ...Window Panel Trim Replacement 4 Remove the rear compartment trim on the side being repaired Refer to Rear Compartment Side Trim Replacement Right Side 1 Sunroof Housing Rear Drain Hose Retainers Qty 4 2 Sunroof Housing Rear Drain Hose Procedure 1 Remove the sunroof housing rear drain hose and grommet from the rear compartment quarter panel 2 Water test the vehicle before installing the headliner t...

Page 585: ...he vehicle 2 Place the sunroof assembly on a clean dry surface 3 Transfer all necessary components to the new module assembly Tighten 9N m 80lbin 2 Sunroof Module Procedure 1 Secure the harness to the sunroof module 2 Adjust the sunroof window Refer to Sunroof Window Height and Opening Fit Adjustment 3 Verify the proper operation of the sunroof before securing the headliner 4 Ensure the motor actu...

Page 586: ...window doesn t go to the vent open position first time release the switch and press the switch again 1 Press and hold the sunroof switch to the vent open position until the sunroof window stops in the vent open position 2 Again press and hold the sunroof switch to the vent open position for at least 10 seconds then the window should move slightly 3 Verify the sunroof operation If the initializatio...

Page 587: ...ctor from the sunroof motor Tighten 6N m 53lbin 2 Sunroof Actuator Motor Procedure 1 Pull downward to disengage the actuator motor from the sunroof module 2 Install the motor verify the sunroof operation 3 Ensure the actuator motor initialization teach process has been done Refer to Sunroof Motor Actuator Initialization Teach Process 4 Verify the proper operation of the sunroof before installing t...

Page 588: ... 1 Remove the stops located at the rear of the sunroof module 2 Remove the sunshade by sliding it rearward out the ends of the module 3 Verify the proper operation of the sunroof sunshade before securing the headliner Sunroof Sunshade Replacement 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 589: ...nstallation 2 Position the sunroof window panel seal onto the window frame locating the starting end of the seal at the relief notch in the center of the passenger side of the frame Note Ensure that the seal is properly seated around the entire perimeter of the window frame 3 Firmly press the window seal into the retainer edge of the sunroof window a 50 50 mixture of soap and water by volume will ...

Page 590: ...o Dome Lamp Bezel Replacement 1 Sunroof Switch Procedure 1 Disconnect electrical connector 2 Depress tabs to release switch Sunroof Switch Replacement 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 591: ...following guidelines Adjust the front of the sunroof window to0 0mm 1 0mm 0 0in 0 04in below the top surface of the roof panel Adjust the rear center line of the sunroof window to2mm to 3mm 0 08in to0 12in below the top surface of the roof panel Caution Refer to Fastener Caution 4 Tighten the sunroof window adjustment screws to 5N m 44lbin 5 Cycle sunroof window through all positions 6 Inspect the...

Page 592: ... Slide the sunshade to the full rearward position 3 Move the sunroof window to the vent position 4 Verify the proper operation of the sunroof Refer to Sunroof Window Height and Opening Fit Adjustment Sunroof Window Replacement 2011 General Motors All rights reserved Roof ROOF 0 5 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 593: ...has two contacts one for open movement and one for close movement When activated each switch contact completes the circuit between the appropriate Sunroof Motor Controller input and battery voltage provided by the energized Rap Accessory Relay Sunroof System Thermal Protection The sunroof controller has a thermal protection algorithm to protect the Sunroof controller and motor from damage due to o...

Page 594: ... Replacement Sedan Shoulder Belt Replacement Rear Sedan Front Seat Belt Guide Adjuster Replacement with AHU 2011 General Motors All rights reserved Index SEAT BELTS 0 6 Repairs and Inspections Required After a Collision Specifications Description and Operation BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 595: ...5N m 33lbft Rear Seat Belt Buckle Fastener 45N m 33lbft Rear Seat Center Shoulder Belt Buckle Fastener 45N m 33lbft Rear Seat Shoulder Belt Anchor Plate Fastener 45N m 33lbft Rear Seat Shoulder Belt Retractor Fastener 45N m 33lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAI...

Page 596: ...tem if you observe the words REPLACE or CAUTION or if a yellow tag is visible Do not replace a seat belt if only the child seat caution label is visible Replace any seat belt system if you are doubtful about its condition This not only includes adult seat belt systems but built in child restraints LATCH system components and any restraint system used to secure infant carriers child restraints and ...

Page 597: ...en the seat belt lower anchor and the stop button Using the measurement obtained above measure and mark the location of the missing stop button on the center of the seat belt webbing 3 Ensure the seat belt latch plate is located above the mark or original hole 1 Seat Belt Stop Button Procedure 1 Work the male half of the stop button through the hole in the webbing or at the marked location 2 Align...

Page 598: ...kle Fastener Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Driver or Passenger Seat Belt Buckle Assembly Procedure Disconnect the electrical connector if equipped Front Seat Belt Buckle Replacement 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 599: ...nt 1 Rear Seat Belt Buckle Fastener Qty 2 Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Rear Seat Belt Buckle Assembly Qty 2 Rear Seat Belt Buckle Replacement 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 600: ... Seat Center Shoulder Belt Buckle Fastener Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Rear Seat Center Shoulder Belt Rear Seat Center Shoulder Belt Replacement Sedan 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 601: ... Anchor Plate Fastener Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Rear Seat Shoulder Belt Retractor Fastener Tighten 45N m 33lbft 3 Rear Seat Shoulder Belt Shoulder Belt Replacement Rear Sedan 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 602: ...elt Fastener Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Front Seat Shoulder Belt Guide Adjuster Bolt Qty 2 Tighten 45N m 33lbft 3 Front Seat Shoulder Belt Guide Adjuster Front Seat Belt Guide Adjuster Replacement with AHU 2011 General Motors All rights reserved Seat Belts SEAT BELTS 0 6 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 603: ... and anchor Both front seat belt pretensioners includes a seat belt switch in the seat buckle which controls a reminder lamp and a tone alarm Note The front passenger seat is equipped with a passenger presence detection sensor which detects an occupant If the passenger presence detection sensor detects an empty front passenger seat then the passenger fasten safety belt indicator will be disabled W...

Page 604: ...e manufacturer For more information refer to the vehicle owners manual and the instruction that came with the child restraint The child seat may only be used in a forward facing seating location The child seat should be installed and secured according to the manufacturer s directions If the child seat has a top strap the seat will need to be anchored Passengers should not be allowed to sit at loca...

Page 605: ...assenger Seat Recliner Handle Replacement 4 Way Standard Driver or Passenger Seat Recliner Handle Replacement 2 Way Uplevel Child Seat Back Cushion Cover Replacement Rear Seat Head Restraint Replacement Rear Seat Head Restraint Guide Replacement Rear Seat Back Cushion Pivot Support Replacement Rear Seat Center Head Restraint Replacement Rear Seat Cushion Cover and Pad Replacement Rear Seat Cushion...

Page 606: ...Fastener 8N m 71lbin Front Seat Back Cushion Frame Bolt 22N m 16lbft Rear Seat Back Outer Pivot Bolt 23N m 17lbft Rear Seat Latch Bolt 45N m 33lbft Rear Seat Back Cushion Bolt AN1 Fixed Bench 22N m 16lbft Rear Seat Back Cushion Hinge Bolt 43N m 32lbft Rear Seat Back Cushion Hinge Nut 43N m 32lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHA...

Page 607: ...o Front Seat Riser Finish Cover Replacement 2 Front Seat Mounting Bolt Qty 4 Caution Refer to Fastener Caution Procedure Adjust the seat to the full forward position to gain access to the rear bolts Tighten 40N m 30lbft 3 Driver or Passenger Seat Assembly Qty 2 Procedure 1 Disconnect the electrical 2 With the aid of an assistant remove the front seat by tilting the seat forward and then lifting an...

Page 608: ... of the finish cover this area needs to be flexed outward then rearward to disengage it from the outer trim panel 2 Remove the finish cover by gently pulling the cover outward to disengage it fully from the outer trim panel Front Seat Outer Recliner Upper Finish Cover Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY ...

Page 609: ...nt to break Procedure Remove the finish cover by firmly grasping the front or rear of the cover and pulling the cover outward then upward to disengage it from the track Front Seat Riser Finish Cover Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 610: ...liner Upper Finish Cover Replacement 1 Front Seat Adjuster Fasteners Qty 2 Caution Refer to Fastener Caution 2 Front Seat Adjuster Driver or Passenger Seat Adjuster Handle Replacement 4 Way Standard 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 611: ...at Adjuster Handle Fastener Qty 2 Caution Refer to Fastener Caution 3 Front Seat Adjuster Handle Procedure Use a flat bladed tool to release the adjuster handle from the seat frame assembly Driver or Passenger Seat Adjuster Handle Replacement 4 Way Uplevel 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 612: ...ocedure Carefully disengage the tray by pulling forward near the bottom of the tray Front Seat Storage Tray Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 613: ...re Slide the armrest cover off the armrest assembly 3 Front Seat Armrest Mounting Bolt Caution Refer to Fastener Caution Tighten 45N m 33lbft 4 Front Seat Armrest Spring Washer 5 Front Seat Armrest Washer 6 Front Seat Armrest Assembly Front Seat Armrest Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 614: ...ward position 2 Depress the flush button on the head restraint guide 3 Remove the head restraint by pulling up on the restraint Driver or Passenger Seat Head Restraint Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 615: ... a suitable flat bladed tool slide the tool on the inside of the guide until it finds the slot Then push the tool forward pulling the guide tab inward while pulling upward to remove the guide from the seat back frame Driver or Passenger Seat Head Restraint Guide Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR...

