Question about 2000 Chevrolet Cavalier

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Blown head gaskit need to remove head and replace with new ong

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  • yadayada
    yadayada May 11, 2010

    what is ong???



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  • Chevrolet Master
  • 2,984 Answers

2.2L (VIN 4) Engine

  1. Before servicing the vehicle, refer to the precautions section.
  2. Relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Remove or disconnect the following:
    • Accessory drive belt
    • Air cleaner outlet duct
    • Engine mount
    • Intake manifold
    • Exhaust manifold
    • Engine Coolant Temperature (ECT) sensor electrical connector
    • Power steering pump
    • Radiator inlet pipe
    • Spark plug wires
    • Rocker arm cover

    NOTE Whenever valve train components are removed, keep them in order for installation purposes.

    • Rocker arms and pushrods
    • Lifters
    • Alternator rear brace and the alternator
    • Power steering pump
    • Radiator inlet pipe
    • Ignition coil assembly
    • Accessory bracket
    • Spark plug wires
    • Cylinder head bolts

    WARNING Two sizes of bolts are used; note the location of each.

    • Cylinder head
  5. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
blown head gaskit - b9d2546.gif
Cylinder head torquing sequence—2.2L (VIN 4) engine

  1. Install or connect the following:
    • Cylinder head with a new gasket and new cylinder head bolts. Torque the long bolts, in sequence to 46 ft. lbs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm) plus an additional 90 degree turn on all the bolts.
    • Lifters
    • Pushrods and rocker arms. Torque nuts to 22 ft. lbs. (30 Nm).
    • Rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
    • Spark plug wires
    • Accessory bracket
    • Ignition coil assembly
    • Radiator inlet pipe
    • Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
    • ECT sensor electrical connector
    • Exhaust manifold. Torque the nuts to 118 inch lbs. (13 Nm).
    • Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
    • Intake manifold. Torque the bolts to 17 ft. lbs. (24 Nm).
    • Engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
    • Air cleaner outlet duct
    • Accessory drive belt
    • Negative battery cable
  2. Refill and bleed the cooling system.
  3. Start the vehicle and inspect for leaks.

Posted on Oct 08, 2009

  • 1 more comment 
  • Greg Bernett
    Greg Bernett Oct 08, 2009

    2.3L & 2.4L Engines


    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.


    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.


    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. Disconnect the heater inlet and throttle body heater hoses from water outlet.

    3. Remove the exhaust manifold.

    4. Remove the intake camshaft housing and lifters, then remove the exhaust camshaft housing and lifters.

    5. Remove the oil fill tube.

    6. Remove the throttle body-to-air cleaner duct.

    7. Disconnect the power brake vacuum hose from throttle body.

    8. Remove the throttle cable bracket.

    9. Remove the throttle body from intake manifold, with electrical harness and throttle cable attached. Position it aside.

    10. Disconnect the MAP sensor vacuum hose from intake manifold.

    11. Remove the intake manifold brace.

    12. Disconnect electrical connectione from the following sensors: MAP sensor, intake air temperature sensor and EVAP canister purge solenoid.

    13. Disconnect the upper radiator hose from water outlet.

    14. Detach the coolant temperature sensors connectors.

    15. Unfasten the cylinder head bolt, then remove cylinder head and gasket.

    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. 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.

      3. 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.

    2. 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 warns not to use a tap to clean cylinder head bolt holes.

    3. 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.

    4. 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.

    5. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.

    6. Place a new cylinder head gasket on the block. Do not use any sealing material.

    7. Carefully place the cylinder head on dowel pins, being careful not to disturb the gasket.

    8. Apply a small amount of clean engine oil to the threads of the cylinder head bolts, and install finger-tight.

  • Greg Bernett
    Greg Bernett Oct 08, 2009

    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. Attach the coolant temperature sensor connections.

    3. Connect upper radiator hose to coolant outlet.

    4. Install manifold brace and tighten to 19 ft. lbs. (26 Nm).

    5. Attach all sensor connections.

    6. Connect the MAP sensor vacuum hose to intake manifold.

    7. Install throttle body to intake manifold, using a new gasket.

    8. 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).

    9. Install the throttle body-to-air cleaner duct.

    10. Install oil fill tube, tighten attaching bolt to 71 inch lbs. (8 Nm).

    11. Install the liftere and camshaft housing.

  • Greg Bernett
    Greg Bernett Oct 08, 2009

    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. Connect negative battery.

    3. Fill coolant system and bleed off air from system. An oil and filter change is recommended.

    4. Check and verify that vehicle has no coolant or vacuum leaks.



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