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:
Tire and Loading Information Label
A vehicle-specific Tire and Loading Information label is attached to the vehicle's
center pillar (B-pillar). The Tire and Loading Information label shows the number
of occupant seating positions (1), and the maximum vehicle capacity weight (2) in
kilograms and pounds.
The Tire and Loadi ...
Throttle Body Installation
Install the throttle body (2) and a NEW throttle body seal ring (1).
Caution: Refer to Fastener Caution.
Install the 4 throttle body bolts (3) and tighten to 8 Y (71 lb in).
...
Camshaft Timing Chain Installation
Special Tools
EN-952 Fixing Pin
EN-953-A Fixing Tool
EN-955-10 Fixing Pin from EN-955 Kit
For equivalent regional tools, refer to Special Tools.
The engine should be adjusted to TDC.
The crankshaft should be locked with EN-952 fixing pin.
The camshaft should be locked with EN-9 ...
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