Chevrolet Sonic Repair Manual: Piston and Connecting Rod Assemble

Chevrolet Sonic Repair Manual / Powertrain / Engine / Engine Block / Cylinder Block / Piston and Connecting Rod Assemble

Special Tools

EN-49941 Remover / Installer Piston Retainer Ring

For equivalent regional tools, refer to Special Tools.

Note:

Lubricate the piston pin with clean engine oil.

Install the connecting rod (3) and the piston pin (2) to the piston (1).
Install the piston and connecting rod assembly to a bench vise. Use aluminium braces.

Warning:

Use extreme care when removing snap rings. Always wear adequate eye protection in order to avoid personal injury.

Warning:

Use care when removing or installing the piston retainer ring. Ensure the EN-49941 remover/installer is installed properly onto the retainer ring and that hands and fingers are kept clear from the front of the tool. Otherwise, bodily injury may occur.

Note:

Notch (2) on right side.

Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (2).
Push the piston pin retainer down with the thumb in the shown position (1) and hold.

Note:

The EN-49941 installer should be applied in a perpendicular position to the piston pin retainer.

Apply the EN-49941 installer (4) to the piston pin retainer in the position shown (3) and push in direction of the arrow while pushing down with the thumb.

Note:

Push the piston pin retainer down in the position shown (2).

Move the EN-49941 installer (1) carefully to the position shown while pushing in direction of the arrow until the piston pin retainer engages in the piston pin retainer groove.
Push down the piston ring retainer to get a proper seat in the groove.

Note:

Notch (4) on left side. EN-49941 installer should be used with left hand.

Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (4).
Push the piston pin retainer down with the thumb in the position shown (1) and hold.

Note:

The EN-49941 installer should be applied in a perpendicular position to the piston pin retainer.

Apply the EN-49941 installer (3) to the piston pin retainer in the position shown (2) and push in direction of the arrow while pushing down with the thumb.

Note:

Push the piston pin retainer down in the position shown (1).

Move the EN-49941 installer (2) carefully to the position shown while pushing in direction of the arrow until the piston pin retainer engages in the piston pin retainer groove.
Push down the piston ring retainer to get a proper seat in the groove.
Remove the piston and connecting rod assembly from the bench vise.

Install the piston rings. Use piston ring pliers (1).

Note:

Mind the TOP marking on the piston rings.

The piston rings must be ordered as followed:

Upper compression ring (1)
Lower compression ring (2)
Piston oil ring with spacer (3), (4)

The piston ring joints must be positioned 90 degrees to each other.

Upper compression ring joint (2)
Lower compression ring joint (5)
Oil ring joint, upper part (1)
Oil ring joint, lower part (4)
Oil ring spacer joint (3)

Engine Front Cover with Oil Pump Replacement

Removal Procedure Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection. Set the engine to TDC. Refer to Camshaft Timing Chain Inspec ...

Piston and Connecting Rod Disassemble

Remove the piston with connection rod. Refer to Piston, Connecting Rod, and Bearing Removal. Note: Note installation position of the piston in respect of the connection rod. ...

Other materials:

Tires and Wheels Description and Operation (Tire Identification)
Identification Accessory and warranty replacement must use TPC spec tires. An outboard orientation stripe is added to the tread surface, with an offset toward the outboard tire face. All GM approved tires (Production, Service and Accessory) have a TPC (Tire Performance C ...

Engine Mount Bracket Installation
Install the engine mount bracket (2). Caution: Refer to Fastener Caution. Install the 3 engine mount bracket bolts and tighten to 60 Y (45 lb ft) + 45?E0°. ...

Engine Oil Cooler Pipe Replacement (LUW)
Engine Oil Cooler Pipe Replacement Callout Component Name Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling. Remove the exhaust manifold with catalytic converter. Refer to Exhaus ...

0.009