Log In
Search suggestions

    My Vehicles

    Viewing all products

    My Store

    405 N COLLEGE ST
    (479) 443-4043

    OPEN 'til 10:00 PM today

    SAVE 20% ON ONLINE SHIP-TO-HOME ORDERS OF $100 OR MORE.

    Use Code: SEECLEAR

    See Details

    GM Cavalier/Sunfire 1995-2000 Repair Guide

    Cylinder Head

    Print

    REMOVAL & INSTALLATION



    2.2L Engine

    See Figures 1 through 15



    Click image to see an enlarged view

    Fig. Fig. 1: Remove the overflow tank retaining bolt and ...



    Click image to see an enlarged view

    Fig. Fig. 2: ... remove the overflow tank



    Click image to see an enlarged view

    Fig. Fig. 3: Remove the motor mount from the vehicle



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the upper radiator hose from the water outlet



    Click image to see an enlarged view

    Fig. Fig. 5: Remove the heater hose from the rear of the cylinder head



    Click image to see an enlarged view

    Fig. Fig. 6: A jackstand and a block of wood can be used instead of a engine support bar


    CAUTION
    The fuel injection system remains 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.

    1. Relieve fuel system pressure using the recommended procedure.
    2.  


    CAUTION
    After relieving system pressure a small amount of fuel may be released when servicing fuel pipes or connections. In order to reduce the chance of personal injury, cover fuel pipes fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is complete.

    1. Disconnect negative battery cable.
    2.  
    3. Remove air cleaner outlet duct assembly.
    4.  
    5. Label and disconnect vacuum lines.
    6.  
    7. Disconnect and tag for identification the electrical connections on the Engine Coolant Temperature (ECT) sensor, Oxygen Sensor (O 2 sensor), IAC, Throttle Position Sensor, MAP sensor, EVAP Canister Purge Solenoid and the fuel injector harness.
    8.  
    9. Remove accelerator control, cruise and TV cables from accelerator control bracket.
    10.  
    11. Remove accelerator control cable bracket.
    12.  
    13. Raise and safely support vehicle.
    14.  
    15. Remove exhaust pipe from exhaust manifold.
    16.  


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

    1. Drain and recover coolant into a suitable container.
    2.  
    3. Lower vehicle.
    4.  
    5. Remove serpentine drive belt.
    6.  
    7. Remove the alternator.
    8.  
    9. Remove the power steering pump and position aside with lines attached.
    10.  
    11. Remove power steering pump bracket.
    12.  
    13. Install engine support fixture J-28467-A or equivalent.
    14.  
    15. Remove the upper motor mount.
    16.  
    17. Remove serpentine drive belt tensioner bracket.
    18.  
    19. Tag and disconnect the spark plug wires.
    20.  
    21. Disconnect EVAP canister purge line, from under manifold.
    22.  
    23. Remove upper hose from coolant outlet.
    24.  
    25. Remove heater hose from coolant outlet.
    26.  
    27. Remove attaching nut holding automatic transaxle filler tube from intake manifold, if equipped.
    28.  
    29. Disconnect fuel lines.
    30.  
    31. Remove valve cover.
    32.  

    Whenever valvetrain components are removed for service, they should be kept in order. They should be installed in the same locations and with the same mating surfaces as when removed.

    1. Remove rocker arms and pushrods.
    2.  
    3. Remove cylinder head bolts. Two sizes of bolts are used. Note the location of each. These bolts are called torque-to-yield. This means that, at assembly, after the bolts are tightened to a specific torque, they are tightened another quarter turn. This stretches the bolts slightly. Therefore, new cylinder head bolts are recommended.
    4.  
    5. Remove cylinder head with both manifolds attached.
    6.  
    7. Remove the intake and exhaust manifolde from the cylinder head.
    8.  

