Nissan Car Altima & Sentra 1999-06

Cylinder Head 1

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Removal & Installation



1.6L & 1.8L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine drive belts
     
    Power steering pulley
     
    Oil pump and bracket
     
    Air duct to the intake manifold collector
     
    Right front wheel
     
    Engine side and under covers
     
    Front exhaust tube
     
    Cylinder head front mounting bracket
     
    Valve cover by loosening the bolts in numerical order
     
    Distributor, plug wires and spark plugs
     
    Spark plugs
     
    Intake manifold support and set the No. 1 cylinder at the Top Dead Center (TDC) position
     
    Idler pulley, camshaft sprockets and timing chains
     
    Camshafts
     

  8.  
  9. Loosen the cylinder head bolts in 2-3 steps in the reverse order of the tightening sequence to prevent warpage or cracking of the cylinder head assembly.

    Cylinder head (carefully), from the block, pulling the head up evenly from both ends. If the head seems stuck, do not pry it off. Tap lightly around the lower perimeter of the head with a rubber mallet to help break the seal. The cylinder head and the intake and exhaust manifolds are removed together.
     
    Cylinder head gasket(s)
     

  10.  

To install:

  1. Thoroughly clean both the cylinder block and head mating surfaces. Avoid scratching either surface.
  2.  
  3. Coat the threads and the seating surface of the head bolts with clean engine oil. Install the cylinder head assembly (always replace the head gasket). Install head bolts (with washers) in their proper locations.
  4.  
  5. For 1.6L engines, tighten the bolts in sequence, as follows:
    1. Step 1: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Bolts 1-10 to 43 ft. lbs. (59 Nm).
    4.  
    5. Step 3: Loosen bolts 1-10 completely.
    6.  
    7. Step 4: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    8.  
    9. Step 5: Bolts 1-10 plus 50-55 degrees.
    10.  
    11. Step 5: Bolts 11-15 to 74 inch lbs. (8 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-1.6L engine

    12.  

  6.  
  7. For 1.8L engines, tighten the bolts in sequence, as follows:
    1. Step 1: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Bolts 1-10 to 43 ft. lbs. (59 Nm).
    4.  
    5. Step 3: Loosen bolts 1-10 completely.
    6.  
    7. Step 4: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    8.  
    9. Step 5: Bolts 1-10 plus 50-55 degrees.
    10.  
    11. Step 5: Bolts 11-14 to 74 inch lbs. (8 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-1.8L engine



      Click image to see an enlarged view

      Fig. Tighten the valve cover bolts in sequence-1.6L and 1.8L engines

    12.  

  8.  
  9. Install or connect the following:

    Camshafts
     
    Idler pulley, camshaft sprockets and timing chains
     
    Intake manifold support
     
    Distributor
     
    Spark plugs and wires
     
    Distributor cap
     
    Rocker arm cover and torque the bolts to 34 inch lbs. (4 Nm)
     
    Cylinder head front mounting bracket
     
    Front exhaust tube
     
    Engine side and under covers
     
    Right front wheel
     
    Air duct to the intake manifold collector
     
    Oil pump and bracket
     
    Power steering pulley
     
    Drive belts
     
    Negative battery cable
     

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

1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine drive belts
     
    Power steering pulley
     
    Oil pump and bracket
     
    Air duct to the intake manifold collector
     
    Right front wheel
     
    Engine side and under covers
     
    Front exhaust tube
     
    Cylinder head front mounting bracket
     
    Rocker cover by loosening the bolts in numerical order
     
    Distributor, plug wires and spark plugs
     
    Spark plugs
     
    Intake manifold support and set the No. 1 cylinder at the Top Dead Center (TDC) position
     
    Idler pulley, camshaft sprockets and timing chains
     
    Camshafts
     

  8.  
  9. Loosen the cylinder head bolts in 2-3 steps in the reverse order of the tightening sequence to prevent warpage or cracking of the cylinder head assembly.
  10.  
  11. Remove or disconnect the following:

    Cylinder head (carefully), from the block, pulling the head up evenly from both ends. If the head seems stuck, do not pry it off. Tap lightly around the lower perimeter of the head with a rubber mallet to help break the seal. The cylinder head and the intake and exhaust manifolds are removed together.
     
    Cylinder head gasket(s)
     

  12.  

