Cylinder Head Assembly: Service and Repair

Removal
1. Drain cooling system, remove battery tray, battery, air filter/air flow sensor assembly, upper belt guard and belt.
2. On 1.9L/4-116 SOHC models, disconnect front header pipe from exhaust manifold and partially remove injector distribution pipe.
3. On all models, disconnect and clear away harnesses, couplings and cables connected to cylinder head.

Fig. 6 Ignition Coil Removal:

4. On 1.9L/4-116 DOHC models, remove bolts (3) and (4), then tilt ignition coil, Fig. 6.

Fig. 7 Intake Manifold Bolt Removal:

5. Remove bolt (5), oil dipstick tube nut (6) and intake manifold securing bolts. Fig. 7.

Fig. 8 Water Jacket Removal:

6. On 1.9L/4-116 SOHC models, disconnect intake manifold retaining bolts and nuts from engine block and bellhousing, then disconnect additional water jacket (3). Fig. 8.
7. Remove right upper engine mount nut and camshaft cover. Raise engine with lifting bracket to remove two engine mount bolts on cylinder head, then rest engine on its silent block.
8. On 1.9L/4-116 DOHC models, discharge refrigerant, then remove A/C compressor. Disconnect exhaust pipe and remove cam cover.
9. Place a suitable floor jack below lower crankcase and remove timing belt.

Fig. 9 Cylinder Head Bolt Sequence:

10. On all models, gradually loosen cylinder head bolts in sequence shown in Fig. 9.
11. Move end of timing cover away from water pump.

Fig. 10 Cylinder Head Removal:

12. Remove oil pipe (2), if equipped, then tilt and remove cylinder head, using handles No. PN91-41 or equivalent. Fig. 10.

Fig. 11 Liner Retaining Straps Installation:

13. Install liner retainer straps No. PN91-52 with bolts No. PN91-53 or equivalents, Fig. 11, and clean mating surface with degreaser. Mating surface should be clean, without gouges or scratches.

Installation

Reverse removal procedure to install, noting the following:

1. Install two centering dowels to assist in aligning head. Install new cylinder head gasket, with inscription facing up.
2. Install cylinder head with camshaft pinions positioned by locking pins. Coat contact face of head bolt and threads with Molykote G Rapid Plus grease or equivalent.

Fig. 9 Cylinder Head Bolt Sequence:

3. Tighten head bolts as follows:
a. Torque in sequence shown in Fig. 9, to 44 ft. lbs.
b. Completely loosen all bolts in same sequence.
c. Re-torque in sequence to 15 ft. lbs.
d. Torque each bolt an additional 300° in same sequence.
4. Install belt, then fill and bleed cooling system.