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.
- 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:
Note:
Do not attempt to machine the lower crankcase to engine block surfaces.
- Wear
- Taper
- Runout
- Ridging
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:
Passenger Sensing System
United States
Canada
The passenger sensing system turns off the front outboard passenger frontal airbag
and knee airbag (if equipped) under certain conditions. No other airbag is affected
by the passenger sensing system. See Passenger Sensing System for important
information.
The ...
Washer Fluid
Open the cap with the washer symbol on it. Add washer fluid until the tank is
full. See Engine Compartment Overview for reservoir location.
Caution
. Do not use engine coolant (antifreeze) in the windshield washer. It
can damage the windshield washer system and paint.
. Do not mi ...
Intake Manifold Installation
Clean the sealing surfaces.
Install the intake manifold (1) along with a NEW intake manifold gasket.
Caution: Refer to Fastener Caution.
Install the 6 intake manifold bolts (1) and tighten to 20 Y (15 lb ft).
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