Page 616: ...he rear of the cover while applying light pressure to the front of the cover Then push the cover rearward to remove it from the seat frame Front Seat Belt Anchor Plate Tensioner Cover Replacement 2 Way 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 617: ...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 Front Seat Belt Anchor Plate Tensioner Cover Replacement 4 Way 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 618: ... Seat Cushion Inner Trim Panel Replacement 1 Front Seat Cushion Frame Bolt Qty 4 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Driver or Passenger Seat Cushion Frame Procedure 1 Disconnect electrical connectors as needed 2 If replacing with a new front seat cushion frame transfer components as necessary Driver or Passenger Seat Cushion Frame Replacement 2011 General Motors All rights re...

Page 619: ... Fastener Caution Tighten 8N m 71lbin 2 Front Seat Cushion Outer Trim Panel Procedure 1 Make sure the seat is in the full up position 2 Gently pull outboard on the front half of the finish cover to disengage the panel rib from the seat frame 3 Firmly grasp the upper area of the finish cover that folds over the seat cushion frame this area needs to be flexed outward while sliding the finish cover u...

Page 620: ...o Fastener Caution Tighten 8N m 71lbin 2 Front Seat Cushion Outer Trim Panel Procedure 1 Make sure the seat is in the full up position 2 Gently pull outboard on the front half of the finish cover to disengage the panel rib from the seat frame 3 Firmly grasp the upper area of the finish cover that folds over the seat cushion frame this area needs to be flexed outward while sliding the finish cover ...

Page 621: ...n Tighten 8N m 71lbin 2 Front Seat Cushion Outer Trim Panel Cap 3 Front Seat Cushion Outer Trim Panel Fasteners Qty 2 Tighten 8N m 71lbin 4 Front Seat Cushion Outer Trim Panel Procedure 1 Make sure the seat is in the full up position 2 Gently pull outboard on the front half of the finish cover to disengage the panel rib from the seat frame 3 Firmly grasp the upper area of the finish cover that fol...

Page 622: ...er to Fastener Caution Tighten 8N m 71lbin 2 Front Seat Cushion Outer Trim Panel Fasteners Qty 2 Tighten 8N m 71lbin 3 Front Seat Cushion Outer Trim Panel Procedure 1 Make sure the seat is in the full up position 2 Gently pull outboard on the front half of the finish cover to disengage the panel rib from the seat frame 3 Firmly grasp the upper area of the finish cover that folds over the seat cush...

Page 623: ...ner Caution Tighten 8N m 71lbin 3 Driver or Passenger Seat Inner Recliner Finish Cover Procedure Firmly grasp the upper area of the finish cover that folds over the seat cushion frame pull upward and then outboard to disengage the finish cover from the seat cushion frame Front Seat Cushion Inner Trim Panel Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO...

Page 624: ...e the J channel and hog ring retainers from the seat cushion frame 2 Disconnect the electrical connectors that attach to the seat cushion if equipped 3 Remove the seat cushion cover and pad from the seat cushion frame as an assembly 4 Separate the seat cushion from the seat cushion pad by pulling the cover away from the pad 2 Front Seat Cushion Pad Note The seat belt presence sensor and heat mat i...

Page 625: ...d restraint guide Refer to Driver or Passenger Seat Head Restraint Guide Replacement 1 Seat Back Cushion Cover Procedure 1 Disengage the j channel retainers and tabs at the bottom of the seat back cover from the seat back cushion frame 2 Disconnect the electrical connector that is attached to the seat back cushion if equipped 3 Remove the seat back cushion cover and pad from the seat cushion frame...

Page 626: ...ion Inner Trim Panel Replacement 1 Front Seat Back Cushion Frame Bolt Qty 4 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Driver or Passenger Seat Back Cushion Frame Procedure 1 Disconnect electrical connectors as needed 2 If replacing with a new front seat back cushion frame transfer components as necessary Driver or Passenger Seat Back Cushion Frame Replacement 2011 General Motors All...

Page 627: ... from the handle assembly 2 Front Seat Recliner Handle Procedure Use a flat bladed tool to release the handle from the seat Driver or Passenger Seat Recliner Handle Replacement 4 Way Standard 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 628: ... from the handle assembly 2 Front Seat Recliner Handle Procedure Use a flat bladed tool to release the handle from the seat Driver or Passenger Seat Recliner Handle Replacement 2 Way Uplevel 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 629: ...rocedure Remove the child seat bracket trim cover using a suitable flat bladed tool Child Seat Back Cushion Cover Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 630: ...e and raise the head restraint to the full up position 2 Depress the small button on the opposite head restraint guide and pull upward to remove from the seat Rear Seat Head Restraint Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 631: ...bladed tool slide the tool between the cushion and the guide until you find the slot on the outboard side of the guide Push inward on the guide slot tab while pulling upward to remove the guide from the seat back frame Rear Seat Head Restraint Guide Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 632: ... Caution Tighten 23N m 17lbft 2 Rear Seat Back Cushion Outer Pivot Bushing 3 Rear Seat Back Cushion Outer Pivot Bolt Spring 4 Rear Seat Back Cushion Pivot Support Housing 5 Rear Seat Back Center Finish Cover Rear Seat Back Cushion Pivot Support Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 633: ...aise the head restraint to the full up position 2 Depress the small button on the opposite head restraint guide and pull upward to remove from the seat Rear Seat Center Head Restraint Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 634: ...ion cover to the pad 2 Pull the cover away from the pad to disengage any retainers Note When installing the rear seat cushion cover pull the cover tightly in all corners to ensure that no creasing occurs 2 Rear Seat Cushion Pad Rear Seat Cushion Cover and Pad Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MA...

Page 635: ... of the seat cushion at the latch locations to disengage the cushion retainers from the floor 3 Push down on the rear of the seat cushion to unhook the cushion from the floor wires Rear Seat Cushion Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 636: ...ack cushion cover and pad Refer to Rear Seat Back Cushion Cover and Pad Replacement 1 Rear Seat Latch Fasteners Qty 2 Caution Refer to Fastener Caution Tighten 45N m 33lbft 2 Rear Seat Latch Rear Seat Latch Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 637: ...ushion Procedure 1 Remove the rear outboard shoulder belts from the shoulder belt bezel and position it out of the way if equipped 2 Pull the seat back cushion forward and upward to remove from the vehicle 3 Transfer components as necessary Rear Seat Back Cushion Replacement AN1 Fixed Bench 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC...

Page 638: ... rear seat back cushion and fold the rear seat back cushion forward 3 Push in on the rear seat back cushion pivot support and release from bracket 2 Rear Seat Back Cushion Procedure 1 Pull up on the outer side of the rear seat back cushion and remove the rear seat back cushion from the bracket and hinge 2 Transfer components as necessary Rear Seat Back Cushion Replacement AMA 40 w Split Back 2011 ...

Page 639: ...cement 4 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 5 Push in on the rear seat back cushion pivot support and release from bracket 2 Rear Seat Back Cushion Procedure 1 Pull up on the outer side of the rear seat back cushion and remove the rear seat back cushion from the bracket and hinge 2 Transfer comp...

Page 640: ...ease located on the top of the rear seat back cushion and fold the rear seat back cushion forward 4 Push in on the rear seat back cushion pivot support and release from bracket 2 Rear Seat Back Cushion Procedure 1 Pull up on the outer side of the rear seat back cushion and remove the rear seat back cushion from the bracket and hinge 2 Transfer components as necessary Rear Seat Back Cushion Replace...

Page 641: ...se from the seat back Note The rear seat shoulder belt opening bezel is part of the rear seat center belt assembly and is replaced as an assembly Rear Seat Shoulder Belt Guide Opening Bezel Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 642: ...hild seat back cushion cover Refer to Child Seat Back Cushion Cover Replacement 5 Remove the rear seat back cushion pivot support Refer to Rear Seat Back Cushion Pivot Support Replacement 6 Remove the rear seat latch Refer to Rear Seat Latch Replacement 1 Rear Seat Back Cushion Panel Procedure 1 Remove the seat back carpet 2 If replacing the seat back panel transfer components as necessary Rear Se...

Page 643: ...upport Replacement 1 Rear Seat Back Cushion Cover Procedure 1 Remove the seat back carpet 2 Disengage the J channel retainers from the seat back cushion frame 3 Remove the hog rings from the under side of the rear seat back cushion cover 4 Pull the cover away from the pad to disengage the hook and loop retainers 5 If replaceing the seat back panel transfer components as necessary Note When install...

