Chevrolet Sonic Repair Manual: 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 surfaces with minor tolerances. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.
Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer's specification must be repaired or replaced.
Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.
When the components are reinstalled into an engine, return the components to their original location, position, and direction.
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 connectin ...
Special Tools
Illustration
Tool Number/Description
207649
Rod Hairpins
547324
Flange Screws
...
Other materials:
Instrument Panel Fuse Block
The instrument panel fuse block is on the underside of the driver side instrument
panel.
The vehicle may not be equipped with all of the fuses, relays, and features shown.
...
Headlamp Replacement
Headlamp Replacement
Callout
Component Name
Preliminary Procedure
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
1
Headlamp Assembly Screw (Qty:?€‰4)
Cautio ...
Transmission Fluid Cooler Flushing and Flow Test
GM studies indicate that plugged or restricted transmission oil coolers and pipes
cause insufficient transmission lubrication and elevated operating temperatures
which can lead to premature transmission failure. Many repeat repair cases could
have been prevented by following published procedur ...
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