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:
Timing Belt Removal
Special Tools
EN-6333 Locking Pin
EN-6340 Locking Tool
For equivalent regional tools, refer to Special Tools.
Note: The timing belt drive gear and oil pump housing must align.
Turn the crankshaft in the direction of engine rotation, by the crankshaft
balancer bolt ...
Drive Range, Third Gear (Gen 2)
As vehicle speed increases and operating conditions become appropriate, the transmission
control module (TCM) processes input signals from the automatic transmission input
and output speed sensors, the throttle position sensor and other vehicle sensors
to determine the precise moment to comman ...
Engine Flywheel Removal
Special Tools
EN-652 Flywheel Holder
For equivalent regional tools, refer to Special Tools.
Install EN-652 holder (1) to hold the engine flywheel (2).
Remove and DISCARD the 6 engine flywheel bolts (2).
Remove the engine flywheel (1). ...
0.0056