Cylinder Head Replacement. Chevrolet Joy 2008

For 1990-2009 cars

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

Caution: Refer to Battery Disconnect Caution in the Preface section.

Caution: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.

1. Relieve the fuel system pressure. Refer to Fuel System Diagnosis .
2. Disconnect the negative battery cable.
3. Remove the air filter, resonator, and the snorkel assembly. Refer to Air Cleaner Assembly Replacement .
4. Remove the surge tank cap (1).
5. Disconnect the lower radiator hose and drain the coolant. Refer to Cooling System Draining and Filling .
6. Disconnect the fuel injector wire connectors (1) and fuel line inlet hose (2).
7. Disconnect the throttle cable (4).
8. Disconnect the manifold absolute pressure (MAP) sensor connector (3).
9. Disconnect the canister solenoid connector (1).
10. Disconnect the brake booster vacuum hose (5).
11. Disconnect the MAP sensor vacuum hose (2).
12. Disconnect the ignition wires (1) from the spark plugs and distributor cap.
13. Disconnect the engine coolant temperature (ECT) sensor connector (2).
14. Disconnect the coolant temperature sensor connector (3).
15. Disconnect the oxygen sensor connector (4).
16. Disconnect the idle air control (IAC) valve connector (5).
17. Disconnect the throttle position (TP) sensor connector (6).
18. Disconnect the fuel injector wire connector (1).
19. Disconnect the distributor optical sensor connector.
20. Remove the exhaust gas recirculation (EGR) solenoid.
21. Disconnect the throttle body coolant outlet hose (1).
22. Disconnect the evaporative emission (EVAP) canister vacuum tube (2).
23. Disconnect the upper radiator hose from the thermostat housing (3).
24. Disconnect the heat core inlet hose from the thermostat housing (4).
25. Disconnect the EGR solenoid vacuum tube.
26. Remove the timing belt. Refer to Timing Belt Replacement .
27. Remove the camshaft gear bolt (1).
28. Remove the camshaft gear from the camshaft (2).
29. Remove the timing belt rear cover bolts (1).
30. Remove the rear cover from the cylinder head and block (2).
31. Remove the front exhaust nuts (3) and the gasket (4).
32. Disconnect the MAP sensor vacuum tube (1).
33. Disconnect the positive crankcase ventilation (PCV) hose and valve (2).
34. Remove the oil filler cap (3).
35. Remove the cylinder head cover hexagon bolts (1).
36. Remove the cylinder head cover with gasket (2).
37. Gradually loosen all of the cylinder head bolts in the sequence shown.
38. Remove the cylinder head bolts (1).
39. Remove the cylinder head assembly from the engine block, with the intake/exhaust manifold, throttle body, distributor housing and cylinder head gasket (1).
40. Inspect the cylinder head gasket for damage.
41. Clean the gasket surfaces of the cylinder head and the engine block.
42. Clean the cylinder head bolts.

### Installation Procedure

1. Install new cylinder head gasket.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the cylinder head and bolts in the sequence shown.

Tighten
Tighten the cylinder head bolts to 85-90 N·m (63-66 lb ft).

3. Install the cylinder head cover, gasket and bolts.

Tighten
Tighten the cylinder head cover bolts to 9-12 N·m (80-106 lb in).

4. Install the oil filler cap (3).
5. Connect the PCV hose and valve (2).
6. Connect the MAP sensor vacuum tube (1).
7. Install the front exhaust pipe, gasket, and nuts (1).

Tighten
Tighten the front exhaust pipe nuts to 25-35 N·m (18-25 lb ft).

8. Install the timing belt rear cover and bolts (2).

Tighten
Tighten the timing belt rear cover bolts to 9-12 N·m (80-106 lb in).

9. Install the camshaft gear and bolt (1).

Tighten
Tighten the camshaft gear bolt to 50-60 N·m (36-44 lb ft).

10. Install the timing belt. Refer to Timing Belt Replacement .
11. Connect the EGR solenoid vacuum tube.
12. Connect the heater core inlet hose to the thermostat housing (4).
13. Connect the upper radiator hose to the thermostat housing (3).
14. Connect the EVAP canister vacuum tube (2).
15. Connect the throttle body coolant outlet hose (1).
16. Install the EGR solenoid.
17. Connect the distributor optical sensor connector.
18. Connect the TP sensor connector (6).
19. Connect the IAC valve connector (5).
20. Connect the oxygen sensor connector (4).
21. Connect the coolant temperature sensor connector (3).
22. Connect the ECT sensor connector (2).
23. Connect the ignition wires (1) from the spark plugs and distributor cap.
24. Connect the MAP sensor vacuum hose (2).
25. Connect the brake booster vacuum hose (5).
26. Connect the canister solenoid connector (1).
27. Connect the MAP sensor connector (3).
28. Connect the throttle cable (4).
29. Connect the fuel injector wire connectors (1) and fuel line inlet hose (2).
30. Install the surge tank cap (1).
31. Connect the lower radiator hose (2) and fill the coolant. Refer to Cooling System Draining and Filling .
32. Install the air filter, resonator, and the snorkel assembly. Refer to Air Cleaner Assembly Replacement .
33. Connect the negative battery cable.