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:
Instrument Panel Lower Airbag Replacement - Driver Side
Instrument Panel Lower Airbag Replacement - Driver Side
Callout
Component Name
Warning: Refer to SIR Inflator Module Handling and Storage
Warning.
Warning: Refer to SIR Warning.
Preliminary Procedure
...
Air Conditioning O-Ring Seal Replacement
Removal Procedure
Disassemble the A/C refrigerant components. Refer to the appropriate
repair procedure
Note: Cap or tape the open A/C refrigerant components immediately
to prevent system contamination.
Cap or tape the A/C refrigerant components.
...
Differential Case Disassemble
Special Tools
6-9607346 Sensor Ring Gear Puller
J-810704 Steering Column Center Bar Puller
J-810721 Axle Shaft Seal Remover Support Base
R-0006749 Support Base
R-0407011 Bearing Race Remover
R-0007761 Universal Handle for Pullers and Installers
S-9407195 Pinion Gear Case Bearing ...
0.0048