GM Malibu/Cutlass 1997-2000

Cylinder Head

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REMOVAL & INSTALLATION



2.4L Engine

The tools required to remove and install the cylinder head on this engine are as follows; a torque angle meter, spark plug wire remover, and engine support fixture and engine lift hook

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the throttle body-to-air cleaner duct.
  6.  
  7. Disconnect the heater inlet and throttle body heater hoses from the water outlet.
  8.  
  9. Disconnect the power brake vacuum hose from the throttle body.
  10.  
  11. Detach the electrical connections from the following components:

    MAP sensor
     
    Intake Air Temperature (IAT) sensor
     
    EVAP canister purge solenoid
     
    Camshaft Position (CMP) sensor
     

  12.  
  13. Remove the alternator stud-ended bolt.
  14.  
  15. Remove the intake manifold brace and manifold. Refer to the procedure earlier in this section.
  16.  
  17. Install the alternator stud-ended bolt.
  18.  
  19. Support the engine.
  20.  
  21. Remove the exhaust manifold as outlined earlier in this section.
  22.  
  23. Disconnect the ignition coil and module assembly wiring. Remove the coil and module assembly-to-camshaft housing bolts, then lift the assembly straight up and extract from the engine.
  24.  
  25. Unbolt and set aside the power steering pump. Make sure when you remove the lines that you plug them to keep fluid from spilling.
  26.  
  27. Tag and plug all vacuum lines at the fuel pressure regulator. Label and remove the fuel injector harness wiring.
  28.  
  29. Slide the fuel line retaining clamp from the bracket on top of the intake camshaft housing.
  30.  
  31. Unbolt the fuel injector rail-to-camshaft housing.
  32.  
  33. Remove the fuel rail from the cylinder head. Refer to .
  34.  



Click image to see an enlarged view

Fig. Removing the fuel rail and pipes-2.4L engine

  1. Disconnect the timing chain housing at the intake camshaft housing, but do not remove it from the vehicle.
  2.  
  3. Disengage the oil pressure switch electrical wiring.
  4.  
  5. Unbolt and extract the transaxle fluid level indicator tube assembly from the exhaust camshaft cover and place it aside.
  6.  


NOTE
Any time the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing-to-cylinder head gasket must be replaced.

  1. Unbolt and remove the intake camshaft housing-to-cylinder head. User the reverse of the tightening procedure when loosening the camshaft housing-to-cylinder head retaining bolts.
  2.  


WARNING
Turn the camshaft housing upside down as soon as it is removed from the cylinder head. The lifters will fall out of the camshaft housing if it is not turned upside down. The lifters can be damaged if they fall out and hit a hard surface.

  1. Remove the intake housing and gasket.
  2.  
  3. Remove the exhaust camshaft housing-to-cylinder head bolts. Use the reverse order of the tightening sequence when loosening the camshaft housing-to-cylinder head bolts.
  4.  
  5. Remove the camshaft housing and gasket, refer to the Camshaft procedure later in this section.
  6.  
  7. Separator the upper radiator hose from the coolant outlet.
  8.  
  9. Disconnect the engine coolant temperature sensor wiring.
  10.  
  11. Remove the cylinder head-to-block bolts in the proper sequence. Refer to the accompanying illustration.
  12.  


WARNING
Cylinder head warpage or cracking could result from removing the bolts in the incorrect order.

  1. Lift the cylinder head from the block, and place the head on wooden blocks on a bench.
  2.  


NOTE
If the head is hard to separate from the block, pry between the head and block with a flat-bladed tool to separate. Be careful not to damage the contact surfaces of the cylinder head or block.

  1. Using a razor blade gasket scraper, carefully clean the surface of the cylinder head and mating surface of the block. Be sure to remove all traces of gasket.
  2.  


NOTE
Do not use an abrasive pad to clean the head or block surfaces. An abrasive pad may cause damage to the components.


CAUTION
Protect your eyes from the flying dirt particles when using high pressured air.

  1. Clean and inspect the cylinder head if reusing the same one. Refer to Engine Reconditioning in this section.
  2.  

To install:

  1. Place a new head gasket on the cylinder block.
  2.  


NOTE
Do not use any sealant on the head or block surfaces.

  1. Place the cylinder head on top of the block over the dowels. The dowels will allow you to place the head in the appropriate position for seating purposes.
  2.  
  3. Sparingly apply clean engine oil to the threads and the bottom of the flange of the new head bolts and allow the oil to drain before installing each one.
  4.  



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.4L engine

  1. Install and tighten the head bolts, in sequence to the following specifications:
    1. Bolts 1 through 8: 40 ft. lbs. (65 Nm)
    2.  
    3. Bolts 9 through 10: 30 ft. lbs. (40 Nm)
    4.  
    5. Turn each bolt an additional 90°, in sequence
    6.  

  2.  


NOTE
Roll the camshaft housing right side up as it is installed onto the cylinder head. The lifters can be damaged if they fall out and hit a hard surface.

  1. Install the camshaft housing, gasket and bolts, but do not tighten at this time.
  2.  
  3. Install the exhaust camshaft housing, gasket and bolts, but do not tighten at this time.
  4.  
  5. Apply pipe sealant or equivalent to the camshaft housing retaining bolt threads. Using a torque angle meter install the bolts and tighten in sequence to 11 ft. lbs. (15 Nm) on the first pass then plus an additional 90° turn on the second pass. Refer to the accompanying illustrations.
  6.  



