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:
Windshield Washer Solvent Container Filler Tube Replacement
Windshield Washer Solvent Container Filler Tube Replacement
Callout
Component Name
Preliminary Procedure
Open and support the hood assembly.
Grasp the top portion of the windshield washer container filler
tube and rotate t ...
Input Shaft Support Replacement (Gen 1)
Input Shaft Support Replacement
Callout
Component Name
1
3-5 Reverse and 4-5-6 Clutch Fluid Seals (Qty: 4)
Note:
Discard the fluid seals. They are not reusable.
Refer to 3-5-Reverse an ...
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Special Tools
DT-41229 Manual Shaft Pin Installer
DT-48550 Detent Lever Pin Remover
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Disconnect the transmission range selector lever cable
terminal (1) from the transmission manual shi ...
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