Cylinder Head Replacement. Pontiac Sun Runner - 2WD (Canada) 1998

For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 41040 Camshaft Sprocket Spanner

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. Release the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 1.6L.
3. Remove the fuel filler cap in order to release the fuel vapor pressure in the fuel tank.
4. Replace the cap after the pressure has been released.
5. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
6. Remove the air intake pipe from the ACL intake hose and the throttle hose. Refer to Air Intake Pipe Replacement.
7. Remove three bolts and the throttle cover from the intake manifold.
8. Disconnect the accelerator cable and kickdown cable (automatic transmission equipped vehicles) from the throttle body bellcrank.
9. Remove the following from the throttle body:

• | One bolt

• | One nut

• | One screw

• | The accelerator cable bracket

10. Remove the following electrical connectors:

• | (TP) Sensor

• | (IAC) Valve

• | (ECT) Sensor

• | ECT Sending Unit

• | A/C ECT Switch (A/C equipped vehicles only)

• | (EVAP) Canister Purge Valve

• | (EGR) Temperature Sensor

• | EGR Solenoid Vacuum Valve

• | EGR By-pass Valve

• | Fuel Injectors

• | Engine Ground Wire From Intake Surge Tank

11. Remove the following vacuum hoses:

• | EVAP Canister Purge Valve

• | Vacuum Modulator Supply Hose (automatic transmission equipped vehicles)

• | Brake Booster Supply Hose

• | EGR Valve

• | EGR Valve Modulator

• | (MAP) Sensor Hose

12. Remove the coolant hose from the IAC valve.
13. Remove the IAC hose from the IAC valve.
14. Remove the coolant hose from the fast idle air valve below the throttle body.
15. Remove the fuel feed hose at the fuel feed hose union (1).
16. Remove the fuel return hose from the fuel return line.
17. Remove the PCV hose from the PCV valve.
18. Loosen the upper radiator hose clamp at the thermostat housing.
19. Remove the upper radiator hose from the thermostat housing.
20. Remove the coolant bypass hose from the intake manifold.
21. Remove one bolt, one nut and generator adjusting arm bracket (1) from the intake manifold.
22. Remove two bolts and the front intake manifold reinforcement bracket from the intake manifold.
23. Remove two bolts and the rear intake manifold reinforcement bracket from the intake manifold.
24. Remove two bolts and the lower intake manifold support bracket from the intake manifold.
25. Remove the following from the cylinder head:

• | Eight nuts

• | Three bolts

• | The intake manifold with the gasket

• | The intake surge tank

• | The throttle body

26. Remove the following from the exhaust manifold:

• | Two nuts

• | Three bolts

• | The upper exhaust manifold heat shield

27. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
28. Remove the following from the exhaust manifold:

• | Two bolts

• | One nut

• | The exhaust manifold reinforcement bracket (1)

29. Remove two bolts and the lower exhaust manifold heat shield (6) from the exhaust manifold.
30. Remove three bolts and the front pipe/Three-Way Catalytic Converter (TWC) assembly with the gasket from the exhaust manifold.
31. Lower the vehicle.
32. Remove the nine exhaust manifold nuts (1).
33. Remove the exhaust manifold (2) with the gasket (1) from the cylinder head.
34. Remove the engine hanger (3) from the cylinder head.
35. Loosen the upper and lower A/C compressor mounting bolts (if equipped).
36. Loosen the upper and lower power steering pump mount bolts.
37. Remove the A/C compressor (if equipped) and/or power steering drive belt from the pulleys.
38. Loosen the upper and lower generator mounting bolts.
39. Remove the generator/coolant pump drive belt from the pulleys.
40. Remove the following from the coolant pump:

• | Four nuts

• | The cooling fan

• | The coolant pump pulley

41. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

42. Remove four bolts and the front skid plate from the vehicle (if equipped).
43. Remove the two radiator shroud bolts.
44. Lower the vehicle.
45. Remove two bolts from the A/C suction line brackets at the right side of the radiator core support (if equipped).
46. Reposition the suction line for the radiator shroud removal access.
47. Remove the two upper radiator shroud bolts and the radiator shroud from the radiator.

Important: If the radiator shroud is difficult to remove, drain the cooling system and disconnect the upper radiator hose from the radiator to gain access.

48. Remove five bolts (3) and the crankshaft pulley from the crankshaft.

Important: It is not necessary to remove the crankshaft pulley center bolt when removing the crankshaft pulley.

49. Disconnect the oil pressure sending unit wire conduit from the timing belt cover.
50. Remove the following from the engine:

• | Eight bolts

• | One nut

• | The timing belt cover

Important: There are two sets of timing marks which must be aligned to ensure the correct engine timing upon the timing belt installation. A notch in the camshaft timing belt gear designated as E must be aligned with the notch in the cylinder head cover. A punch mark on the crankshaft timing belt gear should then align with the arrow in the oil pump casting. Make sure to align both sets of marks prior to the timing belt removal to ensure a correct timing belt installation as well as engine timing.

