Vue 2002-2005

Cylinder Head

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Removal & Installation



2.2L Engine

WARNING
Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    The negative battery cable
     
    The Intake Air Temperature (IAT) sensor connection
     
    The air cleaner assembly
     
    The ignition module assembly
     
    The Electronic Control Module (ECM) connections
     
    The oil dipstick tube bolt
     
    The throttle body electrical connection
     
    The electrical connector from the fuel injector harness and attachment at the bottom of the intake manifold
     
    The electrical connector at the purge solenoid and Manifold Absolute Pressure (MAP) sensor
     
    The vacuum hose at the brake booster
     
    The coolant pipe bracket bolts from the cylinder head
     
    The degas hose clamp from the cylinder head and fuel rail and position aside
     
    The ground strap from the rear cam cover
     
    The fuel rail bracket from the cam cover
     
    The fuel lines
     
    The cam (valve) cover
     

  10.  
  11. Position the No. 1 piston 60° Before Top Dead Center (BTDC) using a 24mm wrench to rotate the camshafts in a clockwise motion and make sure the diamond shaped hole on the intake sprocket is at the 12 o-clock position.
  12.  
  13. Remove the upper timing guide.
    NOTE
    Remove the timing chain tensioner to unload chain tension before removing the timing chain.



    Click image to see an enlarged view

    Fig. Position the No. 1 piston 60 degrees Before Top Dead Center (BTDC) using a 24mm wrench to rotate the camshafts in a clockwise motion and make sure the diamond shaped hole on the intake sprocket is at the 12 o-clock position-2.2L engine

  14.  
  15. Remove the fixed timing chain guide access plug.
  16.  
  17. Remove the upper fixed guide bolt using a magnetic socket.
  18.  
  19. Install a three bar engine support fixture.
  20.  
  21. Remove or disconnect the following:

    The right hand engine mount
     
    The right hand mount bracket
     
    The right wheel splash shield
     

  22.  
  23. Install a 1 in. x 2 in. x 4 in. block of wood between the oil pan and cradle.
  24.  
  25. Remove the accessory drive belt.
  26.  
  27. Remove the accessory drive belt tensioner assembly.
  28.  
  29. Install crankshaft pullet holder J38122A.
  30.  
  31. Remove or disconnect the following:

    The crankshaft balancer (damper) bolt and pulley
     
    The front cover bolts
     
    The lower water pump bolt
     
    The front cover and gasket
     
    The lower fixed guide
     
    The upper radiator hose from the cylinder head
     
    The exhaust manifold pipe nuts
     
    The front and rear Oxygen (O 2 S) sensor electrical connector
     
    The down pipe-to-intermediate pipe nuts
     
    The down pipe
     
    The exhaust camshaft sprocket bolts while holding the camshaft with a 24mm wrench and discard the camshaft sprocket bolts
     
    The exhaust sprocket
     
    The adjustable guide through the top of the cylinder head
     
    The intake camshaft sprocket bolts while holding the camshaft with a 24mm wrench and discard the camshaft sprocket bolts
     
    The intake sprocket
     
    The timing chain assembly
     
    The timing drive sprocket from the crankshaft
     

  32.  
  33. Install a floor jack to support the engine and remove the engine support fixture.
  34.  
  35. Remove the cylinder head bolts using the proper sequence.
  36.  
  37. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-2.2L engine

  38.  

To install:


NOTE
Set the crankshaft to 60° Before Top Dead Center (BTDC) to prevent contact between the pistons and valves.

  1. Install or connect the following:

    The new cylinder head gasket with the side imprinted OPEN facing up
     
    The cylinder head and align it on the dowels
     
    The new cylinder head bolts and torque them in sequence to 22 ft. lbs. (30 Nm) plus 155°
     
    The front 4 cylinder head bolts coated with Loctite® and torque them to 26 ft. lbs. (35 Nm)
     

  2.  
  3. Position the exhaust camshaft with the offset slot in the 2 o-clock position and the intake camshaft with the offset slot in the 11 o-clock position.

    Click image to see an enlarged view

    Fig. Align the copper link on the timing chain with the INT diamond timing mark



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.2L engine

  4.  
  5. Install or connect the following:
    WARNING
    Make certain that all timing marks and colored links are aligned properly before proceeding to the next step. If the timing chain is not aligned properly, severe engine damage may occur.



