Cavalier, Sunfire 2001-2005

Cylinder Head

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Removal & Installation



2.2L (VIN 4) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Whenever valve train components are removed, keep them in order for installation purposes.


    WARNING
    Two sizes of bolts are used; note the location of each.



    Accessory drive belt
     
    Air cleaner outlet duct
     
    Engine mount
     
    Intake manifold
     
    Exhaust manifold
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Power steering pump
     
    Radiator inlet pipe
     
    Spark plug wires
     
    Rocker arm cover
     



    Rocker arms and pushrods
     
    Lifters
     
    Alternator rear brace and the alternator
     
    Power steering pump
     
    Radiator inlet pipe
     
    Ignition coil assembly
     
    Accessory bracket
     
    Spark plug wires
     
    Cylinder head bolts
     



    Cylinder head
     

  8.  
  9. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torquing sequence-2.2L (VIN 4) engine

  1. Install or connect the following:

    Cylinder head with a new gasket and new cylinder head bolts. Torque the long bolts, in sequence to 46 ft. lbs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm) plus an additional 90 degree turn on all the bolts.
     
    Lifters
     
    Pushrods and rocker arms. Torque nuts to 22 ft. lbs. (30 Nm).
     
    Rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Spark plug wires
     
    Accessory bracket
     
    Ignition coil assembly
     
    Radiator inlet pipe
     
    Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    ECT sensor electrical connector
     
    Exhaust manifold. Torque the nuts to 118 inch lbs. (13 Nm).
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Intake manifold. Torque the bolts to 17 ft. lbs. (24 Nm).
     
    Engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Air cleaner outlet duct
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  
  3. Refill and bleed the cooling system.
  4.  
  5. Start the vehicle and inspect for leaks.
  6.  

2.2L (VIN F) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Power steering pump bolts and set pump aside

    Click image to see an enlarged view

    Fig. Remove the power steering pump bolts and set pump aside-2.2L (VIN F) engine

     
    Exhaust manifold
     
    Timing chain
     

  4.  
  5. Drain the cooling system.

    Cylinder head bolts in sequence and discard
     
    Cylinder head and gasket

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts in sequence and discard -2.2L (VIN F) engine

     

  6.  

To install:

  1. Install or connect the following:

    Cylinder head and gasket
     
    NEW cylinder head bolts (except the front bolts) and tighten in sequence to 22 ft. lbs. (30 Nm) and then an additional 155 degrees
     
    NEW front cylinder head bolts and tighten to 26 ft. lbs. (35 Nm)

    Click image to see an enlarged view

    Fig. Install the cylinder head bolts in sequence (except the front bolts)-2.2L (VIN F) engine



    Click image to see an enlarged view

    Fig. Install the front cylinder head bolts-2.2L (VIN F) engine

     
    Timing chain
     
    Exhaust manifold
     
    Intake manifold
     
    Power steering pump and tighten the bolts to 19 ft. lbs. (25 Nm).
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  

 
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