51. Align the timing marks on the cylinder head cover (1) and the camshaft timing belt gear (2).
52. Align the timing marks on the oil pump casting (1) and the crankshaft timing belt gear (2).
53. Loosen the timing belt tensioner bolt.
54. Remove the timing belt tensioner spring (3) from the timing belt tensioner plate.
55. Remove the timing belt from the camshaft and the crankshaft timing belt gears.
56. Using a J 41040 in order to hold the camshaft timing belt gear stationary, remove one bolt and the camshaft timing belt gear from the camshaft.
57. Remove the two bolts and the inside timing belt cover (2) from the cylinder head.
58. Remove two bolts and the A/C mounting bracket with the compressor from the cylinder head.
59. Remove the distributor from the distributor case. Refer to Distributor Replacement in Engine Electrical.
60. Remove six bolts from the cylinder head cover (1) from the cylinder head.
61. Remove the cylinder head cover gasket and the O-rings from the cylinder head cover.

Important: A small amount of oil may drain from the distributor case upon removal from the cylinder head. Place a suitable container underneath the distributor case or use a shop towel to catch and absorb oil.

62. Remove three bolts (2) and the distributor case (1) from the cylinder head.
63. Loosen all of the valve adjusting screw locknuts (3).
64. Loosen all of the valve adjusting screws (2) until all rocker arms move freely.

Notice: Always loosen the camshaft carrier bolts gradually and in the order shown, in order to relieve tension on the camshaft. If the camshaft carrier bolts are removed at random, damage to the camshaft may occur.

65. Remove the following from the cylinder head:

• | Twelve bolts

• | The camshaft carrier caps

• | The camshaft seal

• | The camshaft

Important: Loosen the cylinder head bolts gradually in the specified sequence to prevent the cylinder head distortion.

66. Remove the following from the cylinder block:

• | Ten bolts

• | Cylinder head

• | The cylinder head gasket

67. Clean the mating surfaces of the following:

• | The cylinder head

• | The cylinder block

• | The intake manifold

• | The exhaust manifold

• | The distributor gear case of all gasket or sealant materials.

68. Clean all the bolt threads and bolts.
69. Inspect the cylinder head. Refer to Cylinder Head Disassemble .

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.

70. Inspect the oil jet (2) in the cylinder head for any obstructions and ensure that the oil jet is tightened to its torque specification.

Tighten
Tighten the oil jet to 5 N·m (44 lb in).

### Installation Procedure

1. Apply clean engine oil to the threaded portion of all of the cylinder bolts.
2. Install the new cylinder head gasket and the cylinder head with the distributor case onto the cylinder block. Secure the components with ten bolts.

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. Tighten the cylinder head bolts (1) in three separate steps, following the illustrated sequence.

Tighten

1. Tighten the ten cylinder head bolts on the first pass to 35 N·m (26 lb ft).
2. Tighten the ten cylinder head bolts on the second pass to 55 N·m (41 lb ft).
3. Tighten the ten cylinder head bolts on the final (third) pass to 70 N·m (52 lb ft).

4. Apply a liberal amount of clean engine oil to the camshaft.
5. Apply GM P/N 12346240 or the equivalent to the bottom of the number 6 camshaft carrier cap.

Notice: Always tighten the camshaft carrier cap bolts gradually in the order shown. If the camshaft carrier cap bolts are tightened at random, damage to the camshaft may occur

6. Install the camshaft and the camshaft carrier caps onto the cylinder head. Secure the camshaft and the camshaft carrier caps with 12 bolts.

Tighten
Tighten the camshaft carrier cap to 10 N·m (89 lb in).

7. Apply engine oil to the new camshaft seal lip.
8. Install the new camshaft seal into the cylinder head until the camshaft seal is flush with the camshaft carrier surface.
9. Adjust the valve lash. Refer to Valve Lash Adjustment .
10. Apply GM P/N 12346340 or the equivalent to the surface of the distributor case that mates with the rear rocker arm shaft.
11. Install the distributor case (1) to the cylinder head. Secure the distributor case with three bolts.

Tighten
Tighten the distributor case bolts to 10 N·m (89 lb in).

12. Clean the sealing surfaces on the cylinder head and the cylinder head cover.

Important: A new cylinder head cover gasket and O-rings must be used whenever a cylinder head cover removal and installation is performed. Ensure that new gasket and O-rings are correctly positioned during the cylinder head cover installation.

13. Install a new head cover gasket and four O-rings (2) to the cylinder head cover.
14. Install the cylinder head cover to the cylinder head. Secure the cylinder head cover with six bolts.

