Chevrolet Sonic Repair Manual: Fuel Tank Replacement
- Removal Procedure
-
- Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
- Relieve the fuel pressure. Refer to Fuel Pressure Relief.
- Drain the fuel Tank. Refer to Fuel Tank Draining.
- Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle.
- Remove the harness cover fastener (1) and harness cover (2).
- Disconnect the fuel pump harness electrical connector (3).
- Disconnect the vent hose (1)
- Loosen the hose clamps (2) and slide the filler hose off the fuel tank.
- Disconnect the fuel and evaporative emission connectors (1). Refer to Plastic Collar Quick Connect Fitting Service.
- Support the fuel tank with a suitable stand.
- Remove the fuel tank strap fasteners (1).
- Reposition the fuel tank straps (2) toward the back of the vehicle.
- Lower the fuel tank (1).
- Installation Procedure
-
- 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.
- Transfer parts as necessary.
- Raise the fuel tank (1).
- Support the fuel tank with a suitable stand.
- Position the fuel tank straps (2) onto the fuel tank.
- Install the fuel tank strap fasteners (1) and tighten
to 22 Y(16 lb ft)
.
- Connect the fuel and evaporative emission connectors (1). Refer to Plastic Collar Quick Connect Fitting Service.
- Connect the vent hose (1) .
- Tighten the hose clamps (2) to 4.5 Y(40 lb in).
and slide the filler hose off the fuel tank.
- Connect the fuel pump harness electrical connector (3).
- Install the harness cover (2) and tighten the cover fasteners (1).
- Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Caution:
Refer to Fastener Caution.
Fuel Tank Fuel Pump Module Replacement (Steel Tank)
Special Tools
EN-48279 Fuel Sender Lock Ring Wrench
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Relieve the fuel system pressure. Refer to
Fuel Pres ...
Ignition Coil Replacement
Special Tools
EN-6009 Remover and Installer Ignition Coil
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Remove the engine wiring harness guide ...
Other materials:
Radio Replacement (With US8)
Radio Replacement
Callout
Component Name
Preliminary Procedure
Remove the instrument panel center molding. Refer to
Instrument Panel Center Molding Replacement.
1
Radio Bolts (Qty: 4)
...
Seat Belt Service Precautions
Note: If the vehicle has been in a collision, refer to Repairs
and Inspections Required After a Collision for additional information.
Do not bleach or dye the seat belt webbing. Use only the following items
in order to clean the seat belt webbing:
A mild soap and water ...
Exhaust Manifold Heat Shield Replacement (LUV)
Exhaust Manifold Heat Shield Replacement
Callout
Component Name
Warning: Refer to Exhaust Service Warning.
1
Exhaust Manifold Heat Shield Fasteners (Qty: 3)
Caution: Refer to Fas ...
0.009