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:
Liftgate Window Replacement
Special Tools
BO-24402-A Glass Sealant Remover (Cold Knife)
BO-39032 Stationary Glass Removal Tool
Use an adhesive that is approved by GM
For equivalent regional tools, refer to Special Tools
Removal Procedure
Warning: Refer to Cracked Window Warning.
Note ...
Stationary Window Waterleak Repair
Warning: If any water enters the vehicle interior up to the level
of the carpet or higher and soaks the carpet, the sensing and diagnostic module
(SDM) and the SDM harness connector may need to be replaced. The SDM could be
activated when powered, which could cause deployment of the air ...
Catalytic Converter Replacement (LUV)
Removal Procedure
Warning: Refer to Exhaust Service Warning.
Warning: Refer to Protective Goggles and Glove Warning.
Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat
Shield Replacement.
Remove the catalytic converter heated oxygen senso ...
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