Cylinder Head Replacement. Chevrolet Beretta 1996

For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 28467-360 Engine Support Fixture

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
2. Disconnect the negative battery cable. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   in General Information.
3. Remove the air cleaner outlet duct.
4. Disconnect the vacuum lines.
5. Disconnect the Engine Coolant Temperature Sensor (ECT) electrical connection.
6. Disconnect the Oxygen Sensor (O2S) electrical connection.
7. Disconnect the IAC electrical connection.
8. Disconnect the Throttle Position Sensor (TP) electrical connection.
9. Disconnect the MAP electrical connection.
10. Disconnect the EVAP Canister Purge Solenoid electrical connection.
11. Disconnect the injector harness electrical connection.
12. Remove the following cables from the accelerator control bracket:

• | The accelerator control

• | The cruise control

• | The TV

13. Remove the accelerator control bracket.
14. Raise the vehicle. Refer to SECTION 0A.
15. Remove the exhaust pipe from the exhaust manifold.
16. Drain and recover the coolant. Refer to Coolant Replacement in Engine Cooling.
17. Lower the vehicle.
18. Remove the drive belt. Refer to Drive Belt Replacement .
19. Remove the generator rear brace.
20. Remove the generator. Refer to Generator Replacement in Engine Electrical.
21. Remove the power steering pump. Position the pump aside with the lines attached. Refer to SECTION 3B.
22. Install the J 28467-360 . Use a bolt installed in the engine block to attach the engine support fixture.
23. Remove the drive belt tensioner bracket. Refer to Drive Belt Tensioner Replacement .
24. Disconnect the secondary ignition wires from the spark plugs.
25. Remove the EVAP canister purge line beneath manifold.
26. Disconnect the upper radiator hose from the coolant outlet.
27. Disconnect the heater hose from the coolant outlet.
28. Remove the nut attaching the automatic transmission filler tube to the intake manifold.
29. Disconnect the fuel lines. Refer to Fuel Hose and Pipes (Engine Compartment Fuel Pipes) .
30. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .

Important: When removing valve train components keep them in order. Do this to ensure that the components are installed in the same locations and with the same mating surfaces as when removed.

31. Remove the rocker arms. Refer to Valve Rocker Arm, Push Rod, and Stud Replacement .
32. Remove the pushrods. Refer to Valve Rocker Arm, Push Rod, and Stud Replacement .
33. Remove the cylinder head bolts.
34. Remove the cylinder head.
35. Clean the following components:

• | Head gasket surface

• | Valve rocker arm cover gasket surface

• | Threads.

36. Pry the connecting rod back and forth with a suitable tool.
37. Inspect the rod for binding.
38. Loosen and tighten the bearing cap if necessary.

### Installation Procedure

#### Tools Required

J 36660-A Torque Angle Meter.

Important: Install the cylinder head gasket with the words THIS SIDE UP showing. Do not use sealer on the gasket.

1. Install the cylinder head gasket to the block.
2. Use a socket in order to push the cylinder head gasket over the rear dowel pin.
3. Carefully guide the cylinder head into place over the dowel pins. This operation may require an assistant.
4. Install the cylinder head bolts by hand.

Important: Use J 36660-A in order to tighten all the cylinder head bolts an additional 90 degrees in sequence.

5. Use the following sequence in order to tighten the cylinder head bolts:

Tighten

1. Tighten bolt 1 to 63 N·m (46 lb ft).
2. Tighten bolt 2 to 58 N·m (43 lb ft).
3. Tighten bolt 3 to 58 N·m (43 lb ft).
4. Tighten bolt 4 to 63 N·m (46 lb ft).
5. Tighten bolt 5 to 63 N·m (46 lb ft).
6. Tighten bolt 6 to 58 N·m (43 lb ft).
7. Tighten bolt 7 to 58 N·m (43 lb ft).
8. Tighten bolt 8 to 63 N·m (46 lb ft).
9. Tighten bolt 9 to 63 N·m (46 lb ft).
10. Tighten bolt 10 (stud bolt) to 58 N·m (43 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the rocker arms. Refer to Valve Rocker Arm, Push Rod, and Stud Replacement .
7. Install the pushrods. Refer to Valve Rocker Arm, Push Rod, and Stud Replacement .
8. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
9. Connect the fuel lines. Refer to Fuel Hose and Pipes (Engine Compartment Fuel Pipes) .
10. Install the nut attaching the automatic transmission filler tube to the intake manifold.

Tighten
Tighten the nut to 27 N·m (20 lb ft).

11. Connect the heater hose to the coolant outlet.
12. Connect the upper radiator hose to the coolant outlet.
13. Install the EVAP Canister purge line.
14. Connect the secondary ignition wires to the spark plugs.
15. Install the drive belt tensioner bracket. Refer to Drive Belt Tensioner Replacement .
16. Install the drive belt tensioner bracket bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

17. Remove the J 28467-360 . Remove the bolt used to support the engine.
18. Install the power steering pump bracket. Refer to SECTION 3B1.
19. Install the generator. Refer to Generator Replacement in Engine Electrical.
20. Install the generator rear brace. Refer to Generator Replacement in Engine Electrical.
21. Install the drive belt. Refer to Drive Belt Replacement .
22. Raise the vehicle. Refer to SECTION 0A.
23. Connect the exhaust pipe to the exhaust manifold.
24. Lower the vehicle.
25. Install the accelerator control cable bracket.
26. Install the accelerator control cable bracket bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb in).

27. Install the following cables to the accelerator control bracket:

• | The accelerator control

• | The cruise control

• | The TV

28. Connect the Engine Coolant Temperature Sensor (ECT) electrical connection.
29. Connect the Oxygen Sensor (O2S) electrical connection.
30. Connect the IAC electrical connection.
31. Connect the Throttle Position Sensor (TP) electrical connection.
32. Connect the MAP electrical connection.
33. Connect the EVAP Canister Purge Solenoid electrical connection.
34. Connect the Injector Harness.
35. Connect the vacuum lines.
36. Install the air cleaner outlet duct.
37. Refill the coolant. Refer to Coolant Replacement in Engine Cooling.
38. Connect the negative battery cable.