Infiniti Car 1998-05

Cylinder Head 1

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Engine side cover
     
    Radiator
     
    Air duct to intake manifold
     
    ASCD actuator
     
    Vacuum and fuel hoses
     
    Electrical connectors and wiring
     
    Spark plugs
     
    Rocker cover bolts in sequence
     
    Rocker cover
     
    Steering pump
     
    Intake manifold supports
     
    Water pipe assembly and set the No. 1 piston at Top Dead Center (TDC) of its compression stroke
     

  8.  


NOTE
Rotate the crankshaft until the mating mark on the camshaft sprocket is properly set.



Timing chain tensioner
 
Distributor. Do not turn the rotor with the distributor removed.
 
Camshaft sprockets and brackets
 
Starter
 
Heater hoses
 
Cylinder head bolts in the proper sequence
 

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.0L engine

  1. Apply liquid gasket to the top of the chain cover where it meets the cylinder block before installing the head gasket.
  2.  
  3. Install the gasket and cylinder head on the block.
  4.  


NOTE
Cylinder head bolts may be reused providing the dimension from the bottom of the head to the end of the bolt does not exceed 6.228 in. (158.2mm). If the dimension exceeds the specification, replace the cylinder head bolts.

  1. Tighten the cylinder head bolts as follows:
    1. Tighten all bolts to 29 ft. lbs. (39 Nm) using the proper sequence.
    2.  
    3. Tighten all bolts to 58 ft. lbs. (78 Nm) using the proper sequence.
    4.  
    5. Loosen all bolts completely.
    6.  
    7. Tighten all bolts to 25-33 ft. lbs. (34-44 Nm) using the proper sequence.
    8.  
    9. Tighten all bolts 90-95°.
    10.  
    11. Tighten all bolts an additional 90-95°.
    12.  

  2.  
  3. Install or connect the following:

    Heater hoses
     
    Camshafts and brackets. Ensure that the camshaft keys are at 12 o'clock.
     

  4.  
  5. The procedure for tightening camshaft bolts must be followed exactly to prevent camshaft damage. Tighten the bolts as follows:
    1. Tighten the right camshaft bolts Nos. 9 and 10 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 8 to the same amount.
    2.  
    3. Tighten the left camshaft bolts No. 11 and No. 12 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 10 to the same amount.
    4.  
    5. Tighten all bolts in sequence to 54 inch lbs. (6 Nm).
    6.  
    7. Tighten all bolts in sequence again. Tighten type A, B, and D bolts to 78-102 inch lbs. (9-12 Nm) and type C bolts to 13-19 ft. lbs. (18-25 Nm).
    8.  

  6.  
  7. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Tighten the sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  8.  
  9. Install or connect the following:

    Timing chain guide, distributor, chain tensioner, oil filter bracket and power steering oil pump bracket
     
    Intake manifold supports
     
    Rocker cover. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm).
     


    Click image to see an enlarged view

    Fig. Tighten the rocker cover bolts according to the sequence shown-2.0L engine

    Spark plugs, power steering pump, alternator, water pump pulley and drive belts, air duct to the intake manifold and the radiator
     
    Vacuum and fuel hoses and reconnect all electrical connections
     
    Engine undercover
     
    Right front wheel
     
    Negative battery cable
     

  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Rotate the crankshaft until the mating mark on the camshaft sprocket is properly set.



    Negative battery cable
     
    Right front wheel
     
    Engine side cover
     
    Radiator
     
    Air duct to intake manifold
     
    ASCD actuator
     
    Vacuum and fuel hoses
     
    Electrical connectors and wiring
     
    Spark plugs
     
    Rocker cover bolts in sequence
     
    Rocker cover
     
    Steering pump
     
    Intake manifold supports
     
    Water pipe assembly and set the No. 1 piston at Top Dead Center (TDC) of its compression stroke
     



    Timing chain tensioner
     
    Distributor. Do not turn the rotor with the distributor removed
     
    Camshaft sprockets and brackets
     
    Starter
     
    Heater hoses
     
    Cylinder head bolts in the proper sequence
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.0L engine

  1. Apply liquid gasket to the top of the chain cover where it meets the cylinder block before installing the head gasket.
  2.  
  3. Install the gasket and cylinder head on the block.
    NOTE
    Cylinder head bolts may be reused providing the dimension from the bottom of the head to the end of the bolt does not exceed 6.228 in. (158.2mm). If the dimension exceeds the specification, replace the cylinder head bolts.