Page 644: ...Rear Seat Shoulder Belt Guide Opening Bezel Replacement 1 Rear Seat Back Cushion Cover Procedure 1 Remove the seat back carpet 2 Remove the rear seat center head restraint if equipped 3 Disengage the J channel retainers from the seat back cushion frame 4 Remove the hog rings from the under side of the rear seat back cushion cover 5 Pull the cover away from the pad to disengage the hook and loop re...

Page 645: ...seat back cushion cover 4 Pull the cover away from the pad to disengage the hook and loop retainers 5 If replacing the seat back panel transfer components as necessary Note When installing the rear seat back cushion cover pull the cover tightly in all corners to ensure that no creasing occurs 2 Rear Seat Back Cushion Pad Rear Seat Back Cushion Cover and Pad Replacement AN1 Fixed Bench 2011 General...

Page 646: ...o Rear Seat Back Cushion Pivot Support Replacement 1 Rear Seat Back Cushion Cover Procedure 1 Disengage the J channel retainers from the seat back cushion frame 2 Remove the seat back carpet 3 Remove the hog rings from the under side of the rear seat back cushion cover 4 Pull the cover away from the pad to disengage the hook and loop retainers Note When installing the rear seat back cushion cover ...

Page 647: ...panel carpet Refer to Rear Compartment Floor Panel Carpet Replacement 1 Rear Seat Back Cushion Hinge Bolt Qty 2 Caution Refer to Fastener Caution Tighten 43N m 32lbft 2 Rear Seat Back Cushion Hinge Nut Qty 2 Tighten 43N m 32lbft 3 Rear Seat Back Cushion Hinge Rear Seat Back Cushion Hinge Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVRO...

Page 648: ...ol to tilt the rear of the handle upward then lifting and pulling the bezel rearward to disengage the front hooks Rear Seat Back Cushion Latch Release Knob Bezel Replacement 2011 General Motors All rights reserved Seats SEATS 0 7 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 649: ...estraints and a three passenger folding rear seat Split folding rear seat is optional Seat cushions and seatbacks have formed foam pads which fit the contours of the full panel seatback frame assembly and the designed contour of the seat cushion frame There are no front seat forward or rearward relocation provisions provided at either the seat adjuster to seat frame or the seat adjuster to floor p...

Page 650: ...ment Panel Compartment Module Disable Switch Replacement t Roof Side Rail Inflatable Restraint Module Replacement AYC Front Seat Belt Anchor Plate Tensioner Replacement Driver or Passenger Seat Shoulder Belt Replacement with A69 Driver or Passenger Seat Shoulder Belt Replacement without A69 Repairs and Inspections Required After a Collision Inflatable Restraint Module Handling and Scrapping Preten...

Page 651: ...ble Restraint Front End Discriminating Sensor 7 5N m 66lbin Front Seat Belt Anchor Plate Fastener 8N m 70lbin Front Seat Belt Retractor D Ring Fastener 45N m 33lbft Front Seat Shoulder Belt Retractor Fastener 45N m 33lbft Inflatable Restraint Roof Side Rail Fastener 9 5N m 84lbin Inflatable Restraint Sensing and Diagnostic Module Fastener 10N m 89lbin Inflatable Restraint Side Impact Sensor 7 5 N ...

Page 652: ...assenger seat 10 Passenger Seat Belt Retractor Pretensioner Located under the trim near the bottom of the center pillar on the passenger side of vehicle 11 Driver Seat Belt Retractor Pretensioner Located under the trim near the bottom of the center pillar on the driver side of vehicle 12 Driver Seat Side Air Bag Located on the seat back of driver seat 13 Inflator Module for Left Roof Rail Air Bag ...

Page 653: ...ons Warning When performing service on or near the SIR components or the SIR wiring the SIR system must be disabled Failure to observe the correct procedure could cause deployment of the SIR components Serious injury can occur Failure to observe the correct procedure could also result in unnecessary SIR system repairs The inflatable restraint sensing and diagnostic module SDM maintains a reserved ...

Page 654: ...Turn the ignition switch to the ON position The AIR BAG indicator will flash then turn OFF 4 Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator does not operate as described Refer to Diagnostic System Check Vehicle Disabling Procedure Negative Battery Cable 1 Turn the steering wheel so that the vehicles wheels are pointing straight ahead 2 Place the ignition in the OFF po...

Page 655: ...following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity Do not expose air bags to temperatures above 65 C 149 F Verify the correct replacement part number Do not substitute a component from a different vehicle Use only original GM replacement parts available from your authorized GM dealer Do not use salvaged ...

Page 656: ...aint SIR system Refer to SIR Disabling and Enabling 2 Remove the radiator opening upper cover Refer to Radiator Opening Upper Cover Replacement 1 Inflatable Restraint Front End Discriminating Sensor Assembly Caution Refer to Fastener Caution Procedure 1 Disconnect electrical connector 2 Loosen the bolts and slide the sensor out of the keyhole slots 3 The bolts are integral to the sensor assembly a...

Page 657: ...IR system Refer to SIR Disabling and Enabling 2 Remove the center pillar lower trim panel Refer to Center Pillar Lower Trim Panel Replacement 1 Inflatable Restraint Side Impact Sensor Assembly Caution Refer to Fastener Caution Procedure 1 Disconnect electrical connector 2 Loosen the fasteners and slide the sensor out of the keyhole slots 3 The bolts are integral to the sensor assembly DO NOT remov...

Page 658: ...nsole extension Refer to Front Floor Console Extension Replacement Left Side or Front Floor Console Extension Replacement Right Side 3 Disconnect the electrical connector 1 Inflatable Restraint Sensing and Diagnostic Module Fastener Qty 3 Caution Refer to Fastener Caution Tighten 10N m 89lbin 2 Inflatable Restraint Sensing and Diagnostic Module Assembly Tip When installing ensure the arrow on the ...

Page 659: ...ward through the access hole 1 located on the rear of the steering wheel by pulling the tool outwards 4 Keeping the tool inserted repeat the step for other opening 5 Keeping the upper step pull the steering wheel inflatable restraint module out of the steering wheel 6 Disconnect the electrical connectors 7 Remove the steering wheel inflatable restraint module Installation Procedure 1 Connect the e...

Page 660: ... SIR Disabling and Enabling 5 After replacing the module fully deploy the module before disposal If the module was replaced under warranty fully deploy and dispose of the module after the required retention period Refer to Inflatable Restraint Module Handling and Scrapping 2011 General Motors All rights reserved Restraints RESTRAINTS 0 8 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BO...

Page 661: ... Procedure 1 Disconnect any electrical connectors as necessary 2 Use tape in order to secure the old coil in the center position 3 Remove the old coil from the steering column 4 Transfer the steering angle sensor Refer to Steering Angle Sensor Replacement 5 Ensure the coil is centered during installation If you are installing a NEW coil ensure the centering tab is on the coil If the coil is not ce...

Page 662: ...entering mark 1 of the steering shaft is in the 6 o clock position 2 Turn the lobe of the coil clockwise until the coil ribbon stops Do not force 3 Turn the lobe of the coil counterclockwise approximately 3 turns to the neutral position Note The quantity of electrical connectors may vary depending upon the content of the vehicle 4 Properly align the coil until the centering window turns yellow 1 T...

Page 663: ...straint Module Assembly Procedure 1 Ensure that the instrument panel inflatable restraint module is fully deployed before disposal If the module was replaced under warranty fully deploy and dispose of the module after the required retention period Refer to Inflatable Restraint Module Handling and Scrapping 2 Enable the SIR system Refer to SIR Disabling and Enabling Instrument Panel Inflatable Rest...

Page 664: ...passenger seat Refer to Driver or Passenger Seat Replacement 3 Remove the driver or passenger seat back cushion cover and pad Refer to Driver or Passenger Seat Back Cushion Cover and Pad Replacement 1 Seat Side Inflatable Restraint Module Nut Qty 2 Caution Refer to Fastener Caution Tighten 4N m 35lbin 2 Driver or Passenger Seat Side Inflatable Restraint Module Procedure 1 Disconnect the electrical...

Page 665: ...lacement 1 Inflatable Restraint Instrument Panel Module Disable Switch Assembly Procedure 1 Use a small flat bladed tool to aid in the removal of the switch from the instrument panel side trim panel 2 Disconnect the electrical connector Inflatable Restraint Instrument Panel Compartment Module Disable Switch Replacement 2011 General Motors All rights reserved Restraints RESTRAINTS 0 8 BACK TO CHAPT...

Page 666: ... the headliner Only do those steps in headliner replacement that will lower the headliner enough to gain access to the part Refer to Headlining Trim Panel Replacement 1 Roof Side Rail Inflatable Restraint Module Retainer Qty 2 2 Roof Side Rail Inflatable Restraint Module Fastener Qty 3 Caution Refer to Fastener Caution Tighten 9 5N m 84lbin 3 Roof Side Rail Inflatable Restraint Module Assembly Pro...

Page 667: ...cal laws Preliminary Procedures 1 Move the front seat to the full forward and full up position 2 Disable the SIR Refer to SIR Disabling and Enabling 3 Remove the driver or passenger seat belt tensioner cover Refer to Front Seat Belt Anchor Plate Tensioner Cover Replacement 4 For pretensioner handling and scrapping Refer to Pretensioner Handling and Scrapping 1 Driver or Passenger Seat Belt Tension...

