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:
Exhaust System Replacement
Removal Procedure
Special Tools
CH-6614 Chain Pipe Cutter
For equivalent regional tools, refer to Special Tools.
Warning: Refer to Protective Goggles and Glove Warning
Warning: Refer to Exhaust Service Warning.
Raise and support the vehicle. Refer to Lifting ...
Shift Control Housing Replacement
Removal Procedure
Set the parking brake.
Shift the transmission to the Neutral position.
Remove the battery tray. Refer to
Battery Tray Replacement.
Remove the brake master cylinder assembly from the
power brake booster. Refer to Master Cylinder Replacement.
...
Transmission Rear Mount Replacement
Removal Procedure
Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Using a suitable jack stand, support the rear of the
powertrain.
Remove and DISCARD the transmission mount to bracket
through fastener (1).
Remove the transmiss ...
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