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:
Key with Integrated Transmitter Programming
Keys can be programming in various ways using the procedures outlined below.
Using the Replacing Keys procedures will first erase all the known keys from the
vehicle. Any existing keys and any new keys will then be programmed. This procedure
should be used any time a key is required to be unle ...
Cylinder Head Disassemble
Special Tools
EN-840 Pliers/Remover
EN-8062 Valve Spring Compressor
EN-8062-5 Adapter
EN-50717-2 Compressor Assembly of EN-50717 Kit
For equivalent regional tools, refer to Special Tools.
Install the EN-50717?E assembly (1) to the EN-8062 compressor
(4).
Install the E ...
Synchronizers Cleaning and Inspection
Note: When servicing the synchronizers, retain them in the order
that they are removed. Mark the parts to ensure the correct position for
inspection and assembly.
Clean all the synchronizer parts in a suitable cleaning
solvent and air dry all the parts.
Inspect the 1 ...
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