LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 149 (Engine Mechanical - 2.4L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  2. Drain cooling system.
  3. Remove the intake manifold.
  4. Install the generator stud-ended bolt.
  5. Remove the exhaust manifold.
  6. Install the J 28467-360  and J 28467-380  in order to support the engine.
  7. Remove the ignition coil and the module assembly to the camshaft housing bolts. Remove the assembly by pulling it straight up.
  8. Disconnect the camshaft position sensor connector.
  9. Remove the power steering pump.
  10. Remove the fuel rail from the cylinder head. See FUEL RAIL & INJECTORS .
    11. Fig 1: Fuel Rail
    G01777626Courtesy of GENERAL MOTORS CORP.
  11. Use the following procedure in order to remove the fuel rail from the cylinder head:
  12. Disconnect the timing chain housing at the intake camshaft housing. Do not remove it from the vehicle. Refer to Timing Chain Housing Replacement .
  13. Disconnect the electrical connection from the oil pressure switch.
  14. Remove the intake camshaft housing. Refer to Intake Camshaft, Housing & Lifter Replacement .
  15. Remove the exhaust camshaft housing. Refer to Exhaust Camshaft, Housing & Lifter Replacement .
  16. Disconnect the radiator inlet (upper) hose from the coolant outlet.
  17. Remove the coolant temperature sensor connectors.
  18. Reverse the tightening sequence shown in order to remove the cylinder head to block bolts.
    Fig 2: Cylinder Head Bolt Tightening Sequence
    G01777628Courtesy of GENERAL MOTORS CORP.
  19. Remove cylinder head and gasket.
    NOTE: Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.

    Important: 

    • Use a razor blade gasket scraper in order to clean the cylinder head and the cylinder block gasket surfaces. Do not gouge or scratch the gasket surfaces or the combustion chamber surfaces. Use a new razor blade for each cylinder head and the cylinder block.
    • Hold the gasket scraper so the blade is as parallel to the gasket surface as possible.
    • 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.
    • Do not use any other method or technique to clean the gasket surfaces.
    • Do not use a tap to clean the cylinder head bolt holes. Use a nylon bristle brush.
  20. Clean the old sealer/lube and dirt from the bolt, the studs, and the bolt holes. Clean the bolt holes with a nylon bristle brush.
    CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
  21. When cleaning the cylinder head long bolt holes, use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.
  22. Clean the following components:
    • The cylinder head bolts.
    • The cylinder head. Remove all the varnish, the soot, and the carbon to the bare metal. Do not use a wire brush on any gasket sealing surface.
    • The valve guides
    • The threaded holes
    • The remains of sealer from the plug holes

      Important: 

    • Do not remove the spark plugs from an aluminum cylinder head until the cylinder head has cooled.
    • Clean the dirt and debris from the spark plug recess area.
    • If the spark plug opening threads are damaged and not restorable with a Thread Chaser, use the thread inserts in order to repair the threads.
    • Remove the spark plugs.
    • Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by an improper use of tools. Replace any suspected bolts.
    • Clean and inspect cylinder head. Refer to CYLINDER HEAD .
scientia non olet · About LEMON Manuals