9-3 1999

Cylinder Head

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Removal & Installation



2.0L & 2.3L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Exhaust manifold
     
    Turbocharger unit, if equipped
     
    Oil hoses from the oil cooler if equipped, and plug them
     
    Tensioning pulley and drive belt from the A/C compressor and slacken the securing bolts for the steering pump bracket
     
    Power steering pump drive belt, push the pump aside
     
    Wiring harness clips on the cylinder head
     
    Two bolts in the timing cover, which are screwed into the cylinder head from underneath
     
    Bolts in the right-hand engine mounting, which are screwed into the cylinder head, together with the spacer sleeves
     
    Hose between the thermostat housing and the radiator at the thermostat housing
     
    Fuel pressure regulator and ground leads for the fuel injection system
     
    A/C compressor. Leave lines still attached and carefully put it on the air intake for the heating system.
     
    Bracket for the air conditioning compressor
     
    Intake manifold complete with injectors
     
    Temperature sensor lead
     
    Ignition module cartridge
     
    Valve cover
     
    Crankcase ventilation hose
     
    Semicircular rubber plug halves from the cylinder head
     

  10.  
  11. Line up the 0 mark on the flywheel with the timing mark. Check that the camshaft timing marks are also in line.
    NOTE
    Do not rotate the camshaft or crankshaft after the sprockets have been removed, as rotation of one of the shafts can result in damage to the valves.



    Timing chain tensioner
     
    Camshaft sprockets
     



    Cylinder head bolts
     

  12.  
  13. Siphon off the oil from the cylinder head.
  14.  
  15. Install Guide Pin 83-92-128 in one of the bolt holes and lift off the cylinder head, making sure the pivoting guide for the timing chain is not damaged.
  16.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.0L and 2.3L engines

  1. Align the 0 mark on the flywheel with the timing mark on the housing. Align the marks on the camshafts with their respective timing marks.
  2.  
  3. Install the cylinder head gasket, making sure it is held in position by the guide sleeves in the cylinder head flange.
  4.  
  5. Position the timing chain and pivoting guide for cylinder head installation.
  6.  
  7. Install the cylinder head. Use the guide pin as a pivot for the head, which must be turned slightly to enable it to pass the pivoting guide. Thereafter, alignment will be determined by the guide sleeves.
  8.  
  9. Install the 2 M8 bolts in the underside of the cylinder head.
  10.  
  11. Install the remaining cylinder head bolts and torque them in sequence as follows:
    1. 30 ft. lbs. (44 Nm).
    2.  
    3. 44 ft. lbs. (60 Nm).
    4.  
    5. Plus 90 degrees ( 1 / 4 turn).
    6.  

  12.  
  13. Install or connect the following:

    Camshaft sprockets
     
    Timing chain
     
    Timing chain tensioner
     
    Semi-circular rubber plug halves in the cylinder head
     
    Valve cover and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Crankcase ventilation hose
     
    Ignition module module and torque to 8 ft. lbs. (11 Nm)
     
    Temperature sensor electrical lead
     
    Intake manifold complete with injectors and torque the bolts to 16 ft. lbs. (22 Nm)
     
    A/C compressor bracket
     
    A/C compressor
     
    Fuel pressure regulator
     
    Ground leads for the fuel injection system
     
    Upper radiator hose to thermostat housing
     
    Bolts in the right-hand engine mounting. Screw them into the cylinder head, together with the spacer sleeves.
     
    Wiring harness clips on the cylinder head
     
    Power steering belt
     
    Tensioning pulley and drive belt for the air conditioner compressor
     
    Exhaust manifold and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  14.  
  15. Fill the engine with clean oil.
  16.  
  17. Fill the cooling system.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

 
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