Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Case Porosity Repair

Some external leaks are caused by case porosity in non-pressurized areas.

  1. Thoroughly clean the area to be repaired with a cleaning solvent. Air dry the area.
  2. Warning:

    Epoxy adhesive may cause skin irritations and eye damage. Read and follow all information on the container label as provided by the manufacturer.

  3. Using instructions from the manufacturer, mix a sufficient amount of an epoxy to make the repair.
  4. Apply the epoxy. A clean, dry soldering acid brush can be used to clean the area and also to apply the epoxy cement. Make certain that the area to be repaired is fully covered.
  5. Allow the epoxy cement to cure for three hours before assembling the components.
  6. Repeat the fluid leak diagnosis procedures.
Case - Torque Converter and Differential Housing Side
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Channel Plate - Control Solenoid (w/Body and TCM) Valve Assembly Side
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Other materials:

Plastic Collar Quick Connect Fitting Service
Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning. Note: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. Bartholomew?€‰(1) Q Release?€‰(2) ...

Front Side Door Lock Cylinder Coding (Non Free Wheeling)
The door lock cylinder uses 8 of the 8?€‰cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in. Note: All lock cylinders for side milled keys have right and left tumblers. The locat ...

Fuel Tank Fuel Pump Module Replacement
Special Tools EN-48279 Fuel Sender Lock Ring Tool For equivalent regional tools, refer Special Tools. Removal Procedure Relieve the fuel system pressure. Refer to Fuel Pressure Relief Remove the fuel tank. Refer to Fuel Tank Replacement. Disconnect the electrical c ...

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