Chevrolet Sonic Repair Manual: 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 connecting rod have been disassembled, replace the components as an assembly.
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure installation to their original location and position.
Separate, mark, or organize the following components:
- Piston and the piston pin
- Piston to the specific cylinder bore
- Piston rings to the piston
- Connecting rod to the crankshaft journal
- Connecting rod to the bearing cap—A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
- Crankshaft main and connecting rod bearings
- Camshaft and valve tappets
- Valve to the valve guide
- Valve spring and shim to the cylinder head location
- Engine block main bearing cap location and direction
- Oil pump drive and driven gears
Replacing Engine Gaskets
Gasket Reuse and Applying Sealants
Do not reuse any gasket unless specified.
Gaskets that can be reused will be identified in the service procedure.
Do not apply sealant to any ...
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 surf ...
Other materials:
Power Outlets
The accessory power outlets can be used to plug in electrical equipment, such
as a cell phone or MP3 player.
The vehicle has an accessory power outlet in front of the cupholders on the center
floor console.
Remove the cover to access and replace when not in use.
Warning
Power is always suppl ...
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
Disconnect the brake fluid level indicator switch
electrical connector.
Using a small, flat-bladed tool, lift the locking
tab on the underside of the brake fluid level indicator switch (1) and remove
the switch.
Inspect the maste ...
Rear Seat Cushion Cover and Pad Replacement
Rear Seat Cushion Cover and Pad Replacement
Callout
Component Name
Preliminary Procedure
Remove the rear seat cushion. Refer to Rear Seat Cushion Removal and
Installation
1
Rear Seat Cushion Cov ...
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