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:
Checking Coolant
The vehicle must be on a level surface when checking the coolant level.
It is normal to see coolant moving in the upper coolant hose return line when
the engine is running.
Check to see if coolant is visible in the coolant surge tank. If the coolant
inside the coolant surge tank is boiling, do ...
Instrument Panel Insulator Replacement
Instrument Panel Insulator Replacement
Callout
Component Name
Preliminary Procedures
Disable the SIR system. Refer to SIR Disabling and Enabling.
Remove the passenger inflatable restraint instrument panel lower
module ...
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
207649 Rod Hairpin Clips
547324 Flange Screws
EN-840 Pliers / Remover
EN-958 Installer
EN-45059 Angle Meter
EN-50717 Kit
J-43649?E Rods
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Remove the spark plugs. Refer to Spark ...
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