Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Fuel Tank Replacement

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief.
  3. Drain the fuel Tank. Refer to Fuel Tank Draining.
  4. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle.


  5. Remove the harness cover fastener (1) and harness cover (2).
  6. Disconnect the fuel pump harness electrical connector (3).

  7. Disconnect the vent hose (1)
  8. Loosen the hose clamps (2) and slide the filler hose off the fuel tank.

  9. Disconnect the fuel and evaporative emission connectors (1). Refer to Plastic Collar Quick Connect Fitting Service.


  10. Support the fuel tank with a suitable stand.
  11. Remove the fuel tank strap fasteners (1).
  12. Reposition the fuel tank straps (2) toward the back of the vehicle.

  13. Lower the fuel tank (1).
Installation Procedure

    If replacing the tank, remove the fuel pump module and the evaporative
  1. If replacing the tank, remove the fuel pump module and the evaporative emission canister. Refer to Fuel Tank Fuel Pump Module Replacement  and  Evaporative Emission Canister Replacement.
  2. Transfer parts as necessary.
  3. Raise the fuel tank (1).

  4. Caution:

    Refer to Fastener Caution.

  5. Support the fuel tank with a suitable stand.
  6. Position the fuel tank straps (2) onto the fuel tank.
  7. Install the fuel tank strap fasteners (1) and tighten to 22 Y(16 lb ft)

    .



  8. Connect the fuel and evaporative emission connectors (1). Refer to Plastic Collar Quick Connect Fitting Service.


  9. Connect the vent hose (1) .
  10. Tighten the hose clamps (2) to 4.5 Y(40 lb in).

    and slide the filler hose off the fuel tank.



  11. Connect the fuel pump harness electrical connector (3).
  12. Install the harness cover (2) and tighten the cover fasteners (1).
  13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Fuel Tank Heat Shield Replacement
Removal Procedure Support the fuel tank with a suitable jack. Remove the fuel tank strap fasteners (1) and lower the fuel tank straps (2). Remove the ...

Ignition System
...

Other materials:

Uniform Tire Quality Grading
Quality grades can be found where applicable on the tire sidewall between tread shoulder and maximum section width. For example: Treadwear 200 Traction AA Temperature A The following information relates to the system developed by the United States National Highway Traffic Safety Administration ...

Tire and Wheel Balancing (Balancing/Wheel Weights)
Use 3M wheel weights, refer to Adhesives, Fluids, Lubricants, and Sealers for application. Surface of the wheel must be clean and dry. All tire and wheel assemblies are to be checked for static tolerance of 2 grams and not more than 20 grams per plane, using cut-to-length weight produc ...

Drive Range - Fourth Gear (Gen 2)
As vehicle speed increases, the transmission control module (TCM) processes input signals from the automatic transmission input and output speed sensors, the throttle position sensor and other vehicle sensors to determine the precise moment to command OFF the normally-low 35R pressure control ...

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