General Motors manufactured the 1997 Chevy Cavalier as a sporty sedan and coupe. Regardless if you have a coupe or sedan, replacing the head gasket in the vehicle is the same process. However, it will take time to locate the head gasket, which sits under the cylinder head. When you begin to replace the Cavalier head gasket, you will most likely remove and disconnect a great portion of the upper engine components.
Park the Cavalier overnight to ensure it is cool when you begin replacing the head gasket. Separate the negative cable from the battery. Take off the air cleaner outlet duct components. Place a container under the radiator to empty the coolant system. Mark, tag and detach the vacuum lines.
Detach the electrical connectors: oxygen sensor, engine coolant temperature, map sensor, throttle position sensor and evaporative mission control (EVAP,) canister purge solenoid and fuel injection straps.
Remove and disengage the accelerator control and accelerator brackets. Remove or disconnect the upper engine companies, from hoses, brackets, assemblies and wires, including power steering pump, the top engine mount, heater hose, the hose to the coolant, spark plugs, ignition wires, serpentine drive belt, pushrods and rocker arms.
Unscrew the cylinder head bolts and throw the old bolts away. Note the position of the small and large bolts. Take off the cylinder head along with the attached manifolds. Separate the exhaust manifold and intake manifold from the cylinder head.
Clean the entire surface of the gasket, threads on the bolts and bolt holes. Examine the cylinder head and surface for damage, leaks or cracks.
Replace the exhaust and intake manifold on the vehicle. Position a new head gasket in place. Align with the dowel pins on the engine. Return the cylinder head over the gasket. Torque new cylinder head bolts in the correct pattern. Long bolts torque to 46 foot-pounds. Short bolts torque to 43 foot-pounds and an additional 90 degrees. Position the pushrods, rocker arms and nuts. Torque nuts to 22 foot-pounds.
Replace the other engine block components in reverse order from original installation. Refill the coolant and connect the battery. Consult a Chevrolet Cavalier service manual for the correct torque for all the bolts.