Page 668: ...r 5 Driver or Passenger Seat Belt Tensioner Fastener Tighten 45N m 33lbft 6 Driver or Passenger Seat Belt Tensioner Assembly Procedure Disconnect the electrical connector Restraints RESTRAINTS 0 8 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 669: ...t belt pretensioner Failure to observe the following disposal methods may be a violation of federal state or local laws Preliminary Procedures 1 Move the front seat to a full forward and full up position 2 Disable the SIR Refer to SIR Disabling and Enabling 3 Remove the center pillar upper trim panel Refer to Center Pillar Upper Trim Panel Replacement 1 Driver or Passenger Seat Belt Tensioner Cove...

Page 670: ...or Passenger Seat Shoulder Belt Retractor Assembly Procedure 1 Disconnect the electrical connector 2 Full deploy the module before disposal If the module was replaced under warranty full deploy and dispose of the module after the required retention period Refer to Pretensioner Handling and Scrapping Restraints RESTRAINTS 0 8 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MAN...

Page 671: ...ethods may be a violation of federal state or local laws Preliminary Procedures 1 Remove the center pillar upper trim panel Refer to Center Pillar Upper Trim Panel Replacement 2 Remove the front seat lower finish cover Refer to Front Seat Belt Anchor Plate Tensioner Cover Replacement 1 Front Seat Belt Anchor Plate Fastener Caution Refer to Fastener Caution Tighten 8N m 70lbin 2 Front Seat Belt Ret...

Page 672: ...ag if deployed Seat back cover if side seat air bag is deployed Driver Passenger seat belt anchor and or retractor pretensioners Perform additional inspections on the following components Steering wheel air bag coil and the coil wiring pigtail Inspect for melting scorching or other damage due to excessive heat Mounting points or mounting hardware for the passenger instrument panel air bag steering...

Page 673: ...be replaced Replace the impact sensor whether or not the air bags have deployed Replace the impact sensor even if it appears to be undamaged Impact sensor damage which is not visible such as slight bending of the mounting bracket or cuts in the wire insulation can cause improper operation of the SIR system Do not try to determine whether the impact sensor is undamaged replace the impact sensor Als...

Page 674: ...ulation from the end of these 2additional wires 7 Twist the 2wires together at oneend 8 Place the twisted ends of the 2wires near the deployment battery Do not connect the wires to the battery at this time 9 Using the free ends of the 10m 33ft wires leading to the steering wheel module coil make 2splices oneat each wire from the air bag modules 10 Wrap the wires with insulation tape 11 Now that th...

Page 675: ...r module air bag After deployment the inflator module air bag surface may contain a small amount of sodium hydroxide a by product of the deployment reaction that is irritating to the skin and eyes Most of the powder on the inflator module air bag is harmless as a precaution wear gloves and safety glasses when handling a deployed inflator module air bag and wash your hands with mild soap and water ...

Page 676: ...ll work best in a given situation Deployment Inside the Vehicle Refer to Inflatable Restraint Module Handling and Scrapping for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service Situations that require deployment out...

Page 677: ...c reservoir with water or sand 10 Mount the pretensioner 1 in the SIR deployment fixture 3 with the open end facing up using the following mounting method 10 1 Adjust and secure the EL 39401 B arms 4 to the deployment fixture 3 10 2 To mount use the proper size bolt 2 and nut 5 with washers in order to secure the pretensioner 1 to the deployment fixture brackets 4 10 3 Securely tighten all fastene...

Page 678: ...ople in the immediate area that you intend to deploy the seat belt pretensioner 16 Clear the area of people Object Number 39382 Warning When you are deploying a pretensioner for disposal perform the deployment procedures in the order listed Failure to follow the procedures in the order listed may result in personal injury 17 Separate the 2 banana plugs on the SIR deployment harness Restraints REST...

Page 679: ...fter the pretensioner deploys 21 Seat one banana plug into the other in order to short the deployment harness leads 22 If the pretensioner did not deploy disconnect the adapter and discontinue the procedure Contact the Technical Assistance Group Otherwise proceed to the following steps 23 Put on a pair of shop gloves 24 Disconnect the pigtail adapter from the pretensioner as soon as possible 25 In...

Page 680: ...AG indicator notifying the driver that a malfunction exists In the event that ignition positive voltage is lost during a collision the SDM maintains a 23V loop reserve for deployment of the air bags It is important when disabling the SIR system for servicing or rescue operations to allow the 23V loop reserve to dissipate which could take up to 1minute Air Bags This vehicle contains 6 air bags The ...

Page 681: ...lt Indicators The seat belt indicators are controlled through the inflatable restraint sensing and diagnostic module SDM For further information on seat belt indicators refer to Seat Belt System Description and Operation 2011 General Motors All rights reserved Restraints RESTRAINTS 0 8 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 682: ...8826 J38826 KM799 3 SIR Deployment Harness EL39401 B J39401 B SIR Deployment Fixture Special Tools 2011 General Motors All rights reserved Restraints RESTRAINTS 0 8 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 683: ...Bracket Replacement Turn Signal Multifunction Switch Replacement Steering Wheel Horn Cap Replacement Steering Wheel Replacement Steering Column Replacement NJ1 Steering Column Replacement N40 Steering Angle Sensor Replacement 2011 General Motors All rights reserved Index STEERING 0 9 Specifications Description and Operation BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 684: ... 49N m 36lbft Steering Column Lower Support Bracket Bolts 22N m 16lbft Steering Column Upper Support Bracket Nuts 22N m 16lbft Steering Wheel Bolt 30N m 22lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 685: ...umn copy the match marks from the old parts to the new parts 3 Align the match marks as you install the intermediate steering shaft to the steering column shaft 4 After the installation is complete perform the following tasks Setup the power steering control module Refer to Center the steering angle sensor Refer to 2 1 Setup the power steering control module Refer to Power Steering Control Module ...

Page 686: ...nter SIR Coil 1 With the steering wheel in the straight ahead position LOCK the steering column 2 Remove the upper trim cover and the lower trim cover from the steering column Refer to Steering Column Lower Trim Cover Replacement 3 Remove the instrument panel lower trim pad cover Refer to Instrument Panel Lower Trim Pad Cover Replacement 4 Remove the left side floor air outlet duct Refer to Floor ...

Page 687: ... Fastener Caution 5 Install the intermediate steering shaft upper bolt 2 and tighten to 49N m 36lbft 6 Install the intermediate steering shaft lower bolt 2 and tighten to 49N m 36lbft 7 Connect any electrical connectors as necessary 8 Install the left side floor air outlet duct Refer to Floor Air Outlet Duct Replacement Left Side 9 Install the instrument panel lower trim pad cover Refer to Instrum...

Page 688: ...ures 1 Use a flat bladed plastic trim tool along the right and left sides of the trim panel in order to release the retainers securing the upper trim cover to the lower trim cover 2 Lift the upper trim cover upward and rearward in order to release the retainers along the front forward edge of the upper trim cover Steering Column Upper Trim Cover Replacement 2011 General Motors All rights reserved ...

Page 689: ...eplacement 1 Instrument Panel Steering Column Lower Trim Cover Fastener Caution Refer to Fastener Caution 2 Instrument Panel Steering Column Lower Trim Cover Assembly Steering Column Lower Trim Cover Replacement 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 690: ...ner Caution 2 Turn Signal Switch Bracket Procedure 1 Disconnect any electrical connectors as necessary 2 Release the locking tab in order to disconnect the turn signal switch bracket from the steering column 3 Transfer components as necessary Turn Signal Switch Bracket Replacement 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 201...

Page 691: ...rn Signal Switch Procedure 1 Disconnect any electrical connectors as necessary 2 Release the plastic retaining tabs and remove the turn signal multifunction switch from the turn signal switch bracket Turn Signal Multifunction Switch Replacement 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 692: ...cedure Use flat bladed plastic tool to gently pry horn cap from steering wheel Steering Wheel Horn Cap Replacement 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 693: ...eel Bolt Caution Refer to Fastener Caution Tighten 30N m 22lbft 2 Steering Wheel Procedure 1 Disconnect all electrical connectors as necessary 2 Loosen the steering wheel bolt until 2 to 3threads are left engaged 3 Wiggle the steering wheel until the steering wheel disengages completely 4 Remove the steering wheel bolt 5 Remove the steering wheel 6 Copy the match marks from the old steering wheel ...

Page 694: ...o re center SIR Coil 1 With the steering wheel in the straight ahead position LOCK the steering column 2 Remove the upper trim cover and the lower trim cover from the steering column Refer to Steering Column Lower Trim Cover Replacement 3 Remove the instrument panel lower trim pad cover Refer to Instrument Panel Lower Trim Pad Cover Replacement 4 Remove the left side floor air outlet duct Refer to...

Page 695: ...dity Leaning on the column assembly could cause the jacket to bend or deform Any of the above damage could impair the columns collapsible design Do NOT hammer on the end of the shaft because hammering could loosen the plastic injections which maintain column rigidity If you need to remove the steering wheel refer to the Steering Wheel Replacement procedure in this section 12 Remove the steering co...

