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.
- Install the engine front cover (3).
- Install the 13 engine front cover bolts M6 (1).
- Install the 2 engine front cover bolts M10 (2).
Caution:
Refer to Fastener Caution.
- Tighten the 13 engine front cover bolts M6 to 8 Y (71 lb in)
.
- 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.
- Install EN-49977-200 fixing tool (2) and ensure that the gearing
of the fixing tool engages with the intake camshaft sprocket gearing (1).
- Tighten the 2 fastening bolts (1) of EN-49977-200 fixing tool
while pushing the fixing tool in direction of the arrow.
- 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).
- Install EN-49977?E00 transmitter disc holder (2) to find and
hold the correct position of the camshaft position exciter wheels.
- 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.
- Tighten the NEW intake camshaft sprocket bolt (4) while holding the
hexagon (1) of the intake camshaft to 50 Y (37 lb ft)
.
- Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1)
of the intake camshaft to an additional 60 degrees
.
- Tighten the NEW exhaust camshaft sprocket bolt while holding the hexagon
of the exhaust camshaft to 50 Y (37 lb ft)
.
- Tighten the exhaust camshaft sprocket bolt while holding the hexagon
of the exhaust camshaft to an additional 60 degrees
.
- Remove EN-49977-100 transmitter disc holder and EN-49977-200
fixing tool.
- Upper Timing Chain Guide Installation
-
- Install the upper timing chain guide (2).
- Install the 2 upper timing chain guide bolts (1) and tighten to 8 Y (71 lb in)
.
- Remove EN-953-A fixing tool and EN-952 fixing pin.
- Install crankshaft bearing cap tie plate hole plug and seal ring and
tighten to 50 Y (37 lb ft)
.
Engine Front Cover Disassemble
Remove the intake camshaft position sensor bolt (1).
Remove the intake camshaft position sensor (2) and the seal ring (3).
...
Set engine to TDC. Refer to Camshaft Timing Chain Inspection.
Remove the 13 engine front cover bolts M6 (1).
Remove the 2 engine front cover bolts M10 (2).
...
Other materials:
Radio Replacement (Without US8)
Radio Replacement
Callout
Component Name
Preliminary Procedure
Remove the instrument panel center molding. Refer to
Instrument Panel Center Molding Replacement.
1
Radio Bolts (Qty: 4)
...
Instrument Panel Center Trim Panel Replacement
Instrument Panel Center Trim Panel Replacement
Callout
Component Name
1
Instrument Panel Center Trim Panel (Qty:?€‰2)
Procedure
Use a flat bladed plastic trim tool in order to disengage the retainers
secur ...
Shock Absorber Disposal
Warning: Use the proper eye protection when drilling to prevent metal
chips from causing physical injury.
Clamp the strut in a vise horizontally with the rod (1) completely extended.
Drill a hole in the strut at the center of the end cap (3) using a 5 mm
...
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