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Chevrolet Sonic Repair Manual: Engine Block Cleaning and Inspection

Chevrolet Sonic Repair Manual / Powertrain / Engine / Engine Block / Engine Block Procedures / 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).
  1. Clean the sealing material from the gasket mating surfaces (2).
  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.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the blind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. 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.


    8. Note:

    Do not attempt to machine the lower crankcase to engine block surfaces.

  8. Inspect the engine block for sag in length and width on the sealing surfaces.

  9. 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.


  10. Clean the sealing material from the gasket mating surfaces (1) on the lower crankcase oil pan side.

  11. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge  (1) to measure the bearing bore concentricity and alignment.
  12. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.

  13. Inspect the cylinder bores using the EN-8087 gauge  (1). Inspect for the following items:
  • Check the cylinder bores specifications. Refer to Engine Mechanical Specifications.
  • If the cylinder bores are out of specification, replace the engine block.
    • 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:

    Emergency Trunk Release Handle
    Caution Do not use the emergency trunk release handle as a tie-down or anchor point when securing items in the trunk as it could damage the handle. There is a glow-in-the-dark emergency trunk release handle on the underside of the trunk lid. This handle will glow following exposure to light. ...

    Engine Oil Cooler Coolant Inlet Hose Replacement (LUV)
    Engine Oil Cooler Coolant Inlet Hose Replacement Callout Component Name Preliminary Procedure Open the hood. Drain the cooling system. Refer to Cooling System Draining and Filling. 1 Oil Coo ...

    Intake Manifold Tuning Valve Actuator Replacement
    Intake Manifold Tuning Valve Actuator Replacement Callout Component Name Preliminary Procedure Properly raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 1 Intake Manifold ...

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