Page 696: ...he 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 Tighten the steering column lower fasteners before you tighten the steering column upper fasteners Failure to do this can damage the steering column Tighten the steering column fasteners to the specified torque Overtightening the upper steering column fa...

Page 697: ...r outlet duct Refer to Floor Air Outlet Duct Replacement Left Side 11 Install the instrument panel lower trim pad cover Refer to Instrument Panel Lower Trim Pad Cover Replacement 12 Install the upper trim cover and the lower trim cover to the steering column Refer to Steering Column Lower Trim Cover Replacement 14 Center the steering angle sensor Refer to Steering Angle Sensor Centering Steering S...

Page 698: ... With the steering wheel in the straight ahead position LOCK the steering column 2 Remove the upper trim cover and the lower trim cover from the steering column Refer to Steering Column Lower Trim Cover Replacement 3 Remove the instrument panel lower trim pad cover Refer to Instrument Panel Lower Trim Pad Cover Replacement 4 Remove the left side floor air outlet duct Refer to Floor Air Outlet Duct...

Page 699: ...n the plastic injections which maintain column rigidity If you need to remove the steering wheel refer to the Steering Wheel Replacement procedure in this section 11 Remove the steering column assembly 1 from the vehicle 12 Transfer components as necessary Installation Procedure 1 If you are replacing the steering column or the intermediate steering shaft copy the match marks from the old parts to...

Page 700: ...ighten the 2steering column upper support bracket nuts 1 2 Caution Refer to Fastener Caution 5 Install the 2steering column lower support bracket bolts 1 2 and tighten to 22N m 16lbft 6 Tighten the 2steering column upper support bracket nuts to 22N m 16lbft 7 Connect any electrical connectors as necessary 8 Install the left side floor air outlet duct Refer to Floor Air Outlet Duct Replacement Left...

Page 701: ...in the clip on the steering wheel airbag coil in order to remove the steering angle sensor 2 After the installation is complete center the steering angle sensor Refer to Steering Angle Sensor Centering Steering Angle Sensor Replacement 2011 General Motors All rights reserved Steering STEERING 0 9 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 702: ...the steering function the steering column provides safety and security The energy absorbing column is designed to compress in a front end collision to lessen the chance of driver injury The ignition switch and the lock are mounted on the column allowing the ignition and steering operations to be locked to prevent theft of the car The column levers trigger the turn signals the headlight beams and t...

Page 703: ...Front Suspension Rear Suspension Tires and Wheels 2011 General Motors All rights reserved Index SUSPENSION 10 BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 704: ...t Assembly Removal and Installation Shock Absorber Disposal Strut Strut Component or Spring Replacement 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 Specifications Description and Operation Special Tools BACK TO CHAPTER INDEX Lower Control Arm Replacement Steering Linkage Outer Tie Rod Replacement TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 705: ... Rear Nut First Pass 160N m 118lbft Final Pass plus35degrees Front Suspension Stabilizer Shaft Clamp Bolts 22N m 16lbft Front Suspension Stabilizer Shaft Link Nuts 65N m 48lbft Front Suspension Strut to Steering Knuckle Nuts 110N m 82lbft Front Suspension Strut Upper Mount Nut 65N m 48lbft Front Suspension Strut Lower Mount Nut 65N m 48lbft Fastener Tightening Specifications 2011 General Motors Al...

Page 706: ...abilizer Shaft Link Replacement 4 Remove the lower control arm ball joint bolt and nut from the steering knuckle Refer to Lower Control Arm Replacement 5 Remove the exhaust pipe insulators 1 6 Using a suitable support lower the front suspension frame 1 enough to gain access to the stabilizer shaft insulator bolts Refer to Drivetrain and Front Suspension Frame Replacement Front Suspension SUSPENSIO...

Page 707: ... maneuver the front stabilizer shaft in such away as to remove it from the front suspension frame 8 Remove the front stabilizer shaft 1 from the front suspension frame Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 708: ...or bolts and tighten to 22N m 16lbft 3 Lift the front suspension frame 1 into the proper position Refer to Drivetrain and Front Suspension Frame Replacement 4 Install the lower control arm ball joint to steering knuckle bolts Refer to Lower Control Arm Replacement Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 709: ...all the exhaust pipe insulators 1 7 Install the tire and wheel assembly Refer to Tire and Wheel Removal and Installation 8 Remove the support and lower the vehicle 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 710: ... the stabilizer shaft link nut 2 Remove and discard the stabilizer shaft link nut Replace with NEW only Tighten 65N m 48lbft 2 Front Stabilizer Shaft Link Lower Nut Procedure 1 Use the proper size Allen wrench to hold the stabilizer shaft link stud when loosening or tightening the stabilizer shaft link nut 2 Remove and discard the nut Replace with NEW only Tighten 65N m 48lbft 3 Front Stabilizer S...

Page 711: ...the steering knuckle assembly 1 in a suitable vise 4 Position the CH 50059 1wheel hub bearing removal installation bridge assembly 1 and the CH 50559 2wheel hub bearing removal installation adapter 2 on the wheel bearing inner hub 5 Using the CH 50059 1and the CH 50559 2 remove the wheel hub from the wheel bearing 6 If the inner race of the bearing is pulled out with the hub remove the inner race ...

Page 712: ... the steering knuckle for pitting scoring wear or corrosion If damage cannot be easily cleaned up with light sanding replace the steering knuckle Installation Procedure Note Ensure that the wheel bearing is evenly seated in the steering knuckle 1 Using the CH 50559 4wheel hub bearing installation adapter 1 and the appropriate extension and press install the new bearing into the steering knuckle un...

Page 713: ...ion on the wheel hub 3 Press in the hub until it is correctly seated 4 Using the appropriate tool install the retaining ring 1 5 Verify the hub rotates smoothly 6 Install the steering knuckle assembly in the vehicle Refer to Steering Knuckle Replacement 7 Lower the vehicle 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 20...

Page 714: ...Tire and Wheel Removal and Installation Note DO NOT reuse the ball joint nut The nut is NOT reusable 3 Remove the lower ball joint nut 1 and bolt 2 4 Remove and discard the front lower control bolt 1 Replace with NEW only 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 715: ...Remove the front lower control arm rear nut 1 and bolt 2 6 Remove the front lower control arm 1 Installation Procedure 1 Position the lower control arm 1 in the vehicle Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 716: ... Install the NEW front lower control arm front bolt 1 and tighten to First Pass 115N m 85lbft Final Pass plus an additional65degrees 3 Tighten the NEW front lower control arm rear nut 1 to First Pass 160N m 118lbft Final Pass plus an additional35degrees Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 717: ...30N m 22lbft Final Pass plus an additional35degrees 5 Install the tire and wheel assembly Refer to Tire and Wheel Removal and Installation 6 Remove the support and lower the vehicle Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 718: ...cause bodily injury and damage to the vehicle or component Caution Refer to Fastener Caution Procedure 1 Remove the steering linkage outer tie rod nut DISCARD the nut 2 Install a NEW outer tie rod nut 3 Use the EN 45059 meter in order to tighten the outer tie rod nut to the specification Tighten 1 30N m 22lbft 2 128degrees Special Tools EN 45059 Angle Meter For equivalent regional tools refer to S...

Page 719: ...wedge type tool Damage to the seal or bushing may result Procedure 1 Use the CH 161 B puller in order to separate the steering linkage outer tie rod from the steering knuckle 2 Inspect the steering linkage inner tie rod for bent or damaged threads 3 Clean the tapered surface of the steering knuckle 4 After the installation is complete measure and adjust the front toe Refer to Wheel Alignment Steer...

Page 720: ...1 Verify the customer s concern is present If the concern is present continue to the next step If the concern is not present then the vehicle is operating normally Note The strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure 2 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 3 Visually inspect each of the shock absorbers o...

Page 721: ...abilizer shaft link from the front strut assembly Refer to Stabilizer Shaft Link Replacement 5 Remove the front brake hose 1 from the front strut assembly 6 Remove the speed sensor wring harness from the front strut assembly if needed 7 Remove the outer tie rod end from the steering knuckle Refer to Steering Linkage Outer Tie Rod Replacement 8 Support the lower control arm with a jack stand 9 Remo...

Page 722: ...e 2 Discard the nut and replace with NEW only 12 Remove the front strut assembly from the vehicle 1 13 If removing the front strut assembly to service any of the front strut components refer to Strut Strut Component or Spring Replacement Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 723: ...the NEW front strut nut 1 and the retaining plate 2 Caution Refer to Fastener Caution 3 Using the CH35669 socket 2 and the proper size allen wrench tighten the nut to 35N m 26lbft Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 724: ...ng Linkage Outer Tie Rod Replacement 8 Install the speed sensor wiring harness on the front strut assembly if needed 9 Install the front brake hose 1 on the front strut assembly 10 Install the tire and wheel assembly Refer to Tire and Wheel Removal and Installation 11 Remove the support and lower the vehicle 12 Install the air inlet grille panel Refer to Air Inlet Grille Panel Replacement 2011 Gen...