  4.  
  5. Tighten the cylinder head bolts as follows:
    1. Tighten all bolts to 29 ft. lbs. (39 Nm) using the proper sequence.
    2.  
    3. Tighten all bolts to 58 ft. lbs. (78 Nm) using the proper sequence.
    4.  
    5. Loosen all bolts completely.
    6.  
    7. Tighten all bolts to 25-33 ft. lbs. (34-44 Nm) using the proper sequence.
    8.  
    9. Tighten all bolts 90-95°.
    10.  
    11. Tighten all bolts an additional 90-95°.
    12.  

  6.  
  7. Install or connect the following:

    Heater hoses
     
    Camshafts and brackets. Ensure that the camshaft keys are at 12 o'clock
     

  8.  
  9. The procedure for tightening camshaft bolts must be followed exactly to prevent camshaft damage. Tighten the bolts as follows:
    1. Tighten the right camshaft bolts Nos. 9 and 10 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 8 to the same amount.
    2.  
    3. Tighten the left camshaft bolts No. 11 and No. 12 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 10 to the same amount.
    4.  
    5. Tighten all bolts in sequence to 54 inch lbs. (6 Nm).
    6.  
    7. Tighten all bolts in sequence again. Tighten type A, B, and D bolts to 78-102 inch lbs. (9-12 Nm) and type C bolts to 13-19 ft. lbs. (18-25 Nm).
    8.  

  10.  
  11. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Tighten the sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  12.  
  13. Install or connect the following:

    Timing chain guide, distributor, chain tensioner, oil filter bracket and power steering oil pump bracket
     
    Intake manifold supports
     
    Rocker cover. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm)

    Click image to see an enlarged view

    Fig. Tighten the rocker cover bolts according to the sequence shown-2.0L engine

     
    Spark plugs, power steering pump, alternator, water pump pulley and drive belts, air duct to the intake manifold and the radiator
     
    Vacuum and fuel hoses and reconnect all electrical connections
     
    Engine under cover
     
    Right front wheel
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Rotate the crankshaft until the mating mark on the camshaft sprocket is properly set.



    Negative battery cable
     
    Right front wheel
     
    Engine side cover
     
    Radiator
     
    Air duct to intake manifold
     
    ASCD actuator
     
    Vacuum and fuel hoses
     
    Electrical connectors and wiring
     
    Spark plugs
     
    Rocker cover bolts in sequence
     
    Rocker cover
     
    Steering pump
     
    Intake manifold supports
     
    Water pipe assembly and set the No. 1 piston at Top Dead Center (TDC) of its compression stroke
     



    Timing chain tensioner
     
    Distributor. Do not turn the rotor with the distributor removed
     
    Camshaft sprockets and brackets
     
    Starter
     
    Heater hoses
     
    Cylinder head bolts in the proper sequence
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1998-2001 2.0L engine

  1. Apply liquid gasket to the top of the chain cover where it meets the cylinder block before installing the head gasket.
  2.  
  3. Install the gasket and cylinder head on the block.
    NOTE
    Cylinder head bolts may be reused providing the dimension from the bottom of the head to the end of the bolt does not exceed 6.228 in. (158.2mm). If the dimension exceeds the specification, replace the cylinder head bolts.

  4.  
  5. Tighten the cylinder head bolts as follows:
    1. Tighten all bolts to 29 ft. lbs. (39 Nm) using the proper sequence.
    2.  
    3. Tighten all bolts to 58 ft. lbs. (78 Nm) using the proper sequence.
    4.  
    5. Loosen all bolts completely.
    6.  
    7. Tighten all bolts to 25-33 ft. lbs. (34-44 Nm) using the proper sequence.
    8.  
    9. Tighten all bolts 90-95°.
    10.  
    11. Tighten all bolts an additional 90-95°.
    12.  

