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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 236 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Cylinder Head Removal >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the EGR cover (607), the bolts (608), and the EGR cover gasket (606).
    Fig 1: View of EGR Cover
    GM1275948Courtesy of GENERAL MOTORS CORP.
  2. Remove the cylinder head to the block bolts in sequence.
    Fig 2: Cylinder Head Bolt Removal Sequence
    GM465863Courtesy of GENERAL MOTORS CORP.

    Discard the bolts.

  3. Remove the cylinder head.
    Fig 3: View Of Cylinder Head And Gasket
    GM412427Courtesy of GENERAL MOTORS CORP.
  4. Remove the cylinder head gasket.
  5. Clean all of the gasket surfaces.
    IMPORTANT: Do not use any other method or technique to clean these gasket surfaces.
    IMPORTANT: 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.
  6. Use the following procedures when cleaning the cylinder head and cylinder block surfaces:
    • Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface.
    • Use a new razor blade for each cylinder head and cylinder block.
    • Hold the razor blade as parallel to the gasket surface as possible.
    IMPORTANT: Do not use a tap to clean the cylinder head bolt holes.
  7. Clean the old sealer/lube and dirt from the bolt holes.
  8. Clean the bolt holes with a nylon bristle brush.
    CAUTION: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.
  9. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
  10. Remove any broken long cylinder head bolts using the J 38188  .
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