Protege 1999-2000

Cylinder Head

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Removal & Installation



1.6L (Zm) Engines
  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. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Exhaust manifold insulator and the Exhaust Gas Recirculation (EGR) pipe
     
    Fresh air duct and air cleaner assembly
     
    Accelerator cable and bracket
     
    All vacuum hoses
     
    Engine wiring harness connectors
     
    Fuel supply and return hoses
     
    Intake manifold support bracket
     
    Heater hoses
     
    Camshaft pulleys by holding the them with a wrench
     
    Camshafts
     
    Cylinder head bolts in sequence
     
    Cylinder head
     

  8.  

To install:

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Fig. Cylinder head bolt removal sequence-1.6L (ZM) and 1.8L (FP) engines



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Fig. Replace any bolts that exceed the maximum length-1.6L (ZM) and 1.8L (FP) engines



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Fig. Cylinder head gasket positioning-6-cylinder engines



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Fig. Cylinder head bolt tightening sequence-1.6L (ZM) and 1.8L (FP) engines

  1. Thoroughly, clean the cylinder head and the block contact surfaces.
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 3.956 inch (100.5mm).
  6.  
  7. Install or connect the following:

    New head gasket
     
    Cylinder head
     

  8.  
  9. Torque the cylinder head bolts, in sequence, as follows:
    1. Step 1: 13-16 ft. lbs. (17-22 Nm).
    2.  
    3. Step 2: Turn 85-95 degrees.
    4.  
    5. Step 3: Turn an additional 85-95 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Camshafts
     
    Camshaft pulleys, install the pulleys so that the I mark on the intake side or E mark on the exhaust side are facing up. Torque the bolts to 37-44 ft. lbs. (50-60 Nm).
     
    Heater hoses
     
    Intake manifold support bracket
     
    Fuel hoses
     
    Engine wiring harness connector
     
    Any vacuum hoses that were removed
     
    Accelerator cable and bracket
     
    Air cleaner assembly and fresh air duct
     
    EGR system
     
    Exhaust manifold insulator and front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

 
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