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:
Remote Keyless Entry (RKE) System Operation
The RKE transmitter may work up to 60m (195 ft) away from the vehicle.
Other conditions can affect the performance of the transmitter. See Remote Keyless
Entry (RKE) System.
The RKE transmitter can have one of the two symbols for the remote trunk release.
With Remote Start Shown
The follow ...
Blower Motor Replacement
Removal Procedure — Production Blower Motor
Remove the passenger side instrument panel insulator. Refer to Instrument
Panel Insulator Replacement.
Remove the passenger side inflatable restraint instrument panel lower
module. Refer to Instrument Panel Lower Airbag Replaceme ...
Warm Up Three-Way Catalytic Converter Installation
Install the warm up three way catalytic converter (5) to the brackets and
the turbocharger. Use a NEW warm up three way catalytic converter seal (2).
Note: Never re-use the V-clamp.
Install a NEW warm up three way catalytic converter V-clamp (1).
In ...
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