Click image to see an enlarged view

Fig. Tightening the camshaft housing-to-cylinder head bolts-2.4L engine

  1. Install the timing chain housing and chain, refer to the procedure later in this section.
  2.  
  3. Uncover the fuel injectors and install new O-ring seals. Lubricate the seals with engine oil.
  4.  
  5. Attach the fuel rail to the camshaft housing and secure the bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Install the fuel line retaining clamp and retainer to the bracket on the top of the camshaft housing.
  8.  
  9. Attach the vacuum line to the pressure regulator.
  10.  
  11. Attach the fuel injector harness wiring to each injector. Be sure each harness is on the proper injector.
  12.  
  13. Attach the CMP sensor wiring.
  14.  
  15. Install the power steering pump. Refer to .
  16.  
  17. Connect the oil pressure switch wiring harness.
  18.  
  19. Bolt the transaxle fluid level tube to the exhaust camshaft cover.
  20.  
  21. Reinstall all spark plugs. Make sure they are in the same ports they were removed from. Now is a good time to inspect and replace them as needed.
  22.  
  23. Install the ignition coil and module wiring.
  24.  
  25. Attach all spark plug boots assembles that may have been stuck to a plug back onto the coil and module.
  26.  
  27. Locate the coil and module and place it over the spark plugs and push straight down to secure.
  28.  
  29. Clean any extra lubricant that may have come off of the bolts attaching the coil/module assembly.
  30.  
  31. Apply new sealant onto the ignition coil and module cover assembly-to-camshaft housing bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  32.  
  33. Remove the engine support fixture and hook.
  34.  
  35. Remove the alternator stud bolt.
  36.  
  37. Install the intake manifold and gasket, refer to the procedure earlier in this section.
  38.  
  39. Install the intake manifold brace.
  40.  
  41. Reinstall the alternator stud bolt.
  42.  
  43. Attach any wiring and hoses that are still disconnected.
  44.  
  45. Install the exhaust manifold, throttle body and air cleaner.
  46.  
  47. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks. Top off coolant level if necessary.
  48.  
  49. Connect the negative battery cable.
  50.  

3.1L Engine

CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

LEFT SIDE (FRONT)
  1. Properly relieve the fuel system pressure, as outlined in .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Disconnect the top half of the air cleaner assembly, then remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  



Click image to see an enlarged view

Fig. Exhaust crossover pipe fastener locations



Click image to see an enlarged view

Fig. Crossover heat shield fastener locations

  1. Disconnect the spark plug wires from the spark plugs and looms, then route the wires out of the way.
  2.  
  3. Remove the rocker arm (valve) covers.
  4.  
  5. Remove upper intake plenum and lower intake manifold.
  6.  
  7. Remove the left side exhaust manifold.
  8.  
  9. Remove oil level indicator tube.
  10.  


NOTE
When removing the valve train components they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket.
  4.  

To install:

  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads. Refer to Engine Reconditioning in this section.
  2.  
  3. Place a new cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
  4.  
  5. Coat the bolt threads lightly with sealer, then install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in the sequence shown in the accompanying figure, to the specifications listed on the Torque Specifications Chart at the end of this section.
  8.  
  9. Install the pushrods, rocker arms, balls and rocker arm nuts in their proper locations. Tighten the rocker arm nuts to the specifications listed in the chart found at the end of this section.
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm (valve) covers.
  14.  
  15. Install the oil level indicator tube. Insert the dipstick.
  16.  
  17. Properly route and connect the spark plug wires to spark plugs and looms.
  18.  
  19. Install the left side exhaust manifold.
  20.  
  21. Install the exhaust crossover pipe and heat shield.
  22.  
  23. Refill the cooling system.
  24.  
  25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  26.  
  27. Connect negative battery cable.
  28.  
  29. Start vehicle and verify that there are no leaks.
  30.  



Click image to see an enlarged view

Fig. Cylinder head mounting and bolt tightening sequence-3.1L engine

RIGHT CYLINDER HEAD (REAR)
  1. Relieve the fuel system pressure, as outlined in .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Detach the Oxygen (O2) sensor connector.
  14.  
  15. Disconnect the exhaust pipe from the exhaust manifold.
  16.  
  17. Remove the right side exhaust manifold.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
  22.  
  23. Remove the rocker arm (valve) covers.
  24.  
  25. Remove upper intake plenum and lower intake manifold.
  26.  


NOTE
When removing the valve train components, they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket.
  4.  

To install:

  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads. Refer to Engine Reconditioning in this section.
  2.  
  3. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
  4.  
  5. Coat the bolt threads lightly with sealer, then install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in sequence. Refer to Torque Specifications Chart.
  8.  
  9. Install the pushrods loosely retained with the rocker arm assemblies. Make sure all pushrods are in the correct locations. Coat the ends of the pushrods with prelube. The intake rods are marked yellow and are 5 3 / 4 inch long. The exhaust pushrods are marked green and 6 inches long. balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm (valve) covers.
  14.  
  15. Connect the spark plug wires to spark plugs and wire looms.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Install the exhaust manifold.
  20.  
  21. Connect the exhaust pipe to the exhaust manifold.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Connect the Oxygen (O2) sensor wiring.
  26.  
  27. Install the exhaust crossover pipe and heat shield.
  28.  
  29. Refill the cooling system.
  30.  
  31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start vehicle and verify that there are no leaks.
  36.  

 
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