Page 725: ...le in the shock absorber at the centerpunch 4 using a 5mm 3 16in drill bit Gas or a gas oil mixture will exhaust when the drill bit penetrates the shock absorber Use shop towels in order to contain the escaping oil 4 Make an indentation in the middle 2 of the tube 3 with a centerpunch 5 Drill a second hole in the shock absorber at the centerpunch 2 using a 5mm 3 16in drill bit Oil will exhaust whe...

Page 726: ...mpressor 1 Note The spring is compressed when the strut moves freely 3 Using the spring compressor 1 compress the front spring 4 Using a TORX bit 1 and the appropriate socket 2 loosen the front suspension strut nut 5 Slowly loosen the spring compressor 2 to remove the front suspension strut components to be serviced Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONI...

Page 727: ...rut 5 from the spring compressor Assembly Procedure 1 Install the front suspension strut 5 front suspension strut bumper 4 front spring 3 front spring insulator 2 and the front suspension strut mount 1 in the spring compressor Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 728: ...strut shaft 4 Using the appropriate size socket 2 and the TORX bit 1 tighten the front suspension strut nut to 65N m 48lbft 5 Remove the front suspension strut from the spring compressor 6 Install the front suspension strut to the vehicle Refer to Strut Assembly Removal and Installation 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEV...

Page 729: ... bearing The steering knuckle is allowed to travel up and down independent of the vehicle body structure and frame This up and down motion of the steering knuckle as the vehicle travels over bumps is absorbed predominantly by the coil spring This spring is retained under tension over the strut assembly A strut is used in conjunction with this system in order to dampen out the oscillations of the c...

Page 730: ... Rod Nut Socket CH43631 Ball Joint Remover CH50559 Wheel Hub Bearing Remover Installer Kit Special Tools 2011 General Motors All rights reserved Front Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 731: ...ement Description and Operation 2011 General Motors All rights reserved Rear Suspension SUSPENSION 10 Special Tools Specifications Rear Spring Insulator and Jounce Bumper Replacement BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 732: ...m 43lbft Shock Absorber to Axle Bolt Lower 120N m 89lbft Shock Absorber Nut 25N m 18lbft Shock Absorber to Upper Mount Bolts 58N m 43lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Rear Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 733: ...efer to Shock Absorber Replacement Inspection 1 Verify the customer s concern is present If the concern is present continue to the next step If the concern is not present then the vehicle is operating normally Note The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure 2 Raise and support the vehicle Refer to Lifting and Jacking the V...

Page 734: ...Absorber Upper Bolt Qty 2 Caution Refer to Fastener Caution Procedure Support the rear axle with a hydraulic jack Tighten 58N m 43lbft 2 Rear Shock Absorber Lower Bolt Tighten 120N m 89lbft 3 Rear Shock Absorber Assembly 4 Shock Absorber Nut Tighten 25N m 18lbft 5 Shock Absorber Mount Shock Absorber Replacement Rear Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012...

Page 735: ...6 Shock Absorber Bumper 7 Rear Shock Absorber 2011 General Motors All rights reserved Rear Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 736: ...ydraulic jack 3 Remove the lower rear shock absorber bolt Refer to Shock Absorber Replacement 2 Upper Rear Spring Insulator Tip Ensure that the rear spring insulator is properly seated in the rear frame rail 3 Lower Rear Spring Insulator Tip Ensure that the rear spring insulator is properly seated in the rear axle Rear Spring Insulator and Jounce Bumper Replacement 2011 General Motors All rights r...

Page 737: ...t the weight of the vehicle in the rear Rubber insulators isolate the coil spring at the upper and lower spring seat Shock Absorber The shock absorbers are connected to the rear axle and the vehicle underbody The shock absorbers are non adjustable and non refillable Service of the shocks requires replacement of the shock assembly Wheel Bearing Hub Assembly A single hub and bearing assembly is bolt...

Page 738: ...n Tool Number Description CH43631 Ball Joint Remover Special Tools 2011 General Motors All rights reserved Rear Suspension SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 739: ...r Aluminum Wheel Refinishing 2011 General Motors All rights reserved Tyres and Wheels SUSPENSION 10 Tire and Wheel Removal and Installation Specifications BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 740: ...n Metric English Wheel Nuts 140N m 103lbft Fastener Tightening Specifications 2011 General Motors All rights reserved Tyres and Wheels SUSPENSION 10 BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 741: ...he rim surface at the leak area 9 Use general purpose cleaner such as 3M P N08984 or equivalent to clean the leak area 10 Apply 3mm 0 12in thick layer of adhesive sealant GM P N1052366 or equivalent to the leak area 11 Allow for the adhesive sealant to dry 12 Align the inscribed mark on the tire with the valve stem on the wheel 13 Install the tire to the wheel Refer to Tire Dismounting and Mountin...

Page 742: ... from the wheel 3 Remove the tire from the wheel Refer to Tire Dismounting and Mounting 4 Use a suitable cleaner in order to remove the following contaminants from the wheel Lubricants Wax Dirt Note Do not re machine the wheel Do not use chemicals in order to strip the paint from the wheel 5 Use plastic media blasting in order to remove the paint from the wheel 6 If the wheel had a machined alumin...

Page 743: ... the wheel mounting surface by scraping and wire brushing Installing wheels without good metal to metal contact at the mounting surfaces can cause wheel bolts or nuts to loosen which can later allow a wheel bolt or nut to come off while the vehicle is moving Wheel bolts or nuts must be tightened in sequence and to proper torque to avoid bending the wheel brake drum or rotor Note Wear approved safe...

Page 744: ...ution Improperly tightened wheel bolts or nuts can lead to brake pulsation and rotor damage In order to avoid expensive brake repairs evenly tighten the wheel bolts or nuts to the proper torque specification 4 Using the proper size socket and the torque wrench tighten the wheel nuts in the proper sequence to 140N m 100lbft 5 Install the wheel center cap if required 6 Install the wheel cap nuts if ...

Page 745: ...let Hose Replacement Diesel Side Window Defogger Outlet Grille Replacement Instrument Panel Outer Air Outlet Replacement Left Side Instrument Panel Center Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement Right Side Instrument Panel Outer Air Outlet Duct Replacement Floor Air Outlet Duct Replacement Left Side RHD Floor Air Outlet Duct Replacement Right Side RHD Floor Rear Air Ou...

Page 746: ...onditioning Refrigerant Pressure Sensor 6N m 54lbin Air Inlet Housing Fastener 1 2N m 11lbin Air Inlet Valve Actuator Screw 1 2N m 11lbin Blower Motor Resistor Screw 1 2N m 11lbin Blower Motor Screws 1 2N m 11lbin Blower Motor Service Ring Screws 1 2N m 11lbin Center Air Distributor Duct Screw 2 5N m 22lbin Cover Assembly Screw Heater 1 2N m 11lbin HVAC Module Assembly Fastener 22N m 16lbft Fasten...

Page 747: ...Thermal Expansion Valve Bolt 7N m 62lbin HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 748: ...G oil Condenser Replacement 30 40ml 1 0 1 4oz Evaporator Replacement 30 40ml 1 0 1 4oz Total System PAG Oil Capacity 110ml 3 7oz R 134a Refrigerant Charge 500g 17 6oz Refrigerant System Specifications 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 749: ...e with each other If the refrigerants are mixed compressor failure is likely to occur Refer to the manufacturer instructions included with the service equipment before servicing The air conditioning filling device service center is a complete air conditioning service center for R 134a The ACR2000 recovers recycles evacuates and recharges A C refrigerant quickly accurately and automatically The uni...

Page 750: ...plete and perform the following procedure Inspect and lubricate GE 45268 adapter kit fitting O rings Refer to Air Conditioning O Ring Seal Replacement 1 Install both GE 45268 9 fitting O ring onto GE 45268 10 adapter 2 Install GE 45268 8 fitting O ring onto suction side of GE 45268 10 adapter 3 Install GE 45268 7 fitting O ring onto discharge side of GE 45268 10 adapter Flush Procedure Note Warmer...

Page 751: ...rom the A C compressor to condenser hose Note Flushing will remove all PAG oil from the A C system The A C system must be replenished with the correct amount of PAG oil 21 If you will reinstall the removed A C compressor perform the following procedure Drain PAG oil from the A C compressor Rotate compressor input shaft to assist in draining the PAG oil from compressor Add the total system capacity...

Page 752: ...sor and Condenser Hose Replacement 5 Disconnect the electrical connector 1 Air Conditioning Compressor Bolts Qty 3 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Air Conditioning Compressor Procedure When replacing the A C compressor balance the compressor oil Refer to Air Conditioning Compressor Oil Balancing Air Conditioning Compressor Replacement 1 6L or 1 8L 2011 General Motors All r...

Page 753: ...sor and Condenser Hose Replacement 5 Disconnect the electrical connector 1 Air Conditioning Compressor Bolts Qty 3 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Air Conditioning Compressor Procedure When replacing the A C compressor balance the compressor oil Refer to Air Conditioning Compressor Oil Balancing Air Conditioning Compressor Replacement 1 2L or 1 4L 2011 General Motors All r...

