After replacing the water pump, thermostat, serpentine belt, valve cover gasket and battery this past weekend, I test ran the 99 Sunfire (with 2200 motor) and had white smoke out the tailpipe, it ran like crap and water leaked out between the head and block. Definite head gasket.

I know some people have done them, so I wanted to get some tips and tricks before I start. The manual isn't real detailed, but it's not bad. This will be my first head gasket I've ever done, so bear with me. A buddy of mine used to rebuild diesel engines for OTR trucks, and he will lend me his torque wrenches, but he won't always be available when I need to do the work.

I know the head will be off for a while to go to the machine shop to be checked out, so during that time (aside from closing the hood), how do you keep the elements out of the motor? I live in a small town, and everything I've head about the local machine shop is that they do awesome work, but are covered up and it takes a while to get stuff done. I'm not in any hurry as far as that goes, and I want the job done right.

So, any suggestions or tips?

Biggest thing I can tell you is to just take your time. Mark each push rod and rocker arm from which cylinder and either intake or exhaust valve it came from. Stuff the cylinders with rags and put a large towel over the block to help keep debris down. Iirc I didn't pull the fuel rail off the intake I just pulled the whole intake off the engine and let it lay against the firewall. The cross over coolant pipe that runs from the front of the engine head the o-ring there is a dealer only item along with the Egr plate gasket where the coil pack attaches to the head.


Put new coolant in and change the oil before the first startup to make sure whatever small dirt particles that could have made their way into the engine are gone

Push rods dont matter as much as you think, as long as they are in spec for length. Make sure you clean up the deck of the head since you wont have it out.
Any debris that gets into the cylinder holes blow out with compressed air, and wash down all the passages into the blick with brake cleaner. If the surface of your block is questionable you can use some stuff called flo-ex to help seal on the block side. I use it alot at work on older diesel motors that the owner doesnt want to spend alot on. As said above dump your oil before startup and also dump a quart of oil all over the rockers and down the pushrods to ensure they get lubed. Some assembly lube or white assembly grease on the ends of the rods and where the rockers contact the valves is always good. Run the car with just water in it at first to flush the system. Let it get nice n warm to seal up. And cycle it a few times hot-cold-hot-cold-hot. Dump water and add 50/50 and your good to go. To make life easier buy a pack of them cotton rags to have on hand, and a few cans of brake clean/parts solvent


Have a nice day.

Jordan wrote:Push rods dont matter as much as you think, as long as they are in spec for length. Make sure you clean up the deck of the head since you wont have it out.
Any debris that gets into the cylinder holes blow out with compressed air, and wash down all the passages into the blick with brake cleaner. If the surface of your block is questionable you can use some stuff called flo-ex to help seal on the block side. I use it alot at work on older diesel motors that the owner doesnt want to spend alot on. As said above dump your oil before startup and also dump a quart of oil all over the rockers and down the pushrods to ensure they get lubed. Some assembly lube or white assembly grease on the ends of the rods and where the rockers contact the valves is always good. Run the car with just water in it at first to flush the system. Let it get nice n warm to seal up. And cycle it a few times hot-cold-hot-cold-hot. Dump water and add 50/50 and your good to go. To make life easier buy a pack of them cotton rags to have on hand, and a few cans of brake clean/parts solvent

has it 100% right. while the head is off, and the engine is sitting, if youre not working on it, coat the cylinder bores with assembly lube to combat oxidation. then lay a couple thick rags over the top of the block to help keep stray debris out.



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Awesome advice guys! Thanks! I try to anticipate new things as best I can by seeking out advice from people like you that have done it already. I was raised working on cars, but this will be my first head gasket.