    To install:
    1. Clean all the gasket surfaces completely. Clean the threads on cylinder head bolts and be sure all bolt holes are clean and free of foreign material. It is good practice to clean all internally threaded openings with the proper size thread cutting tap. This removee rust, dirt and old sealer build-up that can prevent getting a proper torque reading when tightening bolts.
    2.  
    3. Inspect cylinder head and block surface for cracks, nicks, heavy scratchee and flatness.
    4.  
    5. Install exhaust and intake manifolds on cylinder head prior to installing cylinder head.
    6.  
    7. Place a new cylinder head gasket in position over the dowel pins on the engine block. Carefully guide the cylinder head into position.
    8.  
    9. Install cylinder head bolts finger-tight. New cylinder head bolts are recommended.
    10.  
    11. Tighten bolts in sequence, tighten the long bolts to 46 ft. lbs. (63 Nm) plue 90 degrees. Tighten the short bolts to 43 ft. lbs. (58 Nm) plue 90 degrees.
    12.  
    13. Install pushrode and rocker arms and rocker arm nuts. Tighten nuts to 22 ft. lbs. (30 Nm).
    14.  
    15. Install valve cover and tighten bolts to 89 inch lbs. (10 Nm).
    16.  
    17. Connect fuel lines.
    18.  
    19. Install transaxle filler tube.
    20.  
    21. Install heater hose to coolant outlet.
    22.  
    23. Install upper radiator hose to coolant.
    24.  
    25. Connect EVAP canister purge line.
    26.  
    27. Attach the ignition wires to spark plugs, as tagged during removal.
    28.  
    29. Install serpentine drive belt tensioner bracket.
    30.  
    31. Remove engine support fixture.
    32.  
    33. Install power steering pump bracket and power steering pump.
    34.  
    35. Install alternator and brace.
    36.  
    37. Install serpentine drive belt.
    38.  
    39. Raise and safely support the vehicle.
    40.  
    41. Connect the exhaust pipe to the exhaust manifold.
    42.  
    43. Lower the vehicle.
    44.  
    45. Install the accelerator control cable bracket and bolts. Tighten bolte to 18 inch lbs. (25 Nm).
    46.  
    47. Connect the accelerator control, cruise and TV cables to control bracket.
    48.  
    49. Attach all of the electrical connections for the sensors.
    50.  
    51. Connect the vacuum lines.
    52.  
    53. Install air cleaner outlet duct assembly.
    54.  
    55. Refill the coolant system.
    56.  
    57. Connect negative battery cable.
    58.  
    59. Start vehicle and inspect for leaks.
    60.  
    61. Bleed air from coolant system ae follows:
      1. Loosen the engine coolant air bleed screw, (located on the top side of the engine coolant outlet) and add coolant until all of the air is evacuated through the air bleed. Tighten the air bleed screw.
      2.  
      3. When filling the coolant system, use coolant meeting GM specifications.
      4.  

    62.  



    Click image to see an enlarged view

    Fig. Fig. 7: Location of the cylinder head retaining bolt holes



    Click image to see an enlarged view

    Fig. Fig. 8: Use a breaker bar or other suitable tool to loosen the cylinder head bolts



    Click image to see an enlarged view

    Fig. Fig. 9: Have an assistant aid you in lifting the cylinder head and attached manifolds off of the engine block



    Click image to see an enlarged view

    Fig. Fig. 10: Remove and discard the old cylinder head gasket



    Click image to see an enlarged view

    Fig. Fig. 11: Use a scraper to remove the old gasket material from the block and the cylinder head



    Click image to see an enlarged view

    Fig. Fig. 12: A new gasket will marked on one side to tell you which side should be facing up



    Click image to see an enlarged view

    Fig. Fig. 13: Cylinder head bolt torque sequence for 2.2L engines



    Click image to see an enlarged view

    Fig. Fig. 14: Make sure you use a torque wrench to tighten the cylinder head bolts or gasket failure is likely



    Click image to see an enlarged view

    Fig. Fig. 15: .Use a torque angle meter to tighten the bolts an additional 90°

    2.3L and 2.4L Engines

    See Figures 16 and 17


    CAUTION
    The fuel injection system remains 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.

    1. Relieve the fuel system pressure.
    2.  


    CAUTION
    After relieving system pressure, a small amount of fuel may be released when servicing fuel pipes or connections. In order to reduce the chance of personal injury, cover fuel pipe fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is complete.

    1. Disconnect the negative battery cable.
    2.  


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

    1. Drain and recover the coolant into a suitable container.
    2.  
    3. Disconnect the heater inlet and throttle body heater hoses from water outlet.
    4.  
    5. Remove the exhaust manifold.
    6.  
    7. Remove the intake camshaft housing and lifters, then remove the exhaust camshaft housing and lifters.
    8.  
    9. Remove the oil fill tube.
    10.  
    11. Remove the throttle body-to-air cleaner duct.
    12.  
    13. Disconnect the power brake vacuum hose from throttle body.
    14.  
    15. Remove the throttle cable bracket.
    16.  
    17. Remove the throttle body from intake manifold, with electrical harness and throttle cable attached. Position it aside.
    18.  
    19. Disconnect the MAP sensor vacuum hose from intake manifold.
    20.  
    21. Remove the intake manifold brace.
    22.  
    23. Disconnect electrical connectione from the following sensors: MAP sensor, intake air temperature sensor and EVAP canister purge solenoid.
    24.  
    25. Disconnect the upper radiator hose from water outlet.
    26.  
    27. Detach the coolant temperature sensors connectors.
    28.  
    29. Unfasten the cylinder head bolt, then remove cylinder head and gasket.
    30.  