To install:

  1. Thoroughly clean both the cylinder block and head mating surfaces. Avoid scratching either surface.
    NOTE
    Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  2.  
  3. Coat the threads and the seating surface of the head bolts with clean engine oil. Install the cylinder head assembly (always replace the head gasket). Install head bolts (with washers) in their proper locations and torque in sequence as follows:
    1. Step 1: Set the camshafts and brackets.
    2.  
    3. Step 2: bolts No-s. 11-15 then 1-10 to 18 inch lbs. (2 Nm).
    4.  
    5. Step 3: Tighten all bolts to 53 inch lbs. (6 Nm).
    6.  
    7. Step 4: Tighten bolts 1-14 to 89 inch lbs. ( 10 Nm).
    8.  
    9. Step 5: Tighten bolts 15 to 73 inch lbs. (8 Nm).
    10.  

  4.  
  5. Install or connect the following:

    Camshafts
     
    Idler pulley, camshaft sprockets and timing chains
     
    Intake manifold support
     
    Distributor
     
    Spark plugs and wires
     
    Distributor cap
     
    Rocker arm cover and torque the bolts to 34 inch lbs. (4 Nm)
     
    Cylinder head front mounting bracket
     
    Front exhaust tube
     
    Engine side and under covers
     
    Right front wheel
     
    Air duct to the intake manifold collector
     
    Oil pump and bracket
     
    Power steering pulley
     
    Drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine drive belts
     
    Power steering pulley
     
    Oil pump and bracket
     
    Air duct to the intake manifold collector
     
    Right front wheel
     
    Engine side and under covers
     
    Front exhaust tube
     
    Cylinder head front mounting bracket
     
    Rocker cover by loosening the bolts in numerical order
     
    Distributor, plug wires and spark plugs
     
    Spark plugs
     
    Intake manifold support and set the No. 1 cylinder at the Top Dead Center (TDC) position
     
    Idler pulley, camshaft sprockets and timing chains
     
    Camshafts
     

  8.  
  9. Loosen the cylinder head bolts in 2-3 steps in the reverse order of the tightening sequence to prevent warpage or cracking of the cylinder head assembly.

    Cylinder head (carefully), from the block, pulling the head up evenly from both ends. If the head seems stuck, do not pry it off. Tap lightly around the lower perimeter of the head with a rubber mallet to help break the seal. The cylinder head and the intake and exhaust manifolds are removed together.
     
    Cylinder head gasket(s)
     

  10.  

To install:

  1. Thoroughly clean both the cylinder block and head mating surfaces. Avoid scratching either surface.
  2.  
  3. Coat the threads and the seating surface of the head bolts with clean engine oil. Install the cylinder head assembly (always replace the head gasket). Install head bolts (with washers) in their proper locations.
  4.  
  5. For 1.8L engines, tighten the bolts in sequence, as follows:
    1. Step 1: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Bolts 1-10 to 43 ft. lbs. (59 Nm).
    4.  
    5. Step 3: Loosen bolts 1-10 completely.
    6.  
    7. Step 4: Bolts 1-10 to 22 ft. lbs. (29 Nm).
    8.  
    9. Step 5: Bolts 1-10 plus 50-55 degrees.
    10.  
    11. Step 5: Bolts 11-14 to 74 inch lbs. (8 Nm).
    12.  

  6.  
  7. Install or connect the following:

    Camshafts
     
    Idler pulley, camshaft sprockets and timing chains
     
    Intake manifold support
     
    Distributor
     
    Spark plugs and wires
     
    Distributor cap
     
    Rocker arm cover and torque the bolts to 34 inch lbs. (4 Nm)
     
    Cylinder head front mounting bracket
     
    Front exhaust tube
     
    Engine side and under covers
     
    Right front wheel
     
    Air duct to the intake manifold collector
     
    Oil pump and bracket
     
    Power steering pulley
     
    Drive belts
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  


    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-1.8L engine



    Click image to see an enlarged view

    Fig. Tighten the rocker cover bolts in sequence-1.8L engines


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

    Negative battery cable
     
    Engine under covers
     
    Right front wheel and engine side cover
     
    Radiator assembly
     
    Air duct and intake manifold
     
    Drive belts and water pump pulley
     
    Alternator
     
    Power steering pump
     
    Cylinder head cover and oil separator
     
    Oil filter and power steering pump brackets
     
    Front exhaust pipe from the exhaust manifold
     
    Distributor assembly
     
    Timing chain, tensioner, chain guide and camshaft sprockets
     
    Camshafts
     
    Water hose from the cylinder block and water hose from the heater
     
    Starter motor
     
    Water pipe bolt
     
    Knock Sensor (KS) harness connector and the Exhaust Gas Recirculation (EGR) tube
     
    Cylinder outside bolts. Remove the cylinder head bolts in 2 or 3 steps.
     
