How to replace a 1995 Pontiac Sunfire head gasket?

Answer 1

Start by obtaining a repair manual for the car (car parts stores have them), and make sure you have the necessary tools:

-Metric sockets (especially 10mm, 13mm, and 15mm) in both short and deep-well.

-Ratchet wrench, breaker bar and torque wrench to fit the sockets, as well as 3-inch and 6-inch extensions.

-Metric wrenches (again, most bolts are 10, 13, or 15).

-There will be one or two small bolts with inch-sized heads, I think 3/8" or something like that. I did this job with just a cheap set of 1/4" drive sockets and the small ratchet.

-A jack to hold the motor up (you have to pull off one of its mounts), and a piece of wood or rubber to put between the jack and motor so you don't dent the oil pan.

The repair manual will give you most of the information on how to do the job. Be sure to pay attention to the special instructions on what order to install / remove bolts--you can damage parts by taking the bolts out in the wrong order! Also, don't be afraid to do things in the obvious way. When it says "remove the intake manifold", for example, that doesn't mean you have to flip to that section and follow every step--just unbolt it and push it out of the way.

After removing the head, you should take it to a shop to be checked and resurfaced. This doesn't cost very much ($50 - $100 in my area), and helps to ensure that you don't have to repeat the job in a couple weeks. Also, be sure to use new head bolts when you reinstall it--even if the manual doesn't specifically tell you to.

Don't give up if you hit a tough spot getting something out. If you have trouble finding a bolt, then a small mirror and flashlight can be helpful, or if that doesn't work, you can always call a dealership and ask (dealerships know EVERYTHING about the cars they sell). Putting the engine back together is generally a lot easier than taking it apart, because you now know how everything fits together.

Do keep track of where small parts and bolts came from, and try not to lose them (they get lost very easily). Finding an exact replacement for a bolt can be a hassle, and can make the job take longer if it has to be ordered. Also, label any wires or hoses that could fit more than one place (most of the wires will only reach one place where they can plug in, so this is mostly for the hoses).

Note that this answer mostly pertains to the 2.2 OHV engine. It would be almost the same for another motor, but might require some different tools or be harder.