Chevrolet Sonic Repair Manual: Hydraulic Brake System Flushing
Warning:
Refer to Brake Fluid Irritant Warning.
Caution:
Refer to Brake Fluid Effects on Paint and Electrical Components
Caution.
- Inspect the brake fluid for the following conditions, indicating brake fluid
contamination:
- Fluid separation, indicating 2 types of fluid are present. A substance other
than the recommended brake fluid has been introduced into the brake hydraulic
system.
- Swirled appearance – oil-based substance
- Layered appearance – silicone-based substance
- Fluid discoloration, indicating the presence of moisture or particles that
have been introduced into the brake hydraulic system.
- Cloudy appearance – moisture
- Dark appearance/suspended particles in fluid – dirt, rust, corrosion
and/or brake dust
Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master
cylinder grommets for swelling, indicating brake fluid contamination.
If the brake fluid WAS contaminated with an oil-based or a silicone-based substance,
indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm
and/or swollen reservoir-to-master cylinder grommets, perform the following:
- Remove ALL of the following components listed from the vehicle. Each component
contains internal rubber seals/linings which have been contaminated by the contaminated
brake fluid in the brake hydraulic system.
Refer to the procedures indicated:
- Master Cylinder Replacement
- Front Brake Hose Replacement
- Rear Brake Hose Replacement
- Front Brake Caliper Replacement
- Rear Brake Cylinder Replacement
- Brake Pressure Modulator Valve Replacement
Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
Dry the brake pipes using non-lubricated, filtered air.
Repair or replace ALL of the following components listed and install them to
the vehicle. Each component contains internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system.
Refer to the procedures indicated:
- Master Cylinder Replacement; also perform the following:
- Clean the brake master cylinder reservoir using denatured alcohol, or equivalent,
then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir
for cracks and/or damage and replace if necessary. Refer to Master Cylinder
Reservoir Replacement.
- Front Brake Hose Replacement
- Rear Brake Hose Replacement
- Front Brake Caliper Replacement
- Rear Brake Cylinder Replacement
- Brake Pressure Modulator Valve Replacement
If the brake fluid WAS NOT contaminated with an oil-based or a silicone-based
substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake
dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed
the moisture or particles to enter the hydraulic system.
Fill the brake master cylinder reservoir to the maximum-fill level with the
approved brake fluid from a clean, sealed brake fluid container.
Pressure bleed the hydraulic brake system. Begin the procedure with the pressure
bleeder reservoir filled to the maximum-fill level with the correct brake fluid
as indicated. Refer to Hydraulic Brake System Bleeding.
System Component Description
The hydraulic brake system consists of the following:
Hydraulic Brake Master Cylinder Reservoir
Contains a supply of brake fluid for the hydraulic br ...
Warning: Refer to Brake Fluid Irritant Warning.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components
Caution.
Visually inspect the brake fluid level through the ...
Other materials:
Remote Vehicle Start
If equipped, this feature allows the engine to be started from outside the vehicle.
(Remote Vehicle Start): This button
will be on the RKE transmitter if the vehicle has remote start.
The climate control system will use the previous settings during a remote start.
The rear defog may come on d ...
Battery Current Sensor Replacement
Removal Procedure
Disconnect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection.
Disconnect the battery current sensor from the body harness connector.
Unclip the battery current sensor from the battery tray.
Remove the battery ...
Engine Oil Cooler Outlet Hose Replacement (LUV)
Engine Oil Cooler Outlet Hose Replacement
Callout
Component Name
Preliminary Procedure
Drain the cooling system. Refer to Cooling System Draining and Filling.
Disconnect the radiator outlet hose. Refer to Radiator Outlet H ...
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