  6.  
  7. Install or connect the following:

    Heater hoses
     
    Camshafts and brackets. Ensure that the camshaft keys are at 12 o'clock
     

  8.  
  9. The procedure for tightening camshaft bolts must be followed exactly to prevent camshaft damage. Tighten the bolts as follows:
    1. Tighten the right camshaft bolts Nos. 9 and 10 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 8 to the same amount.
    2.  
    3. Tighten the left camshaft bolts No. 11 and No. 12 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 10 to the same amount.
    4.  
    5. Tighten all bolts in sequence to 54 inch lbs. (6 Nm).
    6.  
    7. Tighten all bolts in sequence again. Tighten type A, B, and D bolts to 78-102 inch lbs. (9-12 Nm) and type C bolts to 13-19 ft. lbs. (18-25 Nm).
    8.  

  10.  
  11. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Tighten the sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  12.  
  13. Install or connect the following:

    Timing chain guide, distributor, chain tensioner, oil filter bracket and power steering oil pump bracket
     
    Intake manifold supports
     
    Rocker cover. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm)

    Click image to see an enlarged view

    Fig. Tighten the rocker cover bolts according to the sequence shown-1998-2001 2.0L engine

     
    Spark plugs, power steering pump, alternator, water pump pulley and drive belts, air duct to the intake manifold and the radiator
     
    Vacuum and fuel hoses and reconnect all electrical connections
     
    Engine under cover
     
    Right front wheel
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Rotate the crankshaft until the mating mark on the camshaft sprocket is properly set.



    Negative battery cable
     
    Right front wheel
     
    Engine side cover
     
    Radiator
     
    Air duct to intake manifold
     
    ASCD actuator
     
    Vacuum and fuel hoses
     
    Electrical connectors and wiring
     
    Spark plugs
     
    Rocker cover bolts in sequence
     
    Rocker cover
     
    Steering pump
     
    Intake manifold supports
     
    Water pipe assembly and set the No. 1 piston at Top Dead Center (TDC) of its compression stroke
     



    Timing chain tensioner
     
    Distributor. Do not turn the rotor with the distributor removed.
     
    Camshaft sprockets and brackets
     
    Starter
     
    Heater hoses
     
    Cylinder head bolts in the proper sequence
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2002 2.0L engine

  1. Apply liquid gasket to the top of the chain cover where it meets the cylinder block before installing the head gasket.
  2.  
  3. Install the gasket and cylinder head on the block.
    NOTE
    Cylinder head bolts may be reused providing the dimension from the bottom of the head to the end of the bolt does not exceed 6.228 in. (158.2mm). If the dimension exceeds the specification, replace the cylinder head bolts.

  4.  
  5. Tighten the cylinder head bolts as follows:
    1. Tighten all bolts to 29 ft. lbs. (39 Nm) using the proper sequence.
    2.  
    3. Tighten all bolts to 58 ft. lbs. (78 Nm) using the proper sequence.
    4.  
    5. Loosen all bolts completely.
    6.  
    7. Tighten all bolts to 25-33 ft. lbs. (34-44 Nm) using the proper sequence.
    8.  
    9. Tighten all bolts 90-95°.
    10.  
    11. Tighten all bolts an additional 90-95°.
    12.  

  6.  
  7. Install or connect the following:

    Heater hoses
     
    Camshafts and brackets. Ensure that the camshaft keys are at 12 o'clock.
     

  8.  
  9. The procedure for tightening camshaft bolts must be followed exactly to prevent camshaft damage. Tighten the bolts as follows:
    1. Tighten the right camshaft bolts Nos. 9 and 10 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 8 to the same amount.
    2.  
    3. Tighten the left camshaft bolts No. 11 and No. 12 to 18 inch lbs. (2 Nm). Tighten bolts 1 through 10 to the same amount.
    4.  
    5. Tighten all bolts in sequence to 54 inch lbs. (6 Nm).
    6.  
    7. Tighten all bolts in sequence again. Tighten type A, B, and D bolts to 78-102 inch lbs. (9-12 Nm) and type C bolts to 13-19 ft. lbs. (18-25 Nm).
    8.  

  10.  
  11. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Tighten the sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  12.  
  13. Install or connect the following:

    Timing chain guide, distributor, chain tensioner, oil filter bracket and power steering oil pump bracket
     
    Intake manifold supports
     
    Rocker cover. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Tighten the rocker cover bolts according to the sequence shown-2002 2.0L engine

     
    Spark plugs, power steering pump, alternator, water pump pulley and drive belts, air duct to the intake manifold and the radiator
     
    Vacuum and fuel hoses and reconnect all electrical connections
     
    Engine undercover
     
    Right front wheel
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.
  18.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  


NOTE
Before disconnecting any hoses or connectors, note the locations for reassembly.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Left side ornament cover
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and the harness connections
     
    Evaporative emissions (EVAP) canister purge hose
     
    Ignition coils from the spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Right side intake manifold collector supports and remove the collector. Remove the manifold from the cylinder head.
     
    Fuel tube assembly
     
    Rocker arm covers
     
    Engine undercover
     
    Engine side cover
     
    Power steering oil pump and belt
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors.
     

  2.  
  3. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.

    Crankshaft pulley
     
    Air compressor and bracket
     
    Timing chain tensioner and slack side chain guide
     
    Engine oil pan
     

  4.  
  5. Remove the camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
  6.  
  7. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
  8.  


    Click image to see an enlarged view

    Fig. Right cylinder head bolt loosening sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Left cylinder head bolt loosening sequence-3.0L engine



NOTE
Keep all bearing caps and camshafts in proper order for reinstallation.

  1. Loosen the cylinder head bolts in sequence.
  2.  

To install:

  1. Turn the crankshaft until the No. 1 piston is set 240° Before Top Dead Center (BTDC) on compression stroke.
  2.  
  3. Using new head gaskets, install the cylinder heads.
  4.  


    Click image to see an enlarged view

    Fig. Measuring the cylinder head bolts-3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L engine



NOTE
If possible, replacement of the head bolts is suggested.

  1. If replacement of the head bolts is not possible, perform the following bolt measurement:
    1. Measure the diameter of the head bolt (11mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt (48mm) from the bottom of the bolt.
    4.  
    5. Whenever the size difference between the 2 measurements exceeds 0.0043 in. (0.11mm) the head bolts must be replaced.
    6.  

  2.  
  3. Lubricate the head bolt threads and the bolt seat surfaces with new engine oil.
  4.  
  5. Tighten the cylinder head bolts in sequence using the following steps:
    1. Step 1: All bolts in sequence to 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Completely loosen all bolts.
    4.  
    5. Step 3: Tighten all bolts in sequence to 25-33 ft. lbs. (34-44 Nm).
    6.  
    7. Step 4: Tighten all bolts in sequence an additional 90° clockwise.
    8.  
    9. Step 5: Tighten all bolts in sequence an additional 90° clockwise.
    10.  

  6.  
  7. Install or connect the following:

    Camshaft tensioners. Tighten the tensioner mounting bolts to 75-96 inch lbs. (8.4-10.8 Nm).
     

  8.  


NOTE
The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.


NOTE
When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



Camshafts and the bearing caps
 
New O-rings to the front of the engine block
 
Crankshaft sprocket with the mating mark facing out
 

  1. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position.

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     
    Timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks.
     

  2.  
  3. Remove the left and right camshaft tensioner stopper pins.
  4.  
  5. Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.

    Lower timing chain to the water pump sprocket
     

  6.  
  7. Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.
  8.  
  9. Intake sprocket bolts and tighten to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts
  10.  
  11. Timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide
  12.  
  13. Timing cover evenly and gently. Be sure to align the dowel pin holes. Tighten the mounting bolts in sequence

    Front exhaust pipe and its support
     
    A/C compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     

  14.  
  15. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.

    Ring gear cover plate
     
    CKP (PHASE) and CMP sensors
     
    Power steering pump assembly
     
    Drive belts and the idler pulley
     
    Right front inner wheel cover and the right front wheel
     
    Engine undercovers
     
    Intake manifold, using new gaskets. Torque the nuts and bolts in sequence.
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and torque the mounting bolts to 16-18 ft. lbs. (22-25 Nm)
     
    Intake manifold collector support brackets
     
    EGR tube, using new gaskets and torque the mounting bolts to 15-20 ft. lbs. (21-26 Nm) in 2 progressive steps
     
    Spark plugs
     
    Ignition coils and torque the mounting bolts to 27-33 inch lbs. (3-4 Nm)
     
    Cylinder head cover ornament on the left side
     
    Water hoses to the cylinder head and intake manifold
     
    EVAP canister purge hoses
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct-to-intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  16.  
  17. Fill the engine with clean oil.
  18.  
  19. Fill and bleed the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and run at 3000 rpm under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  24.  
  25. Inspect the vehicle for leaks and repair if necessary.
  26.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
    NOTE
    Before disconnecting any hoses or connectors, note the locations for reassembly.

  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Left side ornament cover
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and the harness connections
     
    Evaporative emissions (EVAP) canister purge hose
     
    Ignition coils from the spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Right side intake manifold collector supports and remove the collector. Remove the manifold from the cylinder head
     
    Fuel tube assembly
     
    Rocker arm covers
     
    Engine under cover
     
    Engine side cover
     
    Power steering oil pump and belt
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS).
     

  10.  
  11. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.

    Crankshaft pulley
     
    Air compressor and bracket
     
    Timing chain tensioner and slack side chain guide
     
    Engine oil pan

    Click image to see an enlarged view

    Fig. Right cylinder head bolt loosening sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Left cylinder head bolt loosening sequence-3.0L engine

     

  12.  
  13. Remove the camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
  14.  
  15. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
    NOTE
    Keep all bearing caps and camshafts in proper order for reinstallation.

  16.  
  17. Loosen the cylinder head bolts in sequence.
  18.  

To install:

  1. Turn the crankshaft until the No. 1 piston is set 240° Before Top Dead Center (TDC) on compression stroke.

    Click image to see an enlarged view

    Fig. Measuring the cylinder head bolts-3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L engine

  2.  
  3. Using new head gaskets, install the cylinder heads.
    NOTE
    If possible, replacement of the head bolts is suggested.

  4.  
  5. If replacement of the head bolts is not possible, perform the following bolt measurement:
    1. Measure the diameter of the head bolt (11mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt (48mm) from the bottom of the bolt.
    4.  
    5. Whenever the size difference between the 2 measurements exceeds 0.0043 in. (0.11mm) the head bolts must be replaced.
    6.  

  6.  
  7. Lubricate the head bolt threads and the bolt seat surfaces with new engine oil.
  8.  
  9. Tighten the cylinder head bolts in sequence using the following steps:
    1. Step 1: All bolts in sequence to 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Completely loosen all bolts.
    4.  
    5. Step 3: Tighten all bolts in sequence to 25-33 ft. lbs. (34-44 Nm).
    6.  
    7. Step 4: Tighten all bolts in sequence an additional 90° clockwise.
    8.  
    9. Step 5: Tighten all bolts in sequence an additional 90° clockwise.
    10.  

  10.  
  11. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.


    NOTE
    When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners. Tighten the tensioner mounting bolts to 75-96 inch lbs. (8.4-10.8 Nm)
     



    Camshafts and the bearing caps
     
    New O-rings to the front of the engine block
     
    Crankshaft sprocket with the mating mark facing out
     

  12.  
  13. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position.

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     
    Timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks.
     

  14.  
  15. Remove the left and right camshaft tensioner stopper pins.
  16.  
  17. Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.

    Lower timing chain to the water pump sprocket
     

  18.  
  19. Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.


  20.  
  21. Intake sprocket bolts and tighten to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts
  22.  
  23. Timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide
  24.  
  25. Timing cover evenly and gently. Be sure to align the dowel pin holes. Tighten the mounting bolts in sequence

    Front exhaust pipe and its support
     
    A/C compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     

  26.  
  27. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.

    Ring gear cover plate
     
    CKP (PHASE) and CMP sensors (REF/POS)
     
    Power steering pump assembly
     
    Drive belts and the idler pulley
     
    Right front inner wheel cover and the right front wheel
     
    Engine undercovers
     
    Intake manifold, using new gaskets. Torque the nuts and bolts in sequence
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and torque the mounting bolts to 16-18 ft. lbs. (22-25 Nm)
     
    Intake manifold collector support brackets
     
    EGR tube, using new gaskets and torque the mounting bolts to 15-20 ft. lbs. (21-26 Nm) in 2 progressive steps
     
    Spark plugs
     
    Ignition coils and torque the mounting bolts to 27-33 inch lbs. (3-4 Nm)
     
    Cylinder head cover ornament on the left side
     
    Water hoses to the cylinder head and intake manifold
     
    EVAP canister purge hoses
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct-to-intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  28.  
  29. Fill the engine with clean oil.
  30.  
  31. Fill and bleed the cooling system.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and run at 3000 rpm under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  36.  
  37. Inspect the vehicle for leaks and repair if necessary.
  38.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
    NOTE
    Before disconnecting any hoses or connectors, note the locations for reassembly.