Tighten
Tighten the cylinder head cover bolts to 10 N·m (89 lb in).

15. Install the distributor into the distributor case. Refer to Distributor Replacement in Engine Electrical.
16. Install the A/C mounting bracket with the compressor to the cylinder head.
17. Secure the A/C mounting bracket and the compressor with two bolts.

Tighten
Tighten the A/C mounting bracket bolts to 10 N·m (89 lb in).

18. Install the timing belt cover (2) to the cylinder head. Secure the timing belt cover with two bolts.

Important: During the camshaft timing belt gear installation, align the camshaft dwell pin with the slot in the camshaft timing belt gear designated as E.

19. Use a J 41040 in order to install the camshaft timing belt gear (1) onto the camshaft.
20. Hold the camshaft timing belt gear stationary. Secure the camshaft timing belt with one bolt.

Tighten
Tighten the camshaft timing belt gear bolt to 60 N·m (44 lb ft).

Important: Do not tighten the timing belt tensioner stud and bolt to specification until the timing belt is properly installed. Install the timing belt tensioner stud and bolt finger tight only.

21. Install the timing belt tensioner plate (1) and tensioner (5) to the engine. Secure the timing belt tensioner stud and bolt.

Notice: When installing a new or used timing belt, the directional arrows on the timing belt, the directional arrows on the timing is properly installed. Install the timing belt tensioner stud and bolt finger tight only.

22. Push the timing belt tensioner plate (1) up for the timing belt installation.
23. Install the timing belt onto the camshaft and the crankshaft timing belt gears.
24. Inspect the timing marks on the cylinder head cover and the camshaft timing belt gear for alignment as well as the timing marks on the oil pump casting (1) and the crankshaft timing belt gear (2). If these two sets of timing are not properly aligned, remove the timing belt and align both sets of marks as previously outlined in this procedure.

Important: Rotate the crankshaft two complete revolutions to remove any slack from the timing belt and to properly seat the timing belt. When all slack has been removed from the timing belt. When all slack has been removed from the timing belt, inspect both sets of timing marks to ensure that they are aligned respectively.

25. Install the timing belt tensioner spring to the timing belt tensioner plate (1).

Tighten

• | Tighten the timing belt tensioner stud (2) to 11 N·m (97 lb in).

• | Tighten the timing belt tensioner bolt (4) to 27 N·m (20 lb ft).

26. Install the timing belt cover to the engine. Secure the timing belt cover with one nut and eight bolts.

Tighten
Tighten the timing belt cover with the nut and bolts to 10 N·m (89 lb in).

27. Install the oil pressure sending unit wire conduit to the timing belt cover.
28. Install the crankshaft pulley (4) to the crankshaft. Secure the crankshaft pulley with five bolts (3).

Tighten
Tighten the crankshaft pulley bolts to 16 N·m (12 lb ft).

29. Install the radiator shroud to the radiator. Secure the radiator shroud with two bolts.

Tighten
Tighten the crankshaft pulley bolts to 11 N·m (97 lb in).

30. Carefully reposition the A/C suction line and the brackets to the right side of the radiator core support (if equipped). Secure the A/C suction line and the brackets with two bolts.

Tighten
Tighten the A/C suction line and the bracket bolts to 10 N·m (89 lb in).

31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
32. Install the two lower radiator shroud bolts.

Tighten
Tighten the lower shroud bolts to 11 N·m (97 lb in).

33. Install the front skid plate to the vehicle (if equipped). Secure the front skid plate with four bolts.

Tighten
Tighten the front skid plate bolts to 55 N·m (40 lb ft).

34. Lower the vehicle.
35. Install the coolant pump pulley and the cooling fan to the coolant pump. Secure the coolant pump pulley with four nuts.

Tighten
Tighten the coolant fan nuts to 11 N·m (97 lb in).

36. Install the generator/coolant pump drive belt to the pulleys.
37. Install the A/C compressor (if equipped) and/or power steering drive belt to pulleys.
38. Adjust the generator/coolant pump drive belt. Refer to Cooling and Radiator.
39. Adjust the A/C compressor (if equipped) and/or power steering drive belt. Refer to HVAC and/or Power Gear and Pump.
40. Install a new exhaust manifold gasket (1) and the exhaust manifold (2) with the engine hanger to the cylinder head.
41. Secure the new exhaust manifold gasket and the exhaust manifold with nine nuts (1).

Tighten
Tighten the nine nuts to 23 N·m (17 lb ft).

42. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
43. Install the front pipe/TWC assembly (3) with the new gasket (2) to the exhaust manifold (1). Secure the front pipe/TWC assembly with three bolts.

Tighten
Tighten the front pipe/TWC assembly bolts to 50 N·m (37 lb ft).

