Chevrolet Sonic Repair Manual: Evaporative Emission System Hose/Pipe Replacement

Special Tools

• CH-807 Closure Plugs
• CH-6015 Closure Plugs

For equivalent regional tools, refer to Special Tools.

Removal Procedure

Warning:

Refer to Gasoline/Gasoline Vapors Warning.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Relief the fuel pressure. Refer to Fuel Pressure Relief.



3. Disconnect the evaporative emissions front pipe (1) from the evaporative emissions purge valve (2). Refer to Plastic Collar Quick Connect Fitting Service.
4. Close the evaporative emissions pipe connections with the CH-807 plugs .
5. Unclip the evaporative emissions pipe (1) from the retainer clip (3).
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



7. Remove the frame reinforcement fasteners (1) and remove the frame reinforcement(2).


8. Remove the EVAP canister cover fasteners (1) and cover (2).


9. Open the 5 fuel pipe clips (1).


10. Disconnect the fuel tank evaporative emissions connector (2) from evaporative emissions pipe. Refer to Plastic Collar Quick Connect Fitting Service.
11. Close the evaporative emissions pipe and evaporative emissions fuel tank feed pipe with the CH-6015 plugs .
12. Remove the evaporative emissions pipe.

Installation Procedure

1. Remove the CH-6015 plugs from evaporative emissions fuel tank pipe and evaporative emissions pipe.



2. Install the evaporative emissions pipe and secure with the rear fuel pipe clip.
3. Connect the fuel tank feed pipe connector (2) to the evaporative emissions pipe. Refer to Plastic Collar Quick Connect Fitting Service.



4. Close the 5 fuel pipe clips (1).


5. Install the EVAP canister cover (2) and tighten the EVAP canister cover fasteners (1) to 9 Y (71 lb in)

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6. Install the frame reinforcement (2) and tighten the frame reinforcement fasteners (1) to 60 Y (44 lb ft)

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7. Lower the vehicle.


8. Clip the evaporative emissions pipe (2) into the retainer clip (3).
9. Remove the CH-807 plugs from the evaporative emissions pipe connectors.
10. Connect the front evaporative emissions pipe connector (1) to the evaporative emissions purge valve (2). Refer to Plastic Collar Quick Connect Fitting Service.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

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