    Cylinder head completely with manifolds attached
     

  8.  

To install:

  1. Check all components for wear. Replace as necessary. Clean all mating surfaces and replace the cylinder head gasket.
  2.  


NOTE
If the length of any cylinder head bolt exceeds 6.22 in. (158.2mm), replace the bolt.

  1. Install cylinder head. Torque the cylinder head bolts in the following sequence:
    1. Step 1: 29 ft. lbs. (39 Nm).
    2.  
    3. Step 2: 58 ft. lbs. (78 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence completely.
    6.  
    7. Step 4: 25-33 ft. lbs. (34-44 Nm).
    8.  
    9. Step 5: Plus 90-95 degrees clockwise in sequence.
    10.  
    11. Step 6: Plus additional 90-95 degrees.
    12.  

  2.  


NOTE
Do not turn any bolt 180-200 degrees clockwise all at once.



Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.0L engine



Click image to see an enlarged view

Fig. Tighten the rocker cover bolts in sequence-2.0L engines

  1. Install or connect the following:

    KS connector and EGR tube
     
    Starter motor and the wiring
     
    Water hoses to the engine block and heater
     
    Camshafts
     
    Camshaft sprockets timing chain guide, tensioner and timing chain
     
    Distributor assembly
     
    Front exhaust pipe to the exhaust manifold
     
    Oil filter and power steering pump brackets
     
    Cylinder head cover and oil separator
     
    Power steering pump
     
    Alternator
     
    Drive belts
     
    Air duct and intake manifold
     
    Radiator
     
    Engine side cover and right front wheel
     
    Engine under covers
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine under covers
     
    Right front wheel and engine side cover
     
    Radiator assembly
     
    Air duct and intake manifold
     
    Drive belts and water pump pulley
     
    Alternator
     
    Power steering pump
     
    Cylinder head cover and oil separator
     
    Oil filter and power steering pump brackets
     
    Front exhaust pipe from the exhaust manifold
     
    Distributor assembly
     
    Timing chain, tensioner, chain guide and camshaft sprockets
     
    Camshafts
     
    Water hose from the cylinder block and water hose from the heater
     
    Starter motor
     
    Water pipe bolt
     
    Knock Sensor (KS) harness connector and the Exhaust Gas Recirculation (EGR) tube
     
    Cylinder outside bolts. Remove the cylinder head bolts in 2 or 3 steps.
     
    Cylinder head completely with manifolds attached
     

  8.  

To install:


NOTE
Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  1. Check all components for wear. Replace as necessary. Clean all mating surfaces and replace the cylinder head gasket.
    NOTE
    If the length of any cylinder head bolt exceeds 158.2mm, replace the bolt.

  2.  
  3. Install cylinder head. Torque the cylinder head bolts in the following sequence:
    1. Step 1: 29 ft. lbs. (39 Nm).
    2.  
    3. Step 2: 58 ft. lbs. (78 Nm).
    4.  
    5. Step 3: loosen all bolts in sequence completely.
    6.  
    7. Step 4: 25-33 ft. lbs. (34-44 Nm).
    8.  
    9. Step 5: plus 90-95 degrees clockwise in sequence.
    10.  
    11. Step 6: plus additional 90-95 degrees.
      NOTE
      Do not turn any bolt 180-200 degrees clockwise all at once.

    12.  

  4.  
  5. Install or connect the following:

    KS connector and EGR tube
     
    Starter motor and the wiring
     
    Water hoses to the engine block and heater
     
    Camshafts
     
    Camshaft sprockets timing chain guide, tensioner and timing chain
     
    Distributor assembly
     
    Front exhaust pipe to the exhaust manifold
     
    Oil filter and power steering pump brackets
     
    Cylinder head cover and oil separator
     
    Power steering pump
     
    Alternator
     
    Drive belts
     
    Air duct and intake manifold
     
    Radiator
     
    Engine side cover and right front wheel
     
    Engine under covers
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

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

    Negative battery cable
     
    Engine under covers
     
    Right front wheel and engine side cover
     
    Radiator assembly
     
    Air duct and intake manifold
     
    Drive belts and water pump pulley
     
    Alternator
     
    Power steering pump
     
    Cylinder head cover and oil separator
     
    Oil filter and power steering pump brackets
     
    Front exhaust pipe from the exhaust manifold
     
    Distributor assembly
     
    Timing chain, tensioner, chain guide and camshaft sprockets
     
    Camshafts
     
    Water hose from the cylinder block and water hose from the heater
     
    Starter motor
     
    Water pipe bolt
     
    Knock Sensor (KS) harness connector and the Exhaust Gas Recirculation (EGR) tube
     
    Cylinder outside bolts. Remove the cylinder head bolts in 2 or 3 steps.
     
    Cylinder head completely with manifolds attached
     

  8.  

To install:

  1. Check all components for wear. Replace as necessary. Clean all mating surfaces and replace the cylinder head gasket.
    NOTE
    If the length of any cylinder head bolt exceeds 6.22 in. (158.2mm), replace the bolt.

  2.  
  3. Install cylinder head. Torque the cylinder head bolts in the following sequence:
    1. Step 1: 29 ft. lbs. (39 Nm).
    2.  
    3. Step 2: 58 ft. lbs. (78 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence completely.
    6.  
    7. Step 4: 25-33 ft. lbs. (34-44 Nm).
    8.  
    9. Step 5: Plus 90-95 degrees clockwise in sequence.
    10.  
    11. Step 6: Plus additional 90-95 degrees.
      NOTE
      Do not turn any bolt 180-200 degrees clockwise all at once.



      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-2.0L engine



      Click image to see an enlarged view

      Fig. Tighten the valve cover bolts in sequence-2.0L engines

    12.  

  4.  
  5. Install or connect the following:

    KS connector and EGR tube
     
    Starter motor and the wiring
     
    Water hoses to the engine block and heater
     
    Camshafts
     
    Camshaft sprockets timing chain guide, tensioner and timing chain
     
    Distributor assembly
     
    Front exhaust pipe to the exhaust manifold
     
    Oil filter and power steering pump brackets
     
    Cylinder head cover and oil separator
     
    Power steering pump
     
    Alternator
     
    Drive belts
     
    Air duct and intake manifold
     
    Radiator
     
    Engine side cover and right front wheel
     
    Engine under covers
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The valvetrain components must be reassembled in their original positions.



    Negative battery cable
     
    Intake manifold collector, exhaust manifold and all related components
     
    Distributor assembly. Using a block of wood, set a jack under the aluminum oil pan and remove the front engine mount.
     
    Cylinder head cover
     
    Timing chain and camshaft sprockets
     
    Camshafts
     

  8.  
  9. Loosen the cylinder head bolts in reverse order of tightening.
    NOTE
    A warped or cracked cylinder head could result from loosening in incorrect order. The cylinder head bolts should be loosened in 2 or 3 steps.

  10.  
  11. Remove the cylinder head and the intake manifold. Remove the cylinder head gasket. The lower timing chain will not be disengaged from crankshaft sprocket.
  12.  

To install:

  1. Clean the gasket surfaces.
  2.  
  3. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head and temporarily tighten the cylinder head bolts. This is necessary to avoid damaging the cylinder head gasket. Be sure to install washers between the bolts and cylinder head.
     
    Idler shaft assembly
     
    Upper timing chain and cover
     

  4.  
  5. Tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: 59 ft. lbs. (79 Nm).
    4.  
    5. Step 3: Loosen all the bolts completely.
    6.  
    7. Step 4: 18-25 ft. lbs. (25-34 Nm).
    8.  
    9. Step 5: Plus 86-91 degrees clockwise.

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-2.4L engine



      Click image to see an enlarged view

      Fig. Tighten the rocker arm bolts in sequence-2.4L engines

    10.  

