Cylinder Head Assembly: Service and Repair

1. Release fuel system pressure as outlined under MAINTENANCE PROCEDURES/Fuel System Pressure Release.
2. Raise and support vehicle then drain cooling system and engine oil.

Fig. 16 Cylinder head (Part 1 of 2). 1.8L/4-111.9 engine:

Fig. 16 Cylinder head (Part 2 of 2). 1.8L/4-111.9 engine:

Fig. 17 Cylinder head (Part 1 of 2). 1993-96 2.4L/4-143.5 engine:

Fig. 17 Cylinder head (Part 2 of 2). 1993-96 2.4L/4-143.5 engine:

3. Remove cylinder head in numbered sequence shown in Fig. 16 and 17, noting the following:

Fig. 18 Aligning timing marks. 1.8L/4-111.9 engine:

Fig. 19 Aligning timing marks. 1993-96 2.4L/4-143.5 engine:

a. Rotate crankshaft clockwise direction and align the timing marks, Fig. 18 and 19.
b. Tie camshaft sprocket and timing belt with a cord so that position of camshaft sprocket will not move with respect to the timing belt.
c. Remove camshaft sprocket using spanner wrench tools No. MB990767 and MD998719 or equivalents.

Fig. 20 Cylinder head bolt loosening sequence. 1.8L/4-111.9 and 1993-96 2.4L/4-143.5 engines:

d. Remove cylinder head bolts in two or three steps in numbered sequence shown in Fig. 20.
4. Install cylinder head in reverse numbered sequence shown in Fig. 16 and 17, noting the following:
a. Place cylinder head gasket on block so that ID mark is facing upward.
b. Ensure length of cylinder head bolts do not exceed 3.795 inches on 1.8L/4-111.9 engines or 3.91 inches on 1993-94 2.4L/4-143.5 engine.
c. Apply engine oil to threads of cylinder head bolt before tightening.

Fig. 21 Cylinder head bolt tightening sequence. 1.8L/4-111.9 and 1993-96 2.4L/4-143.5 engines:

Fig. 22 Cylinder head bolt tightening sequence. 1.8L/4-111.9 engine:

Fig. 23 Cylinder head bolt tightening sequence. 1993-96 2.4L/4-143.5 engine:

d. Tighten cylinder head bolts in sequence shown in Fig. 21, using tightening order shown in Figs. 22 and 23.

Fig. 24 Water inlet pipe bolt. 1.8L/4-111.9 engine:

Fig. 25 Water inlet fitting installation. 1993-96 2.4L/4-143.5 engine:

e. Loosen water inlet pipe bolt and apply sealant to thermostat case assembly as shown, Figs. 24 and 25.
f. Apply a small amount of water to O-ring of water inlet pipe and press thermostat case assembly onto water inlet pipe.