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:
Torque Lock (Automatic Transmission)
If you are parking on a hill and you do not shift the transmission into P (Park)
properly, the weight of the vehicle may put too much force on the parking pawl in
the transmission. You may find it difficult to pull the shift lever out of P (Park).
This is called “torque lock.” To prevent t ...
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T40/45/50)
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation
Callout
Component Name
1
Front Differential Carrier Baffle
2
Front Differential Carrier Baffle Bolt M6 x 16& ...
Range Selector Lever Cable Bracket Replacement
Removal Procedure
Set the park brake and chock the wheels.
Disconnect the range selector cable end (1) from the
range selector lever.
Disconnect the range selector cable (2) from the range
selector cable bracket.
Remove the transmission rang ...
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