GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Firefly (Canada) 🢒 Engine 🢒 Engine Mechanical - 1.0L 🢒 Cylinder Head Replacement

Removal Procedure

    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.

  1. Disconnect the negative battery cable.
  2. Remove the intake manifold and the throttle body fuel injection. Refer to Intake Manifold Replacement in Engine Mechanical.
  3. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Mechanical.
  4. Remove the Valve Rocker Arm Cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical.
  5. Remove the timing belt. Refer to Timing Belt Replacement in Engine Mechanical.
  6. Remove the camshaft. Refer to Camshaft Replacement in Engine Mechanical.

    7. Object Number: 177962 Size: SH

    Important: Observe the following before removing the Hydraulic Valve Lash (HVL) adjusters:

       • Mark the position of the Hydraulic Valve Lash (HVL) adjusters in the cylinder head for proper reassembly.
       • Never disassemble the Hydraulic Valve Lash (HVL) adjuster.
       • Do not apply force to the body of the adjuster or the oil in the high pressure chamber.
       • Submerge the removed adjusters in clean engine oil until reinstallation. If the adjusters are left in the air, place with the adjuster bodies facing down. Do not place on the side or with the adjuster bodies facing up.

  7. Remove the six Hydraulic Valve Lash (HVL) Adjusters (1) from the cylinder head.

    8. Object Number: 177970 Size: SH
  8. Remove the eight cylinder head bolts from the engine in the sequence shown.
  9. Remove the cylinder head from the cylinder block.

    10. Object Number: 177969 Size: SH
  10. Remove the cylinder head gasket (1) from the cylinder block.

    11. Object Number: 177971 Size: SH
  11. Remove the cylinder head rubber seal (2) from the cylinder block.

Installation Procedure

    Object Number: 177969 Size: SH
  1. Install the new cylinder head gasket (1) with the TOP mark facing up (toward the cylinder head) and on the crankshaft pulley side.
  2. Install the cylinder head.

    3. Object Number: 177970 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Use the following procedure in order to secure the cylinder head:
    4. 3.1. Apply engine oil to each of the eight cylinder head bolts.
    3.2. Install the eight 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 73 N·m (54 lb ft).


    Object Number: 177971 Size: SH
  4. Install the rubber seal (2) between the coolant pump (1) and the cylinder head (3).

    5. Object Number: 177962 Size: SH
  5. Apply engine oil around the HVL adjusters.
  6. Install the HVL adjuster (1) to the cylinder head.

    7. Object Number: 177971 Size: SH
  7. Install the rubber seal (2) between the coolant pump (1) and the cylinder head (3).
  8. Install the camshaft. Refer to Camshaft Replacement in Engine Mechanical.
  9. Install the timing belt. Refer to Timing Belt Replacement in Engine Mechanical.
  10. Install the Valve Rocker Arm Cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical.
  11. Install the distributor to the cylinder head. Refer to Distributor Replacement in Engine Electrical.
  12. Install the intake manifold and the (TBI) unit. Refer to Intake Manifold Replacement in Engine Mechanical.
  13. Install the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Mechanical.
  14. Connect the negative (-) battery cable.
  15. Refill the engine coolant to specifications. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.
  16. Start the engine and adjust the ignition timing. Refer to Ignition Timing Adjustment in Engine Controls.
  17. Inspect the coolant system for coolant leaks.
  18. Inspect the exhaust system for exhaust leaks.