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:
Secondary Air Injection Pump Installation
Install the secondary air injection pump (1).
Loosely install the secondary air injection pump nut (2) and the 2 secondary
air injection pump bolts (4).
Caution: Refer to Fastener Caution.
Tighten the secondary air injection pump nut (2) an ...
Turbocharger System Description
12
(1)
Turbocharger Bypass Solenoid Valve
(2)
Multifunction Intake Air Sensor
(3)
Turbocharger Wastegate Regulator Solenoid Valve
(4)
Turbocharger
(5)
Turbocharger Bypass Valve
(6)
Turbocharger Was ...
Manual Shift Shaft and Seal Replacement
Special Tools
DT-45201 Cooler Line Seal Remover
DT-49101 Seal Installer
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Remove the battery tray. Refer to
Battery Tray Replacement.
Remove the manual shaft and position switch assembly.
Refer ...
0.0058