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:
Airbag Sensing and Diagnostic Module Replacement
Airbag Sensing and Diagnostic Module Replacement
Callout
Component Name
Warning: Refer to SIR Warning.
Warning: Do not strike or jolt the inflatable restraint sensing
and diagnostic module (SDM). Before apply ...
Engine Replacement
Special Tools
EN-48244 Engine Assembly Remove/Install Pallet Supporter
Removal Procedure
Remove the battery and battery tray. Refer to Battery Tray Replacement.
Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
Recover the refrigerant. Refer to Refrigera ...
Timing Belt Rear Cover Installation
Re-cut the 4 rear timing belt cover threads.
Install the timing belt rear cover (1).
Caution: Refer to Fastener Caution.
Note: Service may offer bolts that are not microencapsulated.
If this is the case apply thread lock agent to the bolt. If fastener is
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