  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Left side ornament cover
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and the harness connections
     
    Evaporative emissions (EVAP) canister purge hose
     
    Ignition coils from the spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Right side intake manifold collector supports and remove the collector. Remove the manifold from the cylinder head
     
    Fuel tube assembly
     
    Rocker arm covers
     
    Engine under cover
     
    Engine side cover
     
    Power steering oil pump and belt
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS).
     

  10.  
  11. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.

    Crankshaft pulley
     
    Air compressor and bracket
     
    Timing chain tensioner and slack side chain guide
     
    Engine oil pan

    Click image to see an enlarged view

    Fig. Right cylinder head bolt loosening sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Left cylinder head bolt loosening sequence-3.0L engine

     

  12.  
  13. Remove the camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
  14.  
  15. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
    NOTE
    Keep all bearing caps and camshafts in proper order for reinstallation.

  16.  
  17. Loosen the cylinder head bolts in sequence.
  18.  

To install:

  1. Turn the crankshaft until the No. 1 piston is set 240° Before Top Dead Center (TDC) on compression stroke.

    Click image to see an enlarged view

    Fig. Measuring the cylinder head bolts-3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L engine

  2.  
  3. Using new head gaskets, install the cylinder heads.
    NOTE
    If possible, replacement of the head bolts is suggested.

  4.  
  5. If replacement of the head bolts is not possible, perform the following bolt measurement:
    1. Measure the diameter of the head bolt (11mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt (48mm) from the bottom of the bolt.
    4.  
    5. Whenever the size difference between the 2 measurements exceeds 0.0043 in. (0.11mm) the head bolts must be replaced.
    6.  

  6.  
  7. Lubricate the head bolt threads and the bolt seat surfaces with new engine oil.
  8.  
  9. Tighten the cylinder head bolts in sequence using the following steps:
    1. Step 1: All bolts in sequence to 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Completely loosen all bolts.
    4.  
    5. Step 3: Tighten all bolts in sequence to 25-33 ft. lbs. (34-44 Nm).
    6.  
    7. Step 4: Tighten all bolts in sequence an additional 90° clockwise.
    8.  
    9. Step 5: Tighten all bolts in sequence an additional 90° clockwise.
    10.  

  10.  
  11. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.


    NOTE
    When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners. Tighten the tensioner mounting bolts to 75-96 inch lbs. (8.4-10.8 Nm)
     



    Camshafts and the bearing caps
     
    New O-rings to the front of the engine block
     
    Crankshaft sprocket with the mating mark facing out
     

  12.  
  13. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position.

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     
    Timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks.
     

  14.  
  15. Remove the left and right camshaft tensioner stopper pins.
  16.  
  17. Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.

    Lower timing chain to the water pump sprocket
     

  18.  
  19. Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.


  20.  
  21. Intake sprocket bolts and tighten to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts
  22.  
  23. Timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide
  24.  
  25. Timing cover evenly and gently. Be sure to align the dowel pin holes. Tighten the mounting bolts in sequence

    Front exhaust pipe and its support
     
    A/C compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     

  26.  
  27. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.

    Ring gear cover plate
     
    CKP (PHASE) and CMP sensors (REF/POS)
     
    Power steering pump assembly
     
    Drive belts and the idler pulley
     
    Right front inner wheel cover and the right front wheel
     
    Engine undercovers
     
    Intake manifold, using new gaskets. Torque the nuts and bolts in sequence
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and torque the mounting bolts to 16-18 ft. lbs. (22-25 Nm)
     
    Intake manifold collector support brackets
     
    EGR tube, using new gaskets and torque the mounting bolts to 15-20 ft. lbs. (21-26 Nm) in 2 progressive steps
     
    Spark plugs
     
    Ignition coils and torque the mounting bolts to 27-33 inch lbs. (3-4 Nm)
     
    Cylinder head cover ornament on the left side
     
    Water hoses to the cylinder head and intake manifold
     
    EVAP canister purge hoses
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct-to-intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  28.  
  29. Fill the engine with clean oil.
  30.  
  31. Fill and bleed the cooling system.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and run at 3000 rpm under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  36.  
  37. Inspect the vehicle for leaks and repair if necessary.
  38.  

 
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