Chevrolet Sonic Repair Manual: Engine Block Cleaning and Inspection
Special Tools
EN-8087 Cylinder Gauge
For equivalent regional tools, refer to Special Tools.
- Clean the sealing material from the gasket mating surfaces (2).
- Clean the engine block (1) and lower crankcase in a cleaning tank with solvent
appropriate for aluminum. Refer to Adhesives, Fluids, Lubricants, and Sealers
for the recommended solvent.
- Flush the engine block with clean water or steam.
- Clean the oil passages.
- Clean the blind holes.
- Spray the cylinder bores and the machined surfaces with engine oil.
- Inspect the threaded holes. Clean the threaded holes with a rifle brush.
If necessary, drill out the holes and install thread inserts. Refer to Thread
Inserts.
Note:
Do not attempt to machine the lower crankcase to engine
block surfaces.
- Inspect the engine block for sag in length and width on the sealing surfaces.
- Inspect the engine block for distortion along the diagonals.
If the deck surface is out of specification, replace the block. Do not machine
the block.
- Clean the sealing material from the gasket mating surfaces (1) on the lower
crankcase oil pan side.
- Inspect the crankshaft main bearing bores. Use the EN-8087 gauge
(1) to measure the bearing bore concentricity and alignment.
- Replace the engine block and bed plate if the crankshaft bearing bores are
out of specification.
- Inspect the cylinder bores using the EN-8087 gauge (1). Inspect
for the following items:
- Wear
- Taper
- Runout
- Ridging
Check the cylinder bores specifications. Refer to Engine Mechanical Specifications.
If the cylinder bores are out of specification, replace the engine block.
Remove the cylinder head locating (1, 2).
Remove the oil pressure switch (1).
Remove the knock sensor bolt (2) and the knock sensor (1).
Clea ...
Other materials:
Hood Adjustment
Hood Adjustment
Callout
Component Name
1
Hood
Caution: Refer to Fastener Caution.
Procedure
Loosen the 4 hood hinge nuts.
Adjust the hood in order to obtain an even gap on both sides between
...
SIR Seatbelt Pretensioner Handling Warning
Warning: When carrying an undeployed inflatable restraint seat belt
retractor pretensioner:
Do not carry the seat belt pretensioner by the seat belt webbing or
pigtail connector, if equipped.
Carry the seat belt pretensioner by the housing, keeping hands and fingers
away fro ...
Brake Pressure Modulator Valve Bracket Replacement
Removal Procedure
Remove the brake pressure modulator valve (BPMV) and bracket assembly.
Refer to Brake Pressure Modulator Valve Replacement.
Remove the BPMV bolts (1).
Remove the BPMV bracket.
Installation Procedure
Install the BPMV br ...
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