44. Install the lower exhaust manifold heat shield (6) to the exhaust manifold. Secure the lower exhaust manifold heat shield with two bolts.

Tighten
Tighten the lower exhaust manifold heat shield bolts to 10 N·m (89 lb in).

45. Install the exhaust manifold bracket (1) to the exhaust manifold and engine block. Secure the exhaust manifold bracket with one nut and two bolts.

Tighten

• | Tighten the mount-to-exhaust bracket bolts to 54 N·m (54 lb ft).

• | Tighten the bracket-to-exhaust manifold nut to 50 N·m (37 lb ft).

46. Lower the vehicle.
47. Install the upper exhaust manifold heat shield (3) to the exhaust manifold (2). Secure the upper exhaust manifold heat shield with two nuts and three bolts

Tighten
Tighten the upper exhaust manifold heat shield nuts and bolts to 10 N·m (89 lb in).

48. Install the air intake pipe bracket to the cylinder head. Secure the air intake pipe bracket with three bolts.

Tighten
Tighten the air intake pipe bracket bolts to 10 N·m (89 lb in).

49. Install a new intake manifold gasket and intake manifold with the intake surge tank and throttle body to the cylinder head. Secure the intake manifold gasket and intake manifold with the intake surge tank and throttle body with eight nuts and three bolts.

Tighten
Tighten the intake manifold nuts and bolts to 23 N·m (17 lb ft).

50. Install the lower intake manifold support bracket (3) to the intake manifold. Secure the lower intake manifold support bracket with two bolts.

Tighten
Tighten the lower intake manifold support bracket bolts to 50 N·m (37 lb ft).

51. Install the rear intake manifold reinforcement bracket to the intake manifold. Secure the rear intake manifold reinforcement bracket with two bolts.

Tighten
Tighten the rear intake manifold support bracket bolts to 50 N·m (37 lb ft).

52. Install the front intake manifold reinforcement bracket to the intake manifold. Secure the front intake manifold reinforcement bracket with two bolts.

Tighten
Tighten the front intake manifold support bracket bolts to 50 N·m (37 lb ft).

53. Install the generator adjusting arm bracket (1) to the intake manifold. Secure the generator adjusting arm bracket with 1 bolt and 1 nut.

Tighten
Tighten the generator adjusting arm bracket nut and bolt to 50 N·m (37 lb ft).

54. Install the coolant bypass hose to the intake manifold.
55. Install the upper radiator hose to the thermostat housing.
56. Tighten the upper radiator hose clamp at the thermostat housing.
57. Install the PCV hose to the PCV valve.
58. Connect the fuel return hose to the fuel return line.
59. Install the fuel feed hose at the fuel feed hose union (1).
60. Install the coolant hoses to the fast idle air valve below the throttle body.
61. Install the IAC air hose to the IAC valve.
62. Install the coolant hose to the IAC valve.
63. Install the following vacuum hoses:

• | The EGR valve modulator

• | The EGR valve

• | The brake booster supply hose

• | The vacuum modulator supply hose (automatic transmission equipped vehicles)

• | The EVAP SP Valve

• | The intake manifold absolute pressure sensor hose

64. Install the following electrical connectors:

• | The engine ground wire to intake manifold

• | The fuel injectors

• | The EGR solenoid vacuum valve

• | The EGR by-pass vacuum valve

• | The exhaust gas recirculation (EGR) temperature sensor

• | The evaporative emission solenoid purge (EVAP SP) valve.

• | The A/C ECT switch (A/C equipped vehicles only)

• | The ECT sensor sending unit

• | The engine coolant temperature (ECT) sensor

• | The Idle Air Control (IAC) Valve

• | The Throttle Position (TP) Sensor

65. Install the accelerator cable bracket (2) to the throttle body. Secure the cable bracket with one screw, one bolt and one nut.

Tighten
Tighten the cable bracket nut and bolt to 23 N·m (17 lb ft).

66. Install the accelerator cable and kickdown cable (automatic transmission equipped vehicles) to the throttle body bellcrank.
67. Adjust the accelerator as necessary. Refer to Engine Fuel in Engine.
68. Adjust the kickdown cable (automatic transmission equipped vehicles) as necessary. Refer to Automatic Transmission On-Vehicle Service in Transaxle.
69. Install the throttle cover from the intake manifold. Secure the throttle cover with three bolts

Tighten
Tighten the throttle cover bolts to 15 N·m (11 lb ft).

70. Refill the cooling system as necessary. Refer to Cooling System Draining and Filling in Engine Cooling.
71. Install the air intake pipe to the throttle body hose and the ACL intake hose. Refer to Air Intake Pipe Replacement.
72. Install the negative battery cable. Refer to Battery Replacement in Engine Electrical.