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:
Drunk Driving
Death and injury associated with drinking and driving is a global tragedy.
Warning
Drinking and then driving is very dangerous. Your reflexes, perceptions, attentiveness,
and judgment can be affected by even a small amount of alcohol. You can have a serious
— or even fatal — collision if y ...
Engine Front Cover and Oil Pump Cleaning and Inspection
Engine Front Cover Cleaning Procedure
Clean the engine front cover sealing surface.
Warning: Wear safety glasses when using compressed air in
order to prevent eye injury.
Caution: To ensure proper engine lubrication, clean clogged
or contaminated oil g ...
Main Shaft Assemble (Gen 2)
Special Tools
3-0207944 Main Shaft Tapered Bearing Insert Tool
For equivalent regional tools, refer to Special Tools.
Install the 4th gear bearing assembly (1).
in!i.l.i-if
Note: The 3rd gear blocking ring lugs must be aligned with the
3rd/4th gear synchronizer ass ...
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