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:
Hood Primary Latch Release Cable Replacement
iv
Hood Primary Latch Release Cable Replacement
Callout
Component Name
Preliminary Procedures
Remove the radiator opening upper cover. Refer to Front Opening
Upper Cover Replacement.
Remove the air inlet grille. Refer to A ...
Front Seat Cushion Outer Trim Panel Replacement
Front Seat Cushion Outer Trim Panel Replacement
Callout
Component Name
Preliminary Procedures
Remove the driver or passenger seat recliner handle. Refer to Front
Seat Back Recliner Handle Replacement
Remove the front seat ...
Fuel Tank Fuel Pump Module Replacement (Steel Tank)
Special Tools
EN-48279 Fuel Sender Lock Ring Wrench
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
Remove the fuel tank. Refer to Fuel Tank Replacement.
Disconnect the ...
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