Cylinder head removal for a 2002 saturn sl2 1.9 engine

SOURCE: 2002 S series Saturn remove and replace ignition cylinder

unfortunately your cylinder's guts exploded in the cylinder housing and you will need to replace both now

SOURCE: how do i remove the head from my saturn 1.9 engine?

Removing it isn't too hard, replacing it is another story. Drain antifreeze. The top radiator hose will need to be taken loose. Air intake from front of car to filter.The fuel lines...You just need to pinch the plastic clips with a pair of needle nose pliers while you pull on the lines.The timing chain will need to come off,make sure the marks are at top dead center, bottom and top sprocket. You will need to take off the EGR valve, The vacuum lines on top of the throttle body. Vacuum line under Air intake. Throttle cable, manifold exhaust, 02 sensor, A/C compressor if you have one, just lay it aside...doesn't need to be discharged. Power steering pump need to take the bolts out of it by turning the sprocket so you can get a deep dwell socket in it...about 3 or 4 bolts there. The tension pulley needs to be taken off, of course after the belt is taken off. A few other things that are obvious by looking. Most importantly, have the head tested before putting on new gasket. The bolts should all be replace on the head since they are torque to yield. The torque procedure is 25lbs, all then 35lbs. all then turn the wrench on all of the bolts from 12 o'clock to 3 o'clock which equals 90 degrees. That will give you the torque to yield...

SOURCE: 1998 Saturn SL1 cylinder head replacement

I recommend buying a Haynes manual (about $20) from automotive store; you'll need it for this task

ZJ Limited

• 17989 Answers
• Posted on Dec 29, 2009

SOURCE: 2002 Saturn SL1 check engine light code P0303

For old models, Saturn/GM also used the same material fiberglass gasket in your model, you almost certainly have a leak from a crumpled, sucked-in gasket as I suffered (and many others). I would say going to Saturn dealership to make repairs is probably not good idea if they are going to put in the same GM intake gasket part. Maybe possible to specify Felpro gasket with whatever shop you go to if you don't do the repair yourself. I would not go too long with your car in that condition as there is localized leaning at your cyl-3, that could cause a burnt exhaust valve there.

The exhaust is extra hot venting out that cylinder. P0303 is misfire at cyl-3. Mine was P0301 (cyl-1). You may get P0507 once in a while when PCM fails to control the fast idle caused by the leak under certain conditions. Most of the time, it is very slow idle caused by 3 cylinders running. You run smoother in cold idle because the IAC opens up to increase idle and end up lowering the manifold vacuum, so the reduced vacuum causes less leaking at the failing intake manifold gasket.

I'd say try cleaning everything with your ignition before replacement; Idle problems could be caused by engine coolant sensor (ECTS). Are you sure it was changed? Did they put on a new wire connector along with it?

Hope helps.

SOURCE: how to remove and replace cylinder head on 2001

This procedure is going to need a long explanation and photos. Get yourself a repair manual on ebay.