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:

Exterior Lamp Controls
The exterior lamp control is on the instrument panel to the outboard side of the steering column. There are four positions: (Off): Briefly turn to this position to turn the automatic light control off or on again. AUTO (Automatic): Turns the headlamps on automatically at normal brightness, ...

Headlining Trim Panel Replacement (Hatchback without Sunroof)
Headlining Trim Panel Replacement Callout Component Name Warning: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged ...

ABS Description and Operation
This vehicle is equipped with the MGH 60 Mando electronic stability control antilock brake system. The electronic brake control module and the brake pressure modulator are serviced separately. The brake pressure modulator uses a four circuit configuration to control hydraulic press ...

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