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:
Hood Insulator Replacement
Hood Insulator Replacement
Callout
Component Name
1
Hood Insulator Plastic Retainer (Qty:?€‰6)
2
Hood Insulator
Procedure
Ensure the 3 integral tabs are secured to the hood.
...
Cylinder Head Installation
Special Tools
EN-45059 Torque Angle Sensor Kit
For equivalent regional tools, refer to Special Tools.
Clean the sealing surfaces.
Inspect for plane surface.
Cylinder block, cylinder head
Straight-edge, feeler gauge
Install the cylinder head gasket.
Install the cylinder head. ...
Intake Manifold Installation (1.6L LDE)
Clean the sealing surfaces.
Insert the NEW gasket.
Caution: Refer to Fastener Caution.
Install the intake manifold (2) and the 7 intake manifold bolts (1) and
tighten to 20 Y (15 lb ft).
Install the intake manifold supp ...
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