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:
Tire Inspection
We recommend that the tires, including the spare tire, if the vehicle has
one, be inspected for signs of wear or damage at least once a month.
Replace the tire if:
The indicators at three or more places around the tire can be seen.
There is cord or fabric showing through the tire's ...
Air Conditioning (AC) Refrigerant Filter Replacement
Special Tools
GE 39400-A Halogen Leak Detector
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
Remove the air conditioning condenser. Refer to Air Conditioning Condenser
Repl ...
Exhaust Manifold Installation
Clean the exhaust manifold sealing surface.
Install a NEW exhaust manifold gasket (1) to the cylinder head.
Caution: Refer to Fastener Caution.
Caution: Refer to Torque-to-Yield Fastener Caution.
Install the exhaust manifold (3) and tighten the NEW nu ...
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