Metro, Prizm 2000-2002

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Exhaust manifold
     
    Rocker arm cover
     
    Timing belt and tensioner
     
    Camshaft
     
    Valve lifters
     
    Distributor
     
    Cylinder head bolts
     
    Cylinder head
     

  4.  

To install:

Click image to see an enlarged view

Fig. Cylinder head gasket positioning-1.0L engine



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Fig. Cylinder head gasket positioning-1.3L engine



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Fig. Cylinder head torque sequence-1.0L engine



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Fig. Cylinder head torque sequence-1.3L engine

  1. Install or connect the following:

    Cylinder head with a new gasket and torque the bolts in 3 even stages, in sequence, to 54 ft. lbs. (73 Nm) on 1.0L engines or 49 ft. lbs. (68 Nm) on 1.3L engines
     
    Valve lifters
     
    Camshaft
     
    Rocker arm cover and torque the bolts to 44 inch lbs. (5 Nm)
     
    Timing belt and tensioner
     
    Distributor
     
    Intake manifold and torque the bolts to 17 ft. lbs. (23 Nm)
     
    Exhaust manifold and torque the bolts to 17 ft. lbs. (23 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and allow it to reach normal operating temperature. Check for leaks and adjust the ignition timing, if necessary.
  4.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Washer tank and pump
     
    Accessory drive belt
     
    Alternator
     
    Accelerator cable from the throttle body
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Air cleaner hose
     
    Throttle Position (TPS) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Coolant bypass hoses
     
    Fuel injector electrical connectors
     
    Fuel injector harness from the intake manifold
     
    Intake manifold support bracket
     
    Oxygen (O 2 S) sensor
     
    Exhaust pipe from the manifold
     

  10.  
  11. Install an engine support fixture.

    A/C receiver pinch clamp and move the receiver aside
     
    Right side engine mount
     
    Ignition coil connectors
     
    Fuel line at the fuel rail
     
    Spark plug wires
     
    Ignition coils
     
    Fuel rail
     
    Ground wires from the cylinder head
     
    Heater hose from the cylinder head
     
    Water bypass pipe
     
    Camshaft Position (CMP) sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Positive Crankcase Ventilation (PCV) valve and hoses
     
    Rocker arm cover
     

  12.  
  13. Set the No. 1 piston to Top Dead Center (TDC) and align the camshaft timing sprockets.
  14.  
  15. Remove or disconnect the following:

    Power steering oil pressure switch connector
     
    Right side lower engine splash shield
     
    Power steering pump
     
    Crankshaft pulley
     
    Crankshaft Position (CKP) sensor
     
    Drive belt tensioner
     
    Right side engine mount bracket
     
    Timing chain tensioner
     
    Timing chain cover
     
    Crank sensor reluctor
     
    Timing chain slipper
     
    Crankshaft sprocket
     
    Timing chain
     
    Camshaft sprockets
     
    Camshaft bearing caps
     
    Camshafts
     
    Valve lifters
     
    Intake manifold
     
    Exhaust manifold
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-Prizm

     

  16.  

To install:

  1. Install the cylinder head with a new gasket.
  2.  
  3. Torque the cylinder head bolts in the following sequence:
    1. 18 ft. lbs. (25 Nm).
    2.  
    3. 36 ft. lbs. (49 Nm).
    4.  
    5. Plus an additional 90 degrees.
    6.  

  4.  
  5. Install or connect the following:

    Camshafts and torque the bearing cap bolts to 10 ft. lbs. (13 Nm)
     
    Camshaft sprockets and torque the bolts to 40 ft. lbs. (55 Nm)
     
    Timing chain
     
    Timing chain cover and torque the bolts to 14 ft. lbs. (18 Nm)
     
    Crankshaft pulley and torque the bolt to 105 ft. lbs. (142 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    ECT sensor
     
    Camshaft sensor and torque the bolt to 11 ft. lbs. (15 Nm)
     
    Water bypass pipe and torque the bolt to 11 ft. lbs. (15 Nm)
     
    Heater hoses
     
    Ground wires to the cylinder head and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Fuel rail and torque the bolts to 10 ft. lbs. (14 Nm)
     
    Fuel line to the rail
     
    Ignition coils and torque the bolts to 10 ft. lbs. (14 Nm)
     
    Right side engine mount and torque the bolts to 40 ft. lbs. (54 Nm)
     
    A/C receiver pinch clamp
     

  6.  
  7. Remove the engine support fixture.

    Exhaust manifold support bracket and torque the bolt to 26 ft. lbs. (35 Nm)
     
    Exhaust pipe with a new gasket and torque the bolts to 46 ft. lbs. (62 Nm)
     
    O 2 sensor and torque the nuts to 30 ft. lbs. (41 Nm)
     
    Fuel injector harness brackets
     
    Vacuum hoses
     
    Intake manifold support bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Fuel injector harness to the intake manifold and torque the bolts to 106 inch lbs. (12 Nm)
     
    Upper radiator hose
     
    Fuel injector connectors
     
    Coolant bypass hoses
     
    MAP sensor electrical connector
     
    IAC valve electrical connector
     
    TPS sensor electrical connector
     
    IAT sensor electrical connector
     
    Accelerator cable to the throttle body
     
    Alternator and torque the bolts to 17 ft. lbs. (23 Nm)
     
    Washer pump and torque the bolt to 89 inch lbs. (10 Nm)
     
    Accessory drive belt
     
    Negative battery cable
     

  8.  
  9. Fill the engine with new oil.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Start the vehicle and check for leaks, repair if necessary. Road test and check for proper operation.
  14.  

 
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