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:
Front Fog Lamp Cover Replacement (Without T3U)
Front Fog Lamp Cover Replacement
Callout
Component Name
Preliminary Procedure
Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
1
Front Fog Lamp Front Cover
Proce ...
Front Seat Cushion Inner Trim Panel Replacement
Front Seat Cushion Inner Trim Panel Replacement
Callout
Component Name
1
Driver or Passenger Seat Inner Recliner Finish Cover Cap
Procedure
Use a flat-bladed tool to release the cap from the recliner cover.
...
Camshaft Seal Replacement
Special Tools
EN 422 Installer
EN 45000 Remover
For equivalent regional tools, refer to Special Tools
Removal Procedure
Remove the intake and exhaust camshaft sprocket. Refer to Camshaft Sprocket
Replacement.
Note: Do not damage the sealing surfaces.
...
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