Page 754: ...A C Compressor Bolt Qty 3 Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 A C Compressor Assembly Procedure 1 Disconnect the electrical connector 2 Use a low viscosity poly alkylene glycol PAG oil Use of the incorrect oil can result in compressor failure 3 When replacing the A C compressor balance the compressor oil Refer to Air Conditioning Compressor Oil Balancing 4 Using GE 39400 A det...

Page 755: ...ing Compressor Bracket Bolt Qty 4 Caution Refer to Fastener Caution Tighten 22N m 17lbft 2 Air Conditioning Compressor Bracket Air Conditioning Compressor Bracket Replacement Diesel 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 756: ...ioning compressor and condenser hose 2 from A C condenser 5 Remove A C compressor and condenser hose bolt 1 6 Remove A C compressor and condenser hose 2 from A C compressor 7 Remove air conditioning compressor and condenser hose nut 1 8 Remove air conditioning compressor and condenser hose 2 from refrigerant hose 9 Remove air conditioning compressor and condenser hose from the vehicle HEATING VENT...

Page 757: ... hose 2 to the A C compressor 5 Install air conditioning compressor and condenser hose bolt 1 Tighten bolt to 22N m 16lbft 6 Install air conditioning compressor and condenser hose 2 to the A C condenser 7 Install air conditioning compressor and condenser hose nut 1 Tighten nut to 22N m 16lbft 8 Connect the A C refrigerant pressure sensor electrical connector 9 Evacuate and charge the refrigerant s...

Page 758: ...ioning compressor and condenser hose 2 from A C condenser 5 Remove A C compressor and condenser hose bolt 1 6 Remove A C compressor and condenser hose 2 from A C compressor 7 Remove air conditioning compressor and condenser hose nut 1 8 Remove air conditioning compressor and condenser hose 2 from refrigerant hose 9 Remove air conditioning compressor and condenser hose from the vehicle HEATING VENT...

Page 759: ... hose 2 to the A C compressor 5 Install air conditioning compressor and condenser hose bolt 1 Tighten bolt to 22N m 16lbft 6 Install air conditioning compressor and condenser hose 2 to the A C condenser 7 Install air conditioning compressor and condenser hose nut 1 Tighten nut to 22N m 16lbft 8 Connect the A C refrigerant pressure sensor electrical connector 9 Evacuate and charge the refrigerant s...

Page 760: ...ing compressor and condenser hose 2 from A C condenser 5 Remove A C compressor and condenser hose bolt 1 6 Remove A C compressor and condenser hose 2 from A C compressor 7 Remove air conditioning compressor and condenser hose nut 1 8 Remove air conditioning compressor and condenser hose 2 from refrigerant hose 9 Remove air conditioning compressor and condenser hose from the vehicle HEATING VENTILA...

Page 761: ...ose 2 to the A C compressor 5 Install air conditioning compressor and condenser hose bolt 1 Tighten bolt to 22N m 16lbft 6 Install air conditioning compressor and condenser hose 2 to the A C condenser 7 Install air conditioning compressor and condenser hose nut 1 Tighten nut to 22N m 16lbft 8 Install front bumper fascia Refer to Front Bumper Fascia Replacement 9 Evacuate and charge the refrigerant...

Page 762: ...placement or Air Cleaner Assembly Replacement 1 Air Conditioning Evaporator Hose Assembly Nut Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Air Conditioning Evaporator Hose Assembly Procedure Discard and replace all sealing washers Refer to Air Conditioning System Seal Replacement Air Conditioning Evaporator Hose Assembly Replacement 2011 General Motors All rights reserved HEATING VENTI...

Page 763: ...r to Air Conditioning Compressor and Condenser Hose Replacement 1 Air Conditioning Condenser Baffel Bolt Qty 4 Caution Refer to Fastener Caution Tighten 10N m 89lbin 2 Air Conditioning Condenser Baffel 3 Air Conditioning Condenser Tip Unclip condenser from radiator Air Conditioning Condenser Replacement 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK T...

Page 764: ... Air Conditioning Evaporator Hose Assembly Replacement 6 Remove the heater outlet hose Refer to Heater Outlet Hose Replacement 7 Remove the heater inlet hose Refer to Heater Inlet Hose Replacement 1 Heater and Air Conditioning Evaporator and Blower Module Fastener Caution Refer to Fastener Caution Tighten 22N m 16lbft 2 Heater and Air Conditioning Evaporator and Blower Module Assembly Heater and A...

Page 765: ...sengage the heater inlet hose quick connect clip 1 at the heater core 3 Remove the heater inlet hose 2 from the heater core 4 Remove the heater inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 5 Remove the heater inlet hose 2 from the engine 6 Remove the heater inlet hose from the vehicle HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROL...

Page 766: ... connector is properly aligned to the heater core pipe position the white mark to the 12 00 O clock position during installation 4 Install the heater inlet hose 2 to the heater core 5 Engage the heater inlet hose quick connect clip 1 at the heater core 6 Fill the cooling system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIO...

Page 767: ...ngage the heater outlet hose quick connect clip 1 at the heater core 3 Remove the heater outlet hose 2 from the heater core 4 Remove the heater outlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 5 Remove the heater outlet hose 2 from the engine 6 Remove the heater outlet hose from the vehicle HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEV...

Page 768: ...k connector is properly aligned to the heater core pipe position the white mark to the 12 00 O clock position during installation 4 Install the heater outlet hose 2 to the heater core 5 Engage the heater outlet hose quick connect clip 1 at the heater core 6 Fill the cooling system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDI...

Page 769: ...nect the heater outlet hose quick connect fitting 1 at the heater core 3 Remove the heater outlet hose 2 from the heater core 4 Remove the heater outlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 5 Remove the heater outlet hose 2 from the engine 6 Remove the heater outlet hose from the vehicle HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CH...

Page 770: ...185 Hose Clamp Pliers 4 Install the heater outlet hose 2 to the heater core 5 Connect the heater outlet hose quick connect fitting 1 at the heater core 6 Fill the cooling system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 771: ...let hose quick connect fitting 1 at the heater core 3 Remove the heater inlet hose 2 from the heater core 4 Remove the heater inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 5 Remove the heater inlet hose 2 from the engine 6 Remove the heater inlet hose from the vehicle 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX ...

Page 772: ... engine using BO 38185 Hose Clamp Pliers 4 Install the heater inlet hose 2 to the heater core 5 Connect the heater inlet hose quick connect fitting 1 at the heater core 6 Fill the cooling system Refer to Cooling System Draining and Filling HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 773: ... hose quick connect fitting 1 at the heater core 3 Remove the heater inlet hose 2 from the heater core 4 Remove the heater inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 5 Remove the heater inlet hose 2 from the engine 6 Remove the heater inlet hose from the vehicle 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO ...

Page 774: ...engine using BO 38185 Hose Clamp Pliers 4 Install the heater inlet hose 2 from the heater core 5 Connect the heater inlet hose quick connect fitting 1 at the heater core 6 Fill the cooling system Refer to Cooling System Draining and Filling HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 775: ...stic trim tool to aid in the removal of the grille assemblies from the instrument panel Side Window Defogger Outlet Grille Replacement 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 776: ...trim tool to aid in the removal of the air outlet assembly from the instrument panel Instrument Panel Outer Air Outlet Replacement Left Side 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 777: ...Instrument Panel Center Air Outlet Assembly Procedure Unsnap the instrument panel center air outlet from the center molding assembly Instrument Panel Center Air Outlet Replacement 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 778: ...rim tool to aid in the removal of the air outlet assembly from the instrument panel Instrument Panel Outer Air Outlet Replacement Right Side 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 779: ...or hoses to gain access to air duct 1 Center Air Distributor Duct Screw Qty 4 Caution Refer to Fastener Caution 2 Center Air Distributor Duct Instrument Panel Outer Air Outlet Duct Replacement 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 780: ...nt Panel Compartment Housing Replacement 1 Floor Air Outlet Duct Fastener 2 Floor Air Outlet Duct Floor Air Outlet Duct Replacement Left Side RHD 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 781: ...pad cover Refer to Instrument Panel Lower Trim Pad Cover Replacement 1 Floor Air Outlet Duct Fastener 2 Floor Air Outlet Duct Floor Air Outlet Duct Replacement Right Side RHD 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 782: ...t Replacement 1 Floor Rear Air Outlet Duct Push In Fastener 2 Floor Rear Air Outlet Duct Floor Rear Air Outlet Duct Replacement Left Side 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 783: ... the floor rear air outlet duct fastener 2 If replacing the floor rear air outlet duct transfer all necessary components 2 Floor Rear Air Outlet Duct Floor Rear Air Outlet Duct Replacement Right Side 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 784: ...5N m 22lbin 2 Heater and Air Conditioning Control Procedure 1 Disconnect the electrical connectors 2 Disconnect the heater and air conditioning temperature control cable Refer to Temperature Control Cable Replacement 3 Disconnect the mode control cable Refer to Mode Control Cable Replacement Heater and Air Conditioning Control Replacement 2011 General Motors All rights reserved HEATING VENTILATION...

Page 785: ...the refrigerant is transferred to the ambient air passing through the condenser Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state The condenser is located in front of the radiator for maximum heat transfer The condenser is made of aluminum tubing and aluminum cooling fins which allows rapid heat transfer for the refrigerant The semi cooled liquid ...

