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:
Steering Gear Boot Replacement
Special Tools
CH-804 Tensioner
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the steering linkage outer tie rod. Refer to Steering Linkage
Outer Tie Rod Rep ...
Tire Pressure Indicator Sensor Replacement
Removal Procedure
Raise the vehicle on a suitable support. Refer to Lifting and Jacking
the Vehicle.
Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel
Removal and Installation.
Dismount the tire from the rim. Refer to Tire Dismounting and Mounting. ...
Transmission Replacement
Removal Procedure
Remove the battery and battery tray. Refer to
Battery Tray Replacement.
Disconnect the transmission range selector lever cable
terminal (1) from the transmission manual pin.
Press the locking tab forward in order to release
the tran ...
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