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 Primary Latch Release Cable Handle Replacement
Hood Primary Latch Release Cable Handle Replacement
Callout
Component Name
Preliminary Procedure
Remove the front side door opening floor carpet retainer. Refer to Front
Side Door Opening Floor Carpet Retainer Replacement. ...
Throttle Body Heater Inlet Hose Replacement (LUW)
Throttle Body Heater Inlet Hose Replacement
Callout
Component Name
Preliminary Procedure
Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet
Duct Replacement.
Drain the cooling system. Refer to Cooling System ...
Definitions and Abbreviations
Throttle Positions
Engine Braking
A condition where the engine is used to slow the vehicle by manually
downshifting during a zero throttle coastdown.
Full Throttle Downshift
A quick apply of the accelerator pedal to its full travel, forcing a
downshift.
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