  6.  
  7. Install or connect the following:

    Camshafts
     
    Timing chains, chain tensioner and camshaft sprockets
     
    Cylinder head cover
     
    Distributor assembly
     
    Intake manifold collector
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain cooling system and engine oil.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose and heater hose
     
    Right side fuse/relay box and move aside
     
    Engine undercover
     
    Resonator and air cleaner case
     
    Engine top cover
     
    All electrical and vacuum lines at the head
     
    Fuse hose quick connector at fuel tube side
     
    Engine harness and power steering hose bracket
     
    Timing chain
     
    Drive belt tensioner
     
    Camshafts
     
    Spark plugs
     
    Exhaust manifold
     

  8.  
  9. Support the engine from above and below with a suitable jack and hoist.
  10.  
  11. Remove or disconnect the following:

    Power steering pump and reservoir and wire aside
     
    Auxiliary drive belts
     
    A/C compressor and wire aside
     
    Upper sway bar links
     
    Front and rear engine mount through bolts
     
    Lower ball joints
     
    2 steering gear housing mounting bolts
     
    Front suspension member bolts and front suspension member
     

  12.  
  13. Loosen the cylinder head bolts in the sequence shown and remove the cylinder head.

    Click image to see an enlarged view

    Fig. Removing the front suspension member-Altima



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.5L engine-Altima and Sentra



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.5L engine-Altima and Sentra

  14.  

To install:

  1. Clean the gasket surfaces.
  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 0.43 in. (11mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt 2.17 in. (55mm) from the bottom of the bolt.
    4.  
    5. Whenever the size difference between the 2 measurements exceeds 0.0091 in. (0.23mm) the head bolts must be replaced.
    6.  

  6.  
  7. Apply clean engine oil to the bolt threads and seating surfaces and tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Loosen all the bolts completely.
    4.  
    5. Step 2: 29 ft. lbs. (33 Nm).
    6.  
    7. Step 4: Plus 75-80 degrees clockwise.
    8.  
    9. Step 5: Plus 75-80 degrees clockwise.
    10.  

  8.  
  9. Install the front suspension member and tighten the bolts to the specifications shown in the illustration.
  10.  
  11. Install or connect the following:

    2 steering gear housing mounting bolts
     
    Lower ball joints
     
    Front and rear engine mount through bolts
     
    Upper sway bar links
     
    A/C compressor
     
    Auxiliary drive belts
     
    Power steering pump and reservoir
     
    Exhaust manifold
     
    Spark plugs
     
    Camshafts
     
    Drive belt tensioner
     
    Timing chain
     
    Engine harness and power steering hose bracket
     
    Fuse hose quick connector at fuel tube side
     
    All electrical and vacuum lines at the head
     
    Engine top cover
     
    Resonator and air cleaner case
     
    Engine undercover
     
    Right side fuse/relay box and move aside
     
    Upper radiator hose and heater hose
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system and engine oil
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain cooling system and engine oil.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower cross brace
     
    Timing chain
     
    Camshafts
     
    Exhaust manifold
     

  8.  
  9. Support the engine from above and below with a suitable jack and hoist.
  10.  
  11. Loosen the cylinder head bolts in the sequence shown and remove the cylinder head.
  12.  

To install:

  1. Clean the gasket surfaces.
  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 0.47 in. (12mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt 2.17 in. (55mm) from the bottom of the bolt.
    4.  
    5. Whenever the size difference between the 2 measurements exceeds 0.0091 in. (0.23mm) the head bolts must be replaced.
    6.  

  6.  
  7. Apply clean engine oil to the bolt threads and seating surfaces and tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Loosen all the bolts completely.
    4.  
    5. Step 2: 29 ft. lbs. (33 Nm).
    6.  
    7. Step 4: Plus 75-80 degrees clockwise.
    8.  
    9. Step 5: Plus 75-80 degrees clockwise.
    10.  

  8.  
  9. Install or connect the following:

    Exhaust manifold
     
    Camshafts
     
    Timing chain
     
    Strut tower cross brace
     
    Negative battery cable
     

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

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 detaching any hoses or connectors, note the locations for reassembly.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold collector
     
    Fuel tube
     
    Intake manifold
     
    Cylinder head covers
     


    Click image to see an enlarged view

    Fig. Tighten the rocker arm bolts in sequence-3.0L and 3.5L engines

    Ignition coils
     
    Exhaust Gas Recirculation (EGR) guide tube
     
    Engine under cover
     
    Right front wheel and engine side cover
     
    Drive belts and idler pulley
     
    Steel (lower) and aluminum (upper) oil pans
     
    Water pump cover
     
    Timing chain case cover
     
    Timing chains, camshaft sprockets and related components
     
    Crankshaft sprocket
     

  2.  
  3. Loosen the bolts that secure the rear timing chain case. The bolts must be loosened in the reverse order of installation sequence.

    Rear timing case cover using seal cutter tool
     

  4.  


