Chevrolet Sonic Repair Manual: Piston, Connecting Rod, and Bearing Removal

1. Install the crankshaft balancer bolt.
2. Set the pistons 1 and 4 to TDC in direction of engine rotation.



Note:

Note cylinder sequence.

3. Mark the connecting rod with the connecting rod bearing cover (1).


4. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 1 and 4.
5. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).


6. Push the pistons 1 and 4 (1) out of the cylinder bore (2).

Note:

The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.

7. Remove the pistons 1 and 4 (1).
8. Turn crankshaft on crankshaft balancer through 180° in direction of rotation of engine.



Note:

Note cylinder sequence.

9. Mark the connecting rod with the connecting rod bearing cover (1).


10. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 2 and 3.
11. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).


12. Push the pistons 2 and 3 (1) out of the cylinder bore (2).

Note:

The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.

13. Remove the pistons 2 and 3 (1).



Note:

Observe correct fitting position, observe alignment.

14. Remove the connecting rod bearing (1, 2).
15. Check the components. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection.

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