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    1983 Peugeot 505 2.3L Diesel 4cyl

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    Nissan Pathfinder 1996-05

    Cylinder Head

    Print

    Removal & Installation



    3.3L Engines
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Remove the or disconnect the following:
      NOTE
      The cylinder head bolts vary in length. Note the bolt locations for assembly.



      Negative battery cable
       
      Accessory drive belts
       
      Front cover
       
      Timing belt. Refer to the Timing Belt unit repair section.
       
      Upper intake manifold
       
      Lower intake manifold
       
      Camshaft sprockets
       
      Rear timing cover
       
      Distributor
       
      Exhaust front pipes
       
      A/C compressor
       
      Alternator
       
      Power steering pump
       
      Accessory brackets
       
      Valve covers. Loosen the bolts in several passes and in sequence.

      Click image to see an enlarged view

      Fig. Valve cover bolt loosening sequence-3.3L engine



      Click image to see an enlarged view

      Fig. Cylinder head loosening sequence-3.3L engine



      Click image to see an enlarged view

      Fig. Exploded view of the cylinder head assembly-3.3L engine

       
      Cylinder heads with the exhaust manifolds attached. Loosen the bolts in several passes and in sequence.
       

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.3L (1996-98) engine



    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.3L (1998 and later) engine

    1. On 1996-97 engines, apply engine oil to the bolt threads and seating surfaces before installing the bolts. Tighten the bolts in sequence as follows:
      1. Step 1: Tighten all bolts to 22 ft. lbs. (29 Nm)
      2.  
      3. Step 2: Tighten all bolts to 43 ft. lbs. (59 Nm)
      4.  
      5. Step 3: Loosen all cylinder head bolts completely
      6.  
      7. Step 4: Tighten all bolts to 22 ft. lbs. (29 Nm)
      8.  
      9. Step 5: Turn all bolts 60-65 degrees clockwise
        NOTE
        Note that bolts 4, 7, 9 and 12 are longer than the others.

      10.  

    2.  
    3. On 1998 and later engines, install the cylinder heads and the lower intake manifold at the same time. Tighten the bolts in sequence as follows:
      1. Step 1: Tighten the cylinder head bolts to 22 ft. lbs. (29 Nm)
      2.  
      3. Step 2: Tighten the cylinder head bolts to 43 ft. lbs. (59 Nm)
      4.  
      5. Step 3: Loosen all cylinder head bolts completely
      6.  
      7. Step 4: Tighten the cylinder head bolts to 84 inch lbs. (10 Nm)
      8.  
      9. Step 5: Tighten the intake manifold fasteners to 35 inch lbs. (4 Nm)
      10.  
      11. Step 6: Tighten the intake manifold fasteners to 13 ft. lbs. (18 Nm)
      12.  
      13. Step 7: Tighten the intake manifold fasteners to 12-14 ft. lbs. (16-20 Nm)
      14.  
      15. Step 8: Loosen all intake fasteners completely
      16.  
      17. Step 9: Tighten the cylinder head bolts to 22 ft. lbs. (29 Nm)
      18.  
      19. Step 10: Tighten the cylinder head bolts 60-65 degrees OR tighten to 40-47 ft. lbs. (54-64 Nm)
      20.  
      21. Step 11: Tighten the cylinder head sub-bolts to 80-105 inch lbs. (9-12 Nm)
      22.  
      23. Step 12: Tighten the intake manifold fasteners to 35 inch lbs. (4 Nm)
      24.  
      25. Step 13: Tighten the intake manifold fasteners to 78 inch lbs. (9 Nm)
      26.  
      27. Step 14: Tighten the intake manifold fasteners to 70-84 inch lbs. (6-7 Nm)
      28.  

    4.  
    5. Install or connect the following:

      Valve covers
       
      Accessory brackets
       
      Power steering pump
       
      Alternator
       
      A/C compressor
       
      Exhaust front pipes
       
      Distributor
       
      Rear timing cover
       
      Camshaft sprockets
       
      Upper intake manifold
       
      Timing belt
       
      Front cover
       
      Accessory drive belts
       
      Negative battery cable
       

    6.  
    7. Fill the cooling system.
    8.  
    9. Start the engine and check for leaks.
    10.  

    3.5L Engine
    1. Remove the engine from vehicle.
    2.  
    3. Remove the exhaust manifolds in reverse order of installation.
    4.  
    5. Place engine on a work stand.
    6.  
    7. Remove the aluminum oil pan
    8.  
    9. Remove the timing chain.
    10.  
    11. Remove the intake manifold in reverse order of installation.
    12.  
    13. Remove the water outlet.
    14.  
    15. Remove the rear timing chain case bolts. Loosen in numerical order as shown in the figure.

      Click image to see an enlarged view

      Fig. Rear timing case loosening sequence-3.5L engine

    16.  
    17. Remove the rear timing chain case.
    18.  
    19. Remove the O-rings to cylinder head.
    20.  
    21. Remove the O-rings to cylinder block.
    22.  
    23. Remove the intake valve timing control solenoid valves.
    24.  
    25. Remove the intake and exhaust camshafts and camshaft brackets. Equally loosen camshaft bracket bolts in several steps in the numerical order shown in the figure. For reinstallation, be sure to put marks on camshaft bracket before removal.

