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:
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential
Ring Gear Installation (6T40/45)
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front
Differential Ring Gear Installation
Callout
Component Name
1
Torque Converter and Differential Housing Seal
2
Fluid Pu ...
Oil Pan Installation
Special Tools
EN-49980 Guidance Pins
For equivalent regional tools, refer to Special Tools.
Clean the sealing surfaces from old sealing material, dirt, oil and grease.
Note: The sealing bead should be applied close to the inner edge
of the oil pan. Take care that the oil suctio ...
Automatic Transmission Flex Plate Installation
Special Tools
EN-652 Automatic Transmission Flex Plate Holder
For equivalent regional tools, refer to Special Tools.
Clean the automatic transmission flex plate bolt threads.
Install the automatic transmission flex plate (2) and
the EN-652 holder to hold the automatic tran ...
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