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:
Drivetrain and Front Suspension Frame Skid Plate Replacement
Removal Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the mounting bolts?€‰(1) for the front suspension frame skid
plate.
Remove the front suspension frame skid plate?€‰(2).
Installation Procedur ...
Adhesive Installation of Liftgate Windows
Warning: Refer to Glass and Sheet Metal Handling Warning.
Use a urethane adhesive systems which meet GM Specification GM?€‰3651G.
Remove all mounds or loose pieces of urethane adhesive from the pinchweld
area.
If the original window is being reused, remove all but approxi ...
Starter Installation
Install the starter (4).
Install the lower starter bolt stud (3) and if equipped the washer.
Install the upper starter bolt (2) and if equipped the washer (1).
Caution: Refer to Fastener Caution.
Tighten the starter bolt and starter bolt stud to 25 ...
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