      Click image to see an enlarged view

      Fig. Right camshaft loosening sequence-3.5L engine



      Click image to see an enlarged view

      Fig. Left camshaft loosening sequence-3.5L engine

    26.  
    27. Remove the RH and LH camshaft chain tensioners from cylinder head.
    28.  
    29. Remove the cylinder head bolts. Cylinder head bolts should be loosened in two or three steps.
    30.  
    31. Remove the cylinder head.
    32.  

    To install:

    1. Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper. Also remove old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt hole and thread.
    2.  
    3. Before installing cam bracket, remove old liquid gasket from mating surface using a scraper.
    4.  
    5. Before installing the cylinder head gasket, be sure that No. 1 cylinder is at TDC. At this time, the crankshaft key should face toward the right bank.
    6.  
    7. Install cylinder heads with new gaskets.
      NOTE
      Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.


      CAUTION
      Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones. Limit (d1 - d2): 0.0043 in. Lubricate threads and seat surfaces of the bolts with new engine oil.



      Click image to see an enlarged view

      Fig. Head bolt checking-3.5L engine



      Click image to see an enlarged view

      Fig. Right cylinder head bolt torque sequence-3.5L and 4.0L engines



      Click image to see an enlarged view

      Fig. Left cylinder head bolt torque sequence-3.5L and 4.0L engines

    8.  
    9. Install cylinder head outside bolts Tighten in numerical order shown in the figure. Tightening procedure:
      1. Tighten all bolts to 98 Nm (10 kg-m, 72 ft-lb).
      2.  
      3. Completely loosen all bolts.
      4.  
      5. Tighten all bolts to 34 to 44 Nm (3.5 to 4.5 kg-m, 25 to 33 ft-lb).
      6.  
      7. Turn all bolts 90 to 95 degrees clockwise.
      8.  
      9. Turn all bolts 90 to 95 degrees clockwise.
      10.  

    10.  
    11. Install camshaft chain tensioners on both sides of cylinder head.
    12.  
    13. Install exhaust and intake camshafts and camshaft brackets.
      NOTE
      Intake camshaft has a drill mark on camshaft sprocket mounting flange. Install it on the intake side. Position camshaft. RH exhaust camshaft dowel pin at about 10 o-clock; LH exhaust camshaft dowel pin at about 2 o-clock



      Click image to see an enlarged view

      Fig. Camshaft identification-3.5L engine

    14.  
    15. Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head. Use Genuine RTV silicone sealant or equivalent. Install camshaft brackets in their original positions. Align stamp mark as shown in the figure. If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Valve clearance (Cold):
      NOTE
      Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them.



      Click image to see an enlarged view

      Fig. Right camshaft bolt torque sequence-3.5L engine



      Click image to see an enlarged view

      Fig. Left camshaft bolt torque sequence-3.5L engine



      Intake 0.26 - 0.34 mm (0.010 - 0.013 in)
       
      Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in)
       

    16.  
    17. Install intake valve timing control solenoid valves.
    18.  
    19. Install O-rings to cylinder block.
    20.  
    21. Install O-rings to cylinder head.
    22.  
    23. Apply sealant to the hatched portion of rear timing chain case. Apply continuous bead of liquid gasket to mating surface of rear timing chain case. Before installation, wipe off the protruding sealant.
    24.  
    25. Align rear timing chain case with dowel pins, then install on cylinder head and block.
    26.  
    27. Tighten rear chain case bolts.

      Click image to see an enlarged view

      Fig. Rear timing case bolt torque sequence-3.5L engine

      1. Tighten bolts in numerical order shown in the figure.
      2.  
      3. Repeat above step a.
      4.  

    28.  
    29. Reinstall all removed parts in reverse order of removal.
    30.  

    4.0L Engine
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the or disconnect the following:

      Negative battery cable
       
      Camshaft
       
      Intake manifold
       
      Exhaust manifold
       
      Thermostat assembly
       
      Heater hoses
       

    6.  
    7. Remove the cylinder head bolts in the proper sequence.
    8.  
    9. Remove the cylinder head and gaskets.
    10.  

    To install:

    1. Install a new cylinder head gasket.
    2.  
    3. Turn the crankshaft until the No. 1 piston is set at Top Dead Center (TDC).
      NOTE
      The crankshaft key should line up with the right bank cylinder center line.

    4.  
    5. Install the cylinder head and tighten the bolts in sequence as follows:
      1. Tighten bolts to 72 ft. lbs. (98 Nm).
      2.  
      3. Completely loosen all bolts.
      4.  
      5. Tighten bolts to 29 ft. lbs. (39 Nm).
      6.  
      7. Tighten bolts an additional 90 degrees.
      8.  
      9. Tighten bolts 90 degrees once more.
      10.  

    6.  
    7. Install or connect the following:

      Heater hoses
       
      Thermostat assembly
       
      Exhaust manifold
       
      Intake manifold
       
      Camshaft
       
      Negative battery cable
       

    8.  
    9. Refill the cooling system to the correct level.
    10.  
    11. Start the engine and check for leaks.
    12.  

     
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