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:
Parking Brake
To set the parking brake, hold the brake pedal down and pull up on the parking
brake lever. If the ignition is on, the brake system warning light will come on.
See Brake System Warning Light.
To release the parking brake, hold the brake pedal down. Pull the parking brake
lever up until you ...
Instrument Panel Outer Air Outlet Duct Replacement
Instrument Panel Outer Air Outlet Duct Replacement
Callout
Component Name
Preliminary Procedures
Remove the instrument panel assembly. Refer to Instrument Panel
Assembly Replacement.
Reposition any wiring or hoses to gain ...
Engine Coolant Thermostat Housing Removal
Caution: Refer to Engine Coolant Thermostat Housing Caution.
Remove the engine coolant thermostat housing retainer nut (4).
Remove the engine coolant thermostat housing retainer (1).
Remove the 4 engine coolant thermostat housing bolts (3).
Remo ...
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