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:
Headlamp Aiming
Visual Aiming Preparation Procedure
Note: Some state and local laws specify requirements for headlamp
aim. Comply with all of these laws when performing any headlamp aiming operations.
Headlamp aim should be checked:
When a new headlamp capsule is installed.
If ser ...
Basecoat/Clearcoat Paint Systems
Warning: Exposure to isocyanates during paint preparation and application
processes can cause severe breathing problems. Read and follow all of the instructions
from the manufacturers of painting materials, equipment, and protective gear.
All paint finish repairs of rigid exterior sur ...
Backup Lamp Switch Replacement
Backup Lamp Switch Replacement
Callout
Component Name
Preliminary Procedure
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
Without draining the coolant or removing ...
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