Here's a general overview of the steps involved. Specific steps and procedures may vary slightly depending on the engine (2.2L or 2.4L) and whether it's a naturally aspirated or turbocharged model. Always consult a repair manual specific to your Cavalier's year, engine, and model for detailed instructions and torque specifications. Improper torque can damage the engine.
1. Preparation:
* Disconnect the battery: This is crucial to prevent electrical shorts.
* Gather tools: You'll need a variety of tools, including sockets, wrenches, screwdrivers, a torque wrench, a jack, jack stands, a drain pan, coolant recovery container, and possibly a harmonic balancer puller.
* Consult a repair manual: This is absolutely essential for torque specs and proper disassembly/assembly procedures. A Haynes or Chilton manual is a good starting point.
* Drain the coolant: Allow the engine to cool completely before draining the coolant.
2. Engine Access:
* Disconnect components: This is where the complexity begins. You'll need to disconnect various components connected to the engine, including:
* Intake manifold: This often involves removing various sensors, vacuum lines, and fuel injectors.
* Exhaust manifold: This may require loosening or removing the exhaust system components.
* Wiring harness: Carefully disconnect various electrical connectors. Label them clearly to ensure correct reassembly.
* Alternator and power steering pump (potentially): Depending on the engine, these may need to be moved or removed for better access.
* Throttle body: Usually needs to come off.
* Accessories: Remove any accessories mounted to the engine that obstruct access to the cylinder head.
3. Cylinder Head Removal:
* Remove the valve cover: This provides access to the valve train.
* Remove the timing belt/chain: This is a critical step, and improper handling can cause serious damage. Mark the timing belt/chain position before removal to ensure correct reinstallation.
* Remove the cylinder head bolts: These bolts must be removed in a specific sequence (consult your repair manual). They are typically torqued to a specific value, and removing them incorrectly could warp the head or block.
* Lift the cylinder head: Carefully lift the cylinder head using an engine hoist or other suitable lifting device.
4. Head Gasket Replacement:
* Inspect the cylinder head and engine block: Check for any damage, cracks, or warping. If damage is found, repair or replacement may be necessary.
* Clean the mating surfaces: Thoroughly clean both the cylinder head and engine block mating surfaces. Any debris or old gasket material can prevent a proper seal.
* Install the new head gasket: Carefully position the new head gasket onto the engine block.
* Reinstall the cylinder head: Carefully lower the cylinder head onto the engine block, ensuring proper alignment.
* Tighten the cylinder head bolts: Tighten the cylinder head bolts in the specified sequence and torque using a torque wrench.
5. Reassembly:
* Reassemble all components: Reinstall all components that were removed in reverse order, paying close attention to wiring, vacuum lines, and fuel lines.
* Refill the coolant: Fill the cooling system with the correct type and amount of coolant.
* Check for leaks: Start the engine and check for any leaks.
This is a simplified overview. The actual process is far more involved and requires specific knowledge and tools. Again, consult a repair manual specific to your vehicle. Attempting this repair without the proper knowledge and tools could lead to significant engine damage. Consider the cost of a professional mechanic versus the potential cost of a botched repair.
