LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 548 (Engine Mechanical - 2.2L) >> Removal And Installation >> Unit Repair Cleaning, Inspection, And Selection >> Cylinder Head And Gasket Surface Clean And Inspect (Unit Repair)

Cylinder Head And Gasket Surface Clean And Inspect (Unit Repair)

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove spark plugs (if necessary).
  2. Inspect cylinder head gasket and mating surfaces for signs of leaks, corrosion and blow-by. If gasket has failed, use the following possible faults to determine cause:
    • Improper installation
    • Loose or warped cylinder head
    • Missing off location or not fully seated dowel pins
    • Corrosion in seal area around the coolant passages
    • Chips or debris in cylinder head bolt holes
      Fig 1: Removing Spark Plugs
      G01039590Courtesy of GENERAL MOTORS CORP.
    • Bolt holes in cylinder block not drilled or tapped deep enough
    • Other
  3. Inspect cylinder head gasket surface.
    • Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in.) band around each combustion chamber (1).
    • Replace cylinder head if corrosion has been found inside a 4 mm (0.375 in.) band around each combustion chamber (3).
    CAUTION: DO NOT USE A WIRE BRUSH ON ANY GASKET SEALING SURFACE.
  4. Clean cylinder head. Remove all varnish, soot and carbon to bare metal.
  5. Clean valve guides.
  6. Clean threaded holes. Use a nylon bristle brush.
  7. Clean remains of sealer from plug holes.
  8. Inspect cylinder head for cracks. Check between valve seats and exhaust ports.
    NOTE: Do not attempt to weld cylinder head, replace it. If cracked, it must be replaced.
    Fig 2: Inspecting Cylinder Head Gasket Surface
    G01039591Courtesy of GENERAL MOTORS CORP.
  9. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
  10. Inspect intake and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by parallel grinding.
  11. Use following steps to determine the amount of reconditioning needed:
    • If warpage is less than 0.010 mm (0.00039 in.), reuse the cylinder head but do not resurface.
    • If warpage is between 0.010 mm (0.00039 in.) and 0.100 mm (0.0039 in.), resurface the cylinder head before reusing.
    • If warpage is over 0.100 mm (0.0039 in.), replace cylinder head.
  12. Inspect all threaded holes for damage. Threads may be reconditioned with thread inserts.
  13. Inspect sealing surfaces.
    Fig 3: Inspecting Cylinder Head For Warpage
    G01039592Courtesy of GENERAL MOTORS CORP.
  14. Inspect cylinder head plugs.
    Fig 4: Inspecting Cylinder Head Plugs
    G01039593Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals