PM ENGINE 1.

8L WORLD 9 - 1461

SPECIAL TOOLS
2.4L ENGINE
9 - 1462 ENGINE 1.8L WORLD PM

HOLDING FIXTURE 9707

1.8L SPROCKET HOLDER 9711

ENGINE LIFT FIXTURE 9704

TENSIONER PIN 9703

FRONT SEAL INSTALLER 9506

PM ENGINE 1.8L WORLD 9 - 1463

REAR MAIN SEAL DRIVER 9706

REAR CRANKSHAFT SEAL GUIDE 9509

LOCKING WEDGE 9701

9 - 1464 ENGINE 1.8L WORLD PM

ELEMENT-AIR CLEANER
REMOVAL
1. Turn Lock Retainers (5) and remove fresh air inlet
(2) from air cleaner housing (1).

2. Disconnect intake air temperature sensor connector

(4).
3. Remove Air inlet tube (5) from air cleaner housing
(1).
4. Unfasten clasps (2) on sides of air cleaner housing
cover (1).
PM ENGINE 1.8L WORLD 9 - 1465

5. Pull air cleaner cover (1) aside.

6. Remove filter element (3).
7. If necessary, clean the inside of the air cleaner
housing (2).

INSTALLATION
1. Install new filter element.

2. Place cover over air cleaner housing. Snap clasps

(2) in place.
3. Install air inlet tube (5).
4. Connect intake air temperature sensor connector
(4).
9 - 1466 ENGINE 1.8L WORLD PM

5. Install fresh air inlet (2) on air cleaner housing (1)

and lock retainers (5).
PM ENGINE 1.8L WORLD 9 - 1467

HOUSING-AIR CLEANER
REMOVAL
1. Remove fresh air inlet (2) from air cleaner housing
(1).

2. Remove intake air temperature sensor electrical

connector (4).
3. Remove air inlet tube (5) from housing (1).
4. Pull housing (1) upward to remove.
9 - 1468 ENGINE 1.8L WORLD PM

INSTALLATION
1. Make sure the rubber grommets, for the air cleaner
housing lower pins, are in place when reinstalling
the air cleaner housing. The rubber grommets
mount to the PDC bracket.
2. Push air cleaner housing (1) down while aligning
pins into the grommets.
3. Connect the throttle body air inlet hose (5) to the
air cleaner housing (1).
4. Connect intake air temperature sensor connector
(4).

5. Install fresh air inlet (2) and lock retainers (5).

PM ENGINE 1.8L WORLD 9 - 1469

CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder.
The valves are arranged in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust
valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Integral oil galleries provide lubrication passages to the variable camshaft timing phasers, camshafts, and valve
mechanisms.

NOTE: Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash
buckets, and camshafts.

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water
jacket or from an oil passage to the exterior of the engine.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from exhaust
• Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cyl-
inder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head
gasket leaking between adjacent cylinders will result in approximately a 50–70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP
REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat
opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE
PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s
pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
9 - 1470 ENGINE 1.8L WORLD PM

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent.
Perform test following the procedures supplied with the tool kit.

REMOVAL - CYLINDER HEAD

1. Perform fuel system pressure release procedure before attempting any repairs
2. Remove clean air hose and air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
3. Disconnect negative cable from battery.
4. Drain cooling system.
5. Remove engine cover.
6. Remove coolant recovery bottle.
7. Remove power steering pump and reposition.
8. Remove windshield washer bottle.
9. Disconnect breather hose.
10. Disconnect PCV hose.
11. Disconnect ignition coil electrical connectors.
12. Remove valve cover.
13. Raise vehicle.
14. Remove right splash shield.
15. Set engine to TDC.
16. Remove accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
17. Remove lower A/C compressor bolts if equiped.
18. Remove lower A/C compressor mount.
19. Remove accessory drive belt lower idler pulley.
20. Remove crankshaft and water pump pulleys.
21. Remove right side engine mount bracket lower bolt.
22. Remove timing chain cover lower bolts.
23. Disconnect oxygen sensor electrical connectors.
24. Remove exhaust pipe at manaverter (AWD).
25. Remove manaverter support bracket retaining bolts (AWD).
26. Lower vehicle.
27. Remove power steering pump and set aside.
28. Support engine with suitable jack.
29. Remove right engine mount.
30. Remove accessory drive upper idler pulley.
31. Remove right upper engine mount bracket.
32. Remove accessory drive belt tensioner.
33. Remove upper timing chain cover retaining bolts.
34. Remove timing chain cover.
35. Remove timing chain tensioner.
36. Remove timing chain.
37. Remove timing chain guides.
38. Disconnect fuel line at the fuel rail.
39. Disconnect fuel injector electrical connectors.
40. Disconnect top engine electrical connectors and reposition harness.
41. Remove fuel rail.
42. Remove lower intake manifold support bracket retaining bolt.
PM ENGINE 1.8L WORLD 9 - 1471

43. Disconnect electronic throttle control electrical connector.

44. Disconnect map sensor electrical connector.
45. Disconnect vacuum lines at intake.
46. Remove intake manifold retaining bolts.
47. Remove upper radiator hose retaining bolts.
48. Remove intake manifold.
49. Remove coolant outlet manifold and set aside.
50. Remove ground strap at right rear of cylinder head.
51. Remove oxygen sensor from maniverter (AWD).
52. Remove maniverter heat shields (AWD).
53. Remove maniverter retaining bolts (AWD).
54. Remove maniverter from cylinder head and reposition out of the way (AWD).
55. Remove camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

NOTE: All of the cylinder head bolts have captured

washersEXCEPTthe front two (1).

56. Remove cylinder head bolts.

57. Remove cylinder head from engine block.
58. Inspect and clean cylinder head and block sealing
surfaces. Refer to Cleaning and Inspection in this
section for procedures.

NOTE: Ensure cylinder head bolt holes in the

block are clean, dry (free of residual oil or cool-
ant), and threads are not damaged.

CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of alumi-
num engine components and multi-layer steel cylinder head gaskets.

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCEDURE). Be
careful not to gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.

INSPECTION
NOTE: Replacement cylinder heads will come complete with valves, seals, springs, retainers, keepers, lash
buckets, and camshafts.
9 - 1472 ENGINE 1.8L WORLD PM

1. Cylinder head must be flat within 0.1 mm (0.004

in.).

2. Inspect camshaft bearing journals for scoring.

3. Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
4. Using a small hole gauge and a micrometer, mea-
sure valve guides in 3 places top (1), middle (2),
and bottom (3). (Refer to 9 - ENGINE - SPECIFI-
CATIONS) Replace guides if they are not within
specification.
5. Check valve guide height.
6. Prior to installing cylinder head, the cylinder block
should be checked for flatness (Refer to 9 -
ENGINE/ENGINE BLOCK - INSPECTION).

INSTALLATION - CYLINDER HEAD

NOTE: Ensure cylinder head bolt holes in the
block are clean, dry (free of residual oil or cool-
ant), and threads are not damaged.

NOTE: The Cylinder head bolts should be exam-

ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced.

Necking can be checked by holding a scale or straight

edge against the threads. If all the threads do not con-
tact the scale (2), the bolt should be replaced.
PM ENGINE 1.8L WORLD 9 - 1473

CAUTION: Always replace the variable valve timing

filter screen (3) when servicing the head gasket or
engine damage could result.

1. Replace the variable valve timing filter screen (3).

2. Place two pea size dots of RTV (1) on cylinder

block as shown.

3. Position the new cylinder head gasket on engine

block with the part number facing up. Ensure gas-
ket is seated over the locating dowels in block.
4. Place two pea size dots of RTV (1) on cylinder
head gasket as shown.

NOTE: The head must be installed within 15 min-

utes before the RTV skins.

5. Position cylinder head onto engine block.

9 - 1474 ENGINE 1.8L WORLD PM

NOTE: The front two cylinder head bolts do not

have captured washers. The washers must be
installed with the bevel up towards the bolt head.

6. Install washers (1) for the front two cylinder head

bolts.

7. Before installing the bolts, the threads should be

lightly coated with engine oil.
8. Install the cylinder head bolts and torque in the
sequence shown above.
• First: All to 30 N·m (25 ft. lbs.)
• Second: All to 61 N·m (50 ft. lbs.)
• Third: All to 61 N·m (45 ft. lbs.)
• Fourth: All an additional 90°

CAUTION: Do not use a torque wrench for the

Fourth step.

9. Install camshafts. (Refer to 9 - ENGINE/CYLINDER

HEAD/CAMSHAFT(S) - INSTALLATION).
10. Install cylinder head cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER -
INSTALLATION).
11. Install maniverter/exhaust manifold to cylinder head. Torque fasteners to 34 N·m (25 ft.lbs.).
12. Install heat shields.Torque fasteners to 9 N·m ( ).
13. Install oxygen sensor in maniverter.
14. Install ground strap at right rear of cylinder head.
PM ENGINE 1.8L WORLD 9 - 1475

15. Install coolant manifold.

16. Install intake manifold.
17. Install intake manifold bolts and torque to 24 N·m (18 ft.lbs.).
18. Install upper radiator hose retaining bracket.
19. Install timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTAL-
LATION).
20. Install timing chain cover, torque m6 bolts to 12 N·m (105 in.lbs.) and m8 bolts to 23 N·m (17 ft.lbs.).
21. Connect cam sensor wiring connector.
22. Install spark plugs and torque to 27 N·m (20 ft.lbs.).
23. Install ignition coils and torque to 8 N·m (70 in.lbs.).
24. Install power steering pump reservoir/bracket to cylinder head.
25. Install exhaust pipe to manifold. Torque fasteners to 28 N·m (20 ft. lbs.).
26. Install accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
27. Connect engine coolant temperature sensor connector.
28. Connect upper radiator hose. Connect heater hoses to thermostat housing.
29. Install heater tube support bracket to cylinder head.
30. Install fastener attaching dipstick tube to lower intake manifold
31. Connect fuel supply line quick-connect at the fuel rail assembly (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCEDURE).
32. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
33. Connect negative cable to battery.
34. Install clean air hose and air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
9 - 1476 ENGINE 1.8L WORLD PM

CAMSHAFT(S)
DESCRIPTION
Both camshafts have six bearing journal surfaces and two cam lobes per cylinder. Flanges on the third journal con-
trol camshaft end play. Cam position sensors are located on the intake and exhaust camshafts on the rear of the
cylinder head.

OPERATION
The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined
lobes to provide accurate valve timing and duration.

STANDARD PROCEDURE
MEASURING CAMSHAFT END PLAY
1. Using a suitable tool, move camshaft as far rear-
ward as it will go.
2. Zero dial indicator.
3. Move camshaft as far forward as it will go.
4. Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
5. If end play is excessive, check cylinder head and
camshaft for wear; replace as necessary.

REMOVAL
1. Remove engine cover by pulling upward.
2. Disconnect negative battery cable.
3. Remove cylinder head cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
4. Raise vehicle.
5. Remove right splash shield.
PM ENGINE 1.8L WORLD 9 - 1477

6. Remove timing tensioner plug from front cover.

7. Insert small allen wrench and lift ratchet (2) upward to release the tensioner. Leave the allen wrench installed
during the remainder of this procedure.
8. Insert wedge 9701 (1).
9 - 1478 ENGINE 1.8L WORLD PM

9. Lightly tap Wedge 9701(2) into place.

10. Remove the front camshaft bearing cap.

11. Slowly remove the remaining camshaft bearing
bolts one turn at a time following the above
sequence.

12. Remove intake camshaft (1) by lifting the rear of

the camshaft upward.
PM ENGINE 1.8L WORLD 9 - 1479

13. Rotate the camshaft while lifting out of the front

bearing cradle.

14. Lift the timing chain (2) off the sprocket (1).
15. Remove exhaust camshaft.

CLEANING
Clean camshafts with a suitable solvent.

INSPECTION
1. Inspect camshaft bearing journals for damage and
binding. If journals are binding, check the cylinder
head for damage. Also check cylinder head oil
holes for clogging.
2. Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.

NOTE: If camshaft is replaced due to lobe wear or

damage, always replace the lash buckets.
9 - 1480 ENGINE 1.8L WORLD PM

INSTALLATION
1. Identify which front cam cap (1) is installed on the
engine you are working on.
2. The cam cap (1) is numbered (2) either one, two,
or three, this corresponds to the select fit bearing
to use.

3. Install the corresponding select fit bearing that will

also be numbered (1) one, two, or three.
4. Oil all of the camshaft journals with clean engine
oil.
5. Install exhaust camshaft and position on bearing
journals in the cylinder head.

6. Align exhaust cam timing mark so it is parallel to

the cylinder head as shown.