GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Firefly (Canada) 🢒 Engine 🢒 Engine Mechanical - 1.3L 🢒 Cylinder Head Replacement

Removal Procedure
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Disconnect the negative battery cable.
  3. Remove the intake manifold and the throttle body. Refer to Intake Manifold Replacement in Engine Mechanical.
  4. Remove the exhaust manifold. Refer to Cylinder Head Replacement in Engine Mechanical.
  5. Remove the timing belt. Refer to Timing Belt Replacement in Engine Mechanical.
  6. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical.
  7. Remove the camshaft. Refer to Camshaft Replacement in Engine Mechanical.

    8. Object Number: 262241 Size: SH

    Notice: In order to prevent warpage of the cylinder head, follow the sequence shown whenever removing or installing the head.

  8. Remove the following components from the vehicle:
    9. • Ten cylinder head bolts
    • Remove the cylinder head bolts in the order specified in the graphic.
    • The cylinder head and cylinder head gasket.

Installation Procedure

    Object Number: 201633 Size: SH
  1. Install the cylinder head gasket (2).

    2. Install the new cylinder head gasket with the TOP mark facing up (toward the cylinder head) and on the crankshaft timing pulley side.


    Object Number: 262005 Size: SH
  2. Install the cylinder head.

    3. Use the following procedure in order to secure the cylinder head:

    2.1. Apply engine oil to each of the ten cylinder head bolts.
    2.2. Install the ten cylinder head bolts in order to secure the cylinder head.

    Install the ten bolts in the order specified in the graphic. Tighten the bolts evenly and in small increments of torque. Repeat the tightening sequence three or four times in order to reach the specified torque.

    Tighten
    Tighten the cylinder head-to-engine block bolts to 68 N·m (49 lb ft).

  3. Install the camshaft. Refer to Camshaft Replacement in Engine Mechanical.
  4. Install the timing belt. Refer to Timing Belt Replacement in Engine Mechanical.
  5. Install the throttle body and the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.
  6. Install the exhaust manifold. Refer to Cylinder Head Replacement in Engine Mechanical.
  7. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical.
  8. Connect the negative battery cable.
  9. Refill the engine coolant to specifications. Refer to Cooling System Draining and Filling in Engine Cooling.
  10. Inspect the coolant system for coolant leaks.
  11. Start the engine.
  12. Inspect the exhaust system for exhaust leaks.