Chevrolet Sonic manuals

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).
  1. Clean the sealing material from the gasket mating surfaces (2).
  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.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the blind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. 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.


  8. Note:

    Do not attempt to machine the lower crankcase to engine block surfaces.

  9. Inspect the engine block for sag in length and width on the sealing surfaces.

  10. 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.


  11. Clean the sealing material from the gasket mating surfaces (1) on the lower crankcase oil pan side.

  12. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge  (1) to measure the bearing bore concentricity and alignment.
  13. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.

  14. Inspect the cylinder bores using the EN-8087 gauge  (1). Inspect for the following items:
  • Check the cylinder bores specifications. Refer to Engine Mechanical Specifications.
  • If the cylinder bores are out of specification, replace the engine block.
  • Engine Block Disassemble
    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 ...

    Cylinder Block
    ...

    Other materials:

    Tire Pressure Monitor
    This vehicle may have a Tire Pressure Monitor System (TPMS). The low tire pressure warning light alerts to a significant loss in pressure of one of the vehicle's tires. If the warning light comes on, stop as soon as possible and inflate the tires to the recommended pressure shown on the T ...

    Engine Overheating
    The vehicle has an indicator to warn of the engine overheating. If the decision is made not to lift the hood when this warning appears, get service help right away. See Roadside Assistance Program. If the decision is made to lift the hood, make sure the vehicle is parked on a level surface. T ...

    Rear Side Door Check Link Replacement
    Rear Side Door Check Link Replacement Callout Component Name Preliminary Procedures Move the window to the full up position. Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement ...

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