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:
Battery Replacement
Removal Procedure
Open the hood.
Disconnect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection.
Remove the battery retainer bolt (1) and the battery retainer (2).
Loosen the battery positive cable ju ...
Radiator Mounting Stud Repair
Repair Procedure
Note: If the radiator is leaky, replace it. Refer to Radiator
Replacement.
Pressure test the cooling system. Refer to Cooling System Leak Testing.
Grind the fracture surface (1) with a proper tool.
Drill a hole in the cente ...
Turbocharger Cleaning and Inspection
Cleaning Procedure
Clean all sealing surfaces.
Clean all threads if necessary.
Inspection Procedure
Inspect the wastegate regulator mechanism (1) for functionality.
Inspect the turbine blades for damage or foreign material.
Inspect the t ...
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