HHR 2006-2008

Cylinder Head

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the hood
  4.  
  5. Remove the fuel rail.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Remove the turbocharger coolant feed pipe.
  10.  
  11. Remove the timing chain.
  12.  
  13. Drain the cooling system.
  14.  
  15. Remove the fuel pump acoustic cover.
  16.  
  17. Remove the negative battery cable ground terminal no. bolt.
  18.  
  19. Remove the negative battery cable ground terminal no. from the engine lift bracket.
  20.  
  21. Disconnect the engine wiring harness electrical connector from the intake Camshaft Position (CMP) sensor.
  22.  
  23. Remove the Evaporative Emission (EVAP) canister purge solenoid valve.
  24.  
  25. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
  26.  
  27. Disconnect the engine wiring harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  28.  
  29. Reposition the radiator inlet hose clamp at the engine.
  30.  
  31. Remove the radiator inlet hose from the cylinder head.
  32.  
  33. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
    WARNING
    In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence 2.0L engine

  34.  
  35. Remove the cylinder head and place on clean work blocks.
  36.  
  37. Remove the cylinder head gasket.
  38.  
  39. Clean all of the gasket surfaces
  40.  
  41. Use the following steps when cleaning the cylinder head and cylinder block surfaces:
    1. Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface.
    2.  
    3. Use a new razor blade on the cylinder head and a new blade on the cylinder block.
    4.  
    5. Hold the razor blade as parallel to the gasket surface as possible.
      WARNING
      Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket.


      WARNING
      DO NOT use any other method or technique to clean these gasket surfaces. DO NOT use a tap to clean the cylinder head bolt holes.

    6.  

  42.  
  43. Clean the bolts holes with a nylon bristle brush.
  44.  
  45. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.
  46.  

To install:


WARNING
DO NOT use any sealing material.

  1. Install the cylinder head gasket.
  2.  
  3. Install the cylinder head.
  4.  
  5. Lightly apply clean engine oil to the threads and the bottom side flange of the head bolts and allow the oil to drain before installing.
  6.  
  7. Install new cylinder head bolts.
  8.  
  9. Install and tighten the cylinder head bolts in the sequence shown.
  10.  
  11. Tighten the bolts to 22 ft. lbs. (30 Nm) plus an additional 155 degrees using a angle meter.
  12.  
  13. Install the new front cylinder head bolts. Tighten the bolts to 26 ft. lbs. (35 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.0L engine



    Click image to see an enlarged view

    Fig. Front cylinder head bolts shown-2.0L engine

  14.  
  15. Install the radiator inlet hose to the cylinder head.
  16.  
  17. Position the radiator inlet hose clamp at the engine.
  18.  
  19. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
  20.  
  21. Connect the engine wiring harness electrical connector to the ECT sensor.
  22.  
  23. Install the EVAP canister purge solenoid valve.
  24.  
  25. Connect the engine wiring harness electrical connector to the intake CMP sensor.
  26.  
  27. Position the negative battery cable ground terminal no. to the engine lift bracket.
  28.  
  29. Install the negative battery cable ground terminal no. bolt and tighten to 89 inch. lbs. (10 Nm).
  30.  
  31. Install the fuel pump acoustic cover.
  32.  
  33. Fill the cooling system.
  34.  
  35. Install the timing chain.
  36.  
  37. Install the turbocharger coolant feed pipe.
  38.  
  39. Install the exhaust manifold.
  40.  
  41. Install the fuel rail.
  42.  
  43. Install the hood.
  44.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the exhaust manifold.
  6.  
  7. Remove the timing chain.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the cylinder head bolts in sequence and discard.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.0L, 2.2L, & 2.4L engines

  12.  
  13. Remove the cylinder head and gasket.
  14.  
  15. Clean all gasket surfaces.
  16.  

To install:

  1. Install the cylinder head and gasket.
    NOTE
    Install NEW cylinder head bolts.

  2.  
  3. Tighten the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm) plus 155°.

    Click image to see an enlarged view

    Fig. Cylinder head tightening sequence-2.0L, 2.2L, & 2.4L engines

  4.  
  5. Install the NEW front cylinder head bolts. Tighten the front cylinder head bolts to 26 ft. lbs. (35 Nm).
  6.  
  7. Install the timing chain.
  8.  
  9. Install the exhaust manifold.
  10.  
  11. Lower the vehicle.
  12.  
  13. Install the intake manifold.
  14.  
  15. Fill the cooling system.
  16.  

 
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