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:
Brake Pressure Modulator Valve Bracket Replacement
Removal Procedure
Remove the brake pressure modulator valve (BPMV) and bracket assembly.
Refer to Brake Pressure Modulator Valve Replacement.
Remove the BPMV bolts (1).
Remove the BPMV bracket.
Installation Procedure
Install the BPMV br ...
Tires and Wheels Description and Operation
There are two types of tire and wheel balancing: static and dynamic.
Static balance is the equal distribution of weight around the wheel. Assemblies
that are statically unbalanced cause a bouncing action called wheel tramp. This
condition may eventually cause uneven tire wear.
...
Manual Transmission Shift Lever and Selector Lever Cable Adjustment
Remove the floor console. Refer to
Front Floor Console Replacement.
Lift upward and disengage (do not remove) both cable lock
adjusters (1) to release the internal cable assembly, one for each side.
Block the shift control housing, push the selector lever ( ...
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