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:
Tire Inspection
We recommend that the tires, including the spare tire, if the vehicle has one,
be inspected for signs of wear or damage at least once a month.
Replace the tire if:
The indicators at three or more places around the tire can be seen.
There is cord or fabric showing through the tire's rubb ...
Fog Lamp Aiming
Preparation Procedure
Note: Horizontal aim is not adjustable on this vehicle. Vertical
aim is done by an adjusting nut located on the rear of the fog lamp. Prior
to aiming the fog lamps, perform the following steps:
Completely assemble all of the components on the vehi ...
Intermediate Steering Shaft Replacement
Intermediate Steering Shaft Replacement
Callout
Component Name
Preliminary Procedure
Remove the steering column and the intermediate steering shaft as an
assembly. Refer to Steering Column Replacement.
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