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:
Fuel Gauge
The fuel gauge indicates about how much fuel is left when the ignition is turned
to ON/RUN.
When the tank nears empty, the low fuel warning light will come on. There is
still a little fuel left, but the vehicle's fuel tank should be filled soon. See
Low Fuel Warning Light for more ...
Engine Heater
The engine heater can provide easier starting and better fuel economy during
engine warm-up in cold weather conditions at or below −18°C (0°F). Vehicles with
an engine heater should be plugged in at least four hours before starting.
1. Turn off the engine.
2. Open the hood and unwrap ...
Generator Replacement (LUV)
Removal Procedure
Disconnect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the drive belt. Refer to Drive Belt Replacement.
Remove the drive bel ...
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