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:
Brake Pedal Travel Measurement and Inspection
Special Tools
CH-28662 Brake Pedal Effort Gauge
For equivalent regional tools, refer to Special Tools.
With the ignition OFF and the brakes cool, apply the brakes 3–5 times, or
until the brake pedal becomes firm, in order to deplete the brake booster power
reserve.
In ...
Exhaust Camshaft Installation
Note: Mind the markings on the camshaft bearing caps. Camshaft
bearing caps should be installed in their original position.
Lubricate camshaft and camshaft bearing caps with engine oil.
Install the exhaust camshaft (3).
Install the 5 camshaft bearing caps̴ ...
Internal Components Removal
Internal Components Removal
Callout
Component Name
1
1??? Clutch Backing Plate Retainer Ring
Warning: The retainer is under tension. Use care when removing
or installing the retainer. Personal injury could r ...
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