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 Upper Compartment Door Latch Replacement
Instrument Panel Upper Compartment Door Latch Replacement
Callout
Component Name
1
Instrument Panel Upper Compartment Door Latch
Procedures
Open the instrument panel compartment door.
Unsnap the instrument com ...
Oil Pan Installation
Special Tools
EN-49980 Guidance Pins
For equivalent regional tools, refer to Special Tools.
Clean the sealing surfaces from old sealing material, dirt, oil and grease.
Note: The sealing bead should be applied close to the inner edge
of the oil pan. Take care that the oil suctio ...
Control Valve Body Cover Installation
Control Valve Body Cover Installation
Callout
Component Name
1
Input Speed Sensor Connector
2
Output Speed Sensor Connector
3
Shift Position Switch Connector
...
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