Chevrolet Sonic Repair Manual: Engine Front Cover and Oil Pump Installation

Special Tools

• EN-952 Fixing Pin
• EN-953-A Fixing Tool
• EN-49977-100 Transmitter Disc Fixation
• EN-49977-200 Fixing Tool

For equivalent regional tools, refer to Special Tools.

Note:

Mind the guide sleeves when installing engine front cover.

1. Install the engine front cover (3).
2. Install the 13 engine front cover bolts M6 (1).
3. Install the 2 engine front cover bolts M10 (2).

Caution:

Refer to Fastener Caution.

4. Tighten the 13 engine front cover bolts M6 to 8 Y (71 lb in)

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5. Tighten the 2 engine front cover bolts M10 to 35 Y (26 lb ft)

   .

Camshaft Sprocket Fastening

Note:

Push the fixing tool in the direction of the arrow to ensure it fully engages.

1. Install EN-49977-200 fixing tool (2) and ensure that the gearing of the fixing tool engages with the intake camshaft sprocket gearing (1).



2. Tighten the 2 fastening bolts (1) of EN-49977-200 fixing tool while pushing the fixing tool in direction of the arrow.
3. Tighten the adjuster bolt (2).



Note:

A wrong installation position is possible. Make sure that the holding tool is fully installed to the cylinder head in areas (3) and (5).

4. Install EN-49977?E00 transmitter disc holder (2) to find and hold the correct position of the camshaft position exciter wheels.
5. Tighten the fastening bolts (6) of EN-49977-100 transmitter disc holder.

Caution:

Refer to Fastener Caution.

Caution:

Refer to Torque-to-Yield Fastener Caution.

6. Tighten the NEW intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to 50 Y (37 lb ft)

   .

7. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to an additional 60 degrees

   .

8. Tighten the NEW exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to 50 Y (37 lb ft)

   .

9. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to an additional 60 degrees

   .

10. Remove EN-49977-100 transmitter disc holder and EN-49977-200 fixing tool.

Upper Timing Chain Guide Installation

1. Install the upper timing chain guide (2).
2. Install the 2 upper timing chain guide bolts (1) and tighten to 8 Y (71 lb in)

   .

3. Remove EN-953-A fixing tool and EN-952 fixing pin.
4. Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 50 Y (37 lb ft)

   .

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