Chevrolet Sonic Repair Manual: Separating Parts
Note:
- Disassembly of the piston, press fit design piston pin, and connecting rod may create scoring or damage to the piston pin and piston pin bore. If the piston, pin, and connecting rod have been disassembled, replace the components as an assembly.
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure installation to their original location and position.
Separate, mark, or organize the following components:
- Piston and the piston pin
- Piston to the specific cylinder bore
- Piston rings to the piston
- Connecting rod to the crankshaft journal
- Connecting rod to the bearing cap—A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
- Crankshaft main and connecting rod bearings
- Camshaft and valve tappets
- Valve to the valve guide
- Valve spring and shim to the cylinder head location
- Engine block main bearing cap location and direction
- Oil pump drive and driven gears
Replacing Engine Gaskets
Gasket Reuse and Applying Sealants
Do not reuse any gasket unless specified.
Gaskets that can be reused will be identified in the service procedure.
Do not apply sealant to any ...
Service Prior to Assembly
The importance of cleanliness during assembly cannot be overstated. Dirt or debris
will cause engine damage. An automobile engine is a combination of many machined,
honed, polished and lapped surf ...
Other materials:
Driver or Passenger Seat Shoulder Belt Replacement (with A69)
Driver or Passenger Seat Shoulder Belt Replacement
Callout
Component Name
Warning: Refer to SIR Warning.
Warning: Refer to SIR Inflator Module Handling and Storage
Warning.
Warning: Refer to SIR ...
Electronic Ignition System Description
Electronic Ignition System Operation
The electronic ignition system produces and controls the high energy secondary
spark. This spark ignites the compressed air/fuel mixture at precisely the correct
time, providing optimal performance, fuel economy, and control of exhaust emissions.
...
Special Tools
Illustration
Tool Number/Description
3-0207944
Main Shaft Tapered Bearing Insert Tool
39506289
Universal Adapter, 2.5L HST Engine
69604356
Gear Pullers
...
0.0048