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:
Full-Cut Method Description
Note:
If corrosion of the pinch-weld flange is present, or if sheet metal
repairs or replacements are required, refinish the pinch-weld flange in
order to present a clean, primer-only surface.
If paint repairs are required, mask the flange bonding area, prior to
applying th ...
Secondary Air Injection Pump Removal
Disconnect the secondary air injection pump pipe (3). Refer to Plastic Collar
Quick Connect Fitting Service.
Remove the secondary air injection pump nut (2) and the 2 secondary air
injection pump bolts (4).
Remove the secondary air injection pump (1 ...
Engine Front Cover with Oil Pump Replacement
Removal Procedure
Disconnect the battery negative cable. Refer to Battery Negative Cable
Disconnection and Connection.
Set the engine to TDC. Refer to Camshaft Timing Chain Inspection.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove ...
0.0058