Page 786: ... 39400 J 39400 GE 50078 Electric Halogen Leak Detector GE 39400 A J 39400 A GE 50078 Halogen Leak Detector GE 41447 J 41447 R 134A A C Tracer Dye Box of 24 Special Tools HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 787: ...43872 Florescent Dye Cleaner GE 45037 J 45037 A C Oil Injector GE 45268 J 45268 A C Flushing Adapter Kit GE 46246 J 46246 Valve Core Tool HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 788: ... 46297 12 J 46297 12 Replacement Dye Cartridges DT 48280 Clutch Plate Holder 2011 General Motors All rights reserved HEATING VENTILATION AND AIR CONDITIONING 11 Hvac BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 789: ...1 Radio Bolts Qty 4 Caution Refer to Fastener Caution 2 Radio Assembly Procedure 1 Disconnect the electrical connections 2 Refer to Control Module References for programming and setup information Radio Replacement With US8 2011 General Motors All rights reserved SONIC BACK TO MAIN INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 790: ...adio Bolts Qty 4 Caution Refer to Fastener Caution 2 Radio Assembly Procedure 1 Disconnect the electrical connections 2 Refer to Control Module References for programming and setup information Radio Replacement Without US8 2011 General Motors All rights reserved SONIC BACK TO CHAPTER INDEX TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 791: ...he engine coolant fan shroud Refer to Engine Coolant Fan Shroud Replacement 5 Remove the radiator hoses Refer to Radiator Inlet Hose Replacement and Radiator Outlet Hose Replacement 6 Remove the radiator upper bracket Refer to Radiator Upper Bracket Replacement 1 Radiator Tip Tilt radiator forward to remove Radiator Replacement Gasoline 2011 General Motors All rights reserved BACK TO MAIN INDEX SO...

Page 792: ... procedure based on the condition of the coolant Normal in appearance Follow the filling procedure Discolored Follow the flush procedure Refer to Coolant System Flushing Filling Procedure Caution The procedure below must be followed Improper coolant level could result in a low or high coolant level condition causing engine damage 1 Raise and support the vehicle Caution Refer to Fastener Caution 2 ...

Page 793: ...ant pressure cap 10 Raise the engine RPM to 2500rpm for 30 40 seconds 11 Shut the engine OFF 12 Allow the engine to cool remove coolant fill cap and repeat steps 4 10 until the coolant level has completely stabilized within the radiator surge tank 13 Inspect and if necessary fill the coolant reservoir bottle as necessary 14 Rinse away any excess coolant from the engine and the engine compartment 1...

Page 794: ...equipped 3 Unclip radiator surge tank outlet hose from fan shroud 4 Disconnect any electrical connecters from the fan shroud 1 Engine Coolant Fan Shroud Tip Unclip engine coolant fan shroud from radiator Engine Coolant Fan Shroud Replacement Gasoline 2011 General Motors All rights reserved BACK TO MAIN INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 795: ...he radiator inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 3 Remove the radiator inlet hose 2 from the engine 4 Remove the radiator inlet hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 5 Remove the radiator inlet hose 2 from the radiator 6 Remove the radiator inlet hose from the vehicle 2011 General Motors All rights reserved BACK TO MAIN INDEX SONIC TO MODEL INDE...

Page 796: ...hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 4 Install the radiator inlet hose 2 to the engine 5 Install the radiator inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 6 Fill the cooling system Refer to Cooling System Draining and Filling BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 797: ...d Filling 2 Remove the radiator inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 3 Remove the radiator inlet hose 2 from the engine 4 Remove the radiator inlet hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 5 Remove the radiator inlet hose 2 from the radiator 6 Remove the radiator inlet hose from the vehicle BACK TO MAIN INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 20...

Page 798: ...radiator using BO 38185 Hose Clamp Pliers 4 Install the radiator inlet hose 2 to the engine 5 Install the radiator inlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 6 Fill the cooling system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 799: ...ders and the person removing the cap Serious bodily injury may result 1 Drain the coolant Refer to Cooling System Draining and Filling 2 Remove the radiator surge tank Refer to Radiator Surge Tank Replacement 3 Remove the electronic control module 1 from the battery tray Note Use a small screwdriver to unclip the retainer clip black arrow and pull the electronic control module out 4 Unclip the ret...

Page 800: ... using the BO 38185 pliers 4 install the radiator inlet hose 3 into the retainer clip 5 Install the electronic control module 1 to the battery tray 6 Install the radiator surge tank Refer to Radiator Surge Tank Replacement 7 Fill the coolant system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BO...

Page 801: ... radiator outlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 3 Remove the radiator outlet hose 2 from the engine 4 Remove the radiator outlet hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 5 Remove the radiator outlet hose 2 from the radiator 6 Remove the radiator outlet hose from the vehicle 2011 General Motors All rights reserved BACK TO MAIN INDEX SONIC TO MODEL I...

Page 802: ... hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 4 Install the radiator outlet hose 2 to the engine 5 Install the radiator outlet hose clamp 1 at the engine using BO 38185 Hose Clamp Pliers 6 Fill the cooling system Refer to Cooling System Draining and Filling BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 803: ...e vehicle Refer to Lifting and Jacking the Vehicle 3 Disconnect the radiator outlet hose quick connect fitting 1 at the engine 4 Remove the radiator outlet hose 2 from the engine 5 Remove the radiator outlet hose clamp 1 at the radiator using BO 38185 Hose Clamp Pliers 6 Remove the radiator outlet hose 2 from the radiator 7 Remove the radiator outlet hose from the vehicle BACK TO MAIN INDEX SONIC ...

Page 804: ...adiator using BO 38185 Hose Clamp Pliers 4 Install the radiator outlet hose 2 to the engine 5 Connect the radiator outlet hose quick connect fitting 1 at the engine 6 Lower the vehicle 7 Fill the cooling system Refer to Cooling System Draining and Filling 2011 General Motors All rights reserved BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 805: ...ooling System Draining and Filling 2 Remove the air cleaner outlet duct Refer to Air Cleaner Outlet Duct Replacement 3 Remove the radiator outlet hose clamp 2 Using the BO 38185 pliers 4 Remove the radiator outlet hose 1 from the oil filter housing 5 Remove the retainer clip 4 6 Remove the radiator outlet hose 1 from the radiator 3 Installation Procedure 1 Install the radiator outlet hose 1 to the...

Page 806: ...or Support Bracket Bolt Caution Refer to Fastener Caution Tighten 9N m 80lbin 2 Radiator Support Bracket Procedure Pull the radiator forward until the bracket is reachable Radiator Upper Bracket Replacement 2011 General Motors All rights reserved BACK TO MAIN INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 807: ...ttery negative cable nut 2 5 Remove the battery negative cable 1 from the battery Installation Procedure 1 Install the battery negative cable 1 to the battery Caution Refer to Fastener Caution 2 Fasten the battery negative cable nut 2 and tighten the nut to 4 5N m 40lbin 3 Insert the ignition key and turn the ignition to the ON position 4 Program volatile memory Refer to Control Module References ...

Page 808: ... Refer to Fastener Caution Tighten 4 5N m 40lbin 2 Battery Negative Cable Procedure 1 Disconnect the battery negative cable from the battery 2 After connecting the battery negative cable insert the ignition key and turn the ignition to the ON position 3 Program the volatile memory Refer to Control Module References Battery Negative Cable Disconnection and Connection LSF LDV 2011 General Motors All...

Page 809: ...Refer to Power Steering Pump Belt Replacement 2 Remove the front wheelhouse liner inner front extension Refer to Front Wheelhouse Liner Inner Front Extension Replacement 3 Release tension to the drive belt tensioner by rotating counterclockwise 1 and lock with EN 6349 pin 2 4 Remove the drive belt 1 BACK TO MAIN INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 810: ...pply tension to the tensioner clockwise 1 5 Install the front wheelhouse liner inner front extension Refer to Front Wheelhouse Liner Inner Front Extension Replacement 6 Install the power steering pump belt if equipped Refer to Power Steering Pump Belt Replacement 2011 General Motors All rights reserved BACK TO CHAPTER INDEX SONIC TO MODEL INDEX CHEVROLET SONIC 2012 BODY REPAIR MANUAL ...

Page 811: ...lieve the tension of the drive belt 1 Refer to Drive Belt Replacement 2 Install CH 49800 installer 3 on the power steering pump pulley 3 Install NEW power steering belt 2 aligning pulley water pump 4 Rotate the power steering pump pulley clockwise using hex wrench on the shaft power steering pump pulley 5 Remove the CH 49800 installer 3 6 Install the drive belt Refer to Drive Belt Replacement 2011...

Page 812: ...he crankshaft pulley 2 Using a socket and ratchet on the crankshaft pulley bolt 4 rotate the crankshaft in the direction of the arrow until the belt 1 is fully installed on the air conditioning A C compressor 2 2011 General Motors All rights reserved 3 After the belt is on the air conditioning A C compressor pulley 2 rotate the crankshaft 3 an additional complete revolution and ensure the air cond...

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