    To install:
    1. This is an aluminum cylinder head and must be treated with care. Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and block. GM saye that abrasive pads should not be used for the following reasons:
      1. Abrasive pads will produce a fine grit that the oil filter will not be able to remove from the oil. This grit is abrasive and has been known to cause internal engine damage.
      2.  
      3. Abrasive pads can easily remove enough metal to round cylinder head edges. This has been known to affect the gasket's ability to seal, especially in the narrow areas between the combustion chambers and coolant jackets. The cylinder head gasket is likely to leak if these edges are rounded.
      4.  
      5. Abrasive pads can also remove enough metal to affect cylinder head flatness. It takes only about 15 seconds to remove 0.008 in. (0.20mm) of metal from the cylinder head with an abrasive pad. If the cylinder head flatness is out of specification, the gasket will not be able to seal and the gasket will leak.
      6.  

    2.  
    3. Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. Use a new razor blade for each cylinder head. Hold the scraper so the razor blade is as parallel to the gasket surface as possible. Do not use any other method or technique to clean these gasket surfaces. In addition, GM warne not to use a tap to clean cylinder head bolt holes.
    4.  
    5. When working on an aluminum head, do not remove spark pluge from an aluminum cylinder head until the cylinder head has cooled. Always clean all dirt and debris from the spark plug recess area. If the spark plug opening threads are damaged and NOT restorable with a Thread Chaser, replace the cylinder head. GM DOES NOT approve of the installation of thread inserts into the spark plug openings on this engine. If threads are installed into the spark plug openings, severe engine damage will occur.
    6.  
    7. Clean all the gasket surfacee completely. Clean the threads on cylinder head bolts and be sure all bolt holes are clean and free of debris. New bolts are recommended.
    8.  
    9. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
    10.  
    11. Place a new cylinder head gasket on the block. Do not use any sealing material.
    12.  
    13. Carefully place the cylinder head on dowel pins, being careful not to disturb the gasket.
    14.  
    15. Apply a small amount of clean engine oil to the threads of the cylinder head bolts, and install finger-tight.
    16.  



    Click image to see an enlarged view

    Fig. Fig. 16: Head bolt torque sequence-2.3L and 2.4L engines

    1. Tighten head bolts in sequence. Tighten bolts 1 through 8 to 40 ft. lbs. (65 Nm);, then, tighten bolts 9 and 10 to 30 ft. lbs. (40 Nm). Turn all 10 bolts an additional 90 degreee ( 1 / 4 turn) in sequence.
    2.  
    3. Attach the coolant temperature sensor connections.
    4.  
    5. Connect upper radiator hose to coolant outlet.
    6.  
    7. Install manifold brace and tighten to 19 ft. lbs. (26 Nm).
    8.  
    9. Attach all sensor connections.
    10.  
    11. Connect the MAP sensor vacuum hose to intake manifold.
    12.  
    13. Install throttle body to intake manifold, using a new gasket.
    14.  
    15. Install accelerator control cable bracket to the throttle body, and tighten the bolte to 106 inch lbs. (13 Nm). Tighten the nut to 19 ft. lbs. (26 Nm).
    16.  
    17. Install the throttle body-to-air cleaner duct.
    18.  
    19. Install oil fill tube, tighten attaching bolt to 71 inch lbs. (8 Nm).
    20.  
    21. Install the liftere and camshaft housing.
    22.  



    Click image to see an enlarged view

    Fig. Fig. 17: Exploded view of the camshaft housing cover mounting-2.3L and 2.4L engines

    1. Install the exhaust manifold, then tighten the exhaust nuts to 26 ft. lbs. (35 Nm).
    2.  
    3. Connect negative battery.
    4.  
    5. Fill coolant system and bleed off air from system. An oil and filter change is recommended.
    6.  
    7. Check and verify that vehicle has no coolant or vacuum leaks.
    8.  

     
    AutoZone Logo