NOTE
Remove the O-rings from the front of the engine block.



Camshafts
 
Cylinder head bolts in the reverse order of the tightening sequence. The bolts should be loosened in 2-3 steps.
 


NOTE
A warped or cracked cylinder head could result from removing the bolts in incorrect order.



Cylinder heads from the vehicle
 
Discard the head gaskets
 

  1. Remove all traces of liquid gasket from the timing chain case and from the water pump covers.
  2.  
  3. Remove all traces of liquid gasket from the engine block.
  4.  
  5. Inspect the timing chain for excessive wear or damage and replace as necessary.
  6.  

To install:

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


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 0.43 in. (11mm) from the bottom of the bolt.
    2.  
    3. Measure the diameter of the head bolt 1.89 in. (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. Install the cylinder head bolts and torque in sequence as follows:
    1. Step 1: 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Completely loosen all bolts.
    4.  
    5. Step 3: 25-33 ft. lbs. (34-44 Nm).
    6.  
    7. Step 4: plus 90-95 degrees clockwise.
    8.  
    9. Step 5: plus 90-95 degrees clockwise.
    10.  

  4.  
  5. Install or connect the following:

    Camshafts and related components
     
    New O-rings to the front of the engine block
     

  6.  
  7. Apply sealant to the hatched portion of the of the rear timing chain case.
  8.  
  9. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block.
  10.  
  11. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).
  12.  
  13. Install or connect the following:

    Water pump cover
     
    Upper and lower oil pans
     
    Idler pulley and drive belts
     
    Cylinder head covers
     
    Intake manifold
     
    Fuel tube
     
    Intake manifold collector
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
  16.  
  17. Fill the engine with clean oil.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  


    Click image to see an enlarged view

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



    Click image to see an enlarged view

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


  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 detaching any hoses or connectors, note the locations for reassembly.

  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold collector
     
    Fuel tube
     
    Intake manifold
     
    Cylinder head covers
     
    Ignition coils
     
    Exhaust Gas Recirculation (EGR) guide tube
     
    Engine under cover
     
    Right front wheel and engine side cover
     
    Drive belts and idler pulley
     
    Steel (lower) and aluminum (upper) oil pans
     
    Water pump cover
     
    Timing chain case cover
     
    Timing chains, camshaft sprockets and related components
     
    Crankshaft sprocket
     

  10.  
  11. Loosen the bolts that secure the rear timing chain case. The bolts must be loosened in the reverse order of installation sequence.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Remove the O-rings from the front of the engine block.


    NOTE
    A warped or cracked cylinder head could result from removing the bolts in incorrect order.



    Rear timing case cover using seal cutter tool
     



    Camshafts
     
    Cylinder head bolts in the reverse order of the tightening sequence. The bolts should be loosened in 2-3 steps.
     



    Cylinder heads from the vehicle
     
    Discard the head gaskets
     

  14.  
  15. Remove all traces of liquid gasket from the timing chain case and from the water pump covers.
  16.  
  17. Remove all traces of liquid gasket from the engine block.
  18.  
  19. Inspect the timing chain for excessive wear or damage and replace as necessary.
  20.  

To install:

  1. Turn the crankshaft until the No. 1 piston is set 240 degrees before Top Dead Center (TDC) on compression stroke.
  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 0.11mm the head bolts must be replaced.
      NOTE
      Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

    6.  

  6.  
  7. Install the cylinder head bolts and torque in sequence as follows:
    1. Step 1: 72 ft. lbs. (98 Nm).
    2.  
    3. Step 2: Completely loosen all bolts.
    4.  
    5. Step 3: 25-33 ft. lbs. (24-44 Nm).
    6.  
    7. Step 4: plus 90-95 degrees clockwise.
    8.  
    9. Step 5: plus 90-95 degrees clockwise.
    10.  

  8.  
  9. Install or connect the following:

    Camshafts and related components
     
    New O-rings to the front of the engine block
     

  10.  
  11. Apply sealant to the hatched portion of the of the rear timing chain case.
  12.  
  13. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block.
  14.  
  15. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).

    Water pump cover
     
    Upper and lower oil pans
     
    Idler pulley and drive belts
     
    Cylinder head covers
     
    Intake manifold
     
    Fuel tube
     
    Intake manifold collector
     
    Negative battery cable
     

  16.  
  17. Fill the cooling system.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  

 
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