    The timing chain around the intake camshaft sprocket with the copper link aligned with the INT diamond timing mark
     
    The sprocket to the camshaft and align it with the offset slot
     
    The new camshaft sprocket bolt, but do not tighten yet
     
    The timing chain around the crankshaft sprocket and align the silver link to the timing mark
     
    The adjustable timing chain guide through the opening on top of the cylinder head and torque the bolt to 89 inch lbs. (10 Nm)
     
    The timing chain around the exhaust camshaft sprocket with the silver link aligned with the offset slot. Install but do not tighten a new sprocket bolt
     

  6.  
  7. Torque the intake and exhaust camshaft bolts to 63 ft. lbs. (85 Nm) plus 30°.
  8.  
  9. Install or connect the following:

    The fixed timing guide and torque the bolt to 89 inch lbs. (10 Nm)
     
    The fixed timing guide bolt access plug after applying Loctite® to the threads and torque it to 30 ft. lbs. (40 Nm)
     
    The timing chain tensioner and torque the bolts 55 ft. lbs. (75 Nm)
     

  10.  
  11. Tap the top of the timing chain between the camshaft sprockets to engage the tensioner.
  12.  
  13. Install or connect the following:

    The upper timing chain guide and torque the bolts to 89 inch lbs. (10 Nm)
     
    The front cover with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    The water pump bolt and torque it to 18 ft. lbs. (25 Nm)
     
    The crankshaft damper and torque the bolt to 74 ft. lbs. (100 Nm) plus 75°
     
    The accessory drive belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)
     
    The exhaust manifold pipe to the manifold and tighten the nuts to 22 ft. lbs. (30 Nm)
     
    The oil dipstick tube bolt to 89 inch lbs. (10 Nm)
     
    The engine mount bracket and torque the bolts to 66 ft. lbs. (90 Nm)
     
    The engine mount to body nuts to 81 ft. lbs. (110 Nm)
     
    The engine mount to the bracket and torque the bolts to 41 ft. lbs. (55 Nm)
     

  14.  
  15. Install the remaining components in the reverse order of removal.
  16.  
  17. Fill the engine with the proper amount of clean oil.
  18.  
  19. Fill the cooling system.
  20.  
  21. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
  22.  
  23. Start the engine, check for leaks, and repair if necessary.
  24.  

3.0L Engine
Front Cylinder Head

WARNING
Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Intake plenum
     
    Intake manifold
     
    Intake manifold spacer
     
    Coolant bridge
     
    Upper radiator hose from the coolant extension housing
     

  10.  
  11. Properly support the powertrain assembly.

    Front transmission mount through bolt
     
    Extension housing over the coolant module
     
    Oil level indicator tube
     
    Coolant extension housing by twisting it off
     
    Front camshaft cover
     
    Electronic Control Module (ECM) from the bracket
     
    Ground wires from the lift bracket
     
    Oxygen (O 2 S) sensor electrical connector
     
    Rear lift bracket
     
    Down pipe from the exhaust manifold
     
    Front timing belt cover
     
    Timing belt
     
    Timing belt tensioner bracket
     
    Rear timing belt cover
     
    Camshaft position (CMP) sensor electrical connector
     
    Exhaust camshaft
     
    Loosen the cylinder head bolts in stages as shown
     
    Cylinder head
     
    Exhaust manifold from the cylinder head (if necessary)

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal for the front and rear cylinder heads-3.0L engine

     

  12.  

To install:

Click image to see an enlarged view

Fig. Front and rear cylinder head bolt tightening sequence-3.0L engine

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    New cylinder head gasket with the part number imprint facing the top of the engine
     
    Cylinder head
     

  2.  
  3. Torque the new cylinder head bolts, in sequence, as follows:
    1. 18 ft. lbs. (25 Nm).
    2.  
    3. 90 degree turn.
    4.  
    5. 90 degree turn.
    6.  
    7. 90 degree turn.
    8.  
    9. 15 degree turn.
    10.  

  4.  
  5. Install or connect the following:

    Coolant pipe with new sealing rings
     
    Engine lift bracket bolt and torque it to 15 ft. lbs. (20 Nm)
     
    Upper radiator hose to the coolant pipe
     
    Front transmission mount through bolt
     
    Exhaust camshaft
     
    CMP sensor electrical connector
     
    Rear timing belt cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Camshaft gears
     
    Timing belt tensioner bracket
     
    Timing belt
     
    Front timing belt cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Down pipe to the exhaust manifold
     
    O 2 S electrical connector
     
    Front camshaft cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Coolant bridge and torque the bolt to 22 ft. lbs. (33 Nm)
     
    Intake manifold spacer and torque the bolts in a spiral direction from the inside and working out to 11 ft. lbs. (16 Nm)
     
    Intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Intake plenum and torque the bolts to 71 inch lbs. (8 Nm)
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Fill the cooling system.
  10.  
  11. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
  12.  
  13. Start the engine, check for leaks, and repair if necessary.
  14.  

Rear Cylinder Head

WARNING
Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Intake plenum
     
    Intake manifold
     
    Intake manifold spacer
     
    Coolant bridge
     
    Rear camshaft cover
     
    Oxygen (O 2 S) sensor electrical connector
     
    Front timing belt cover
     
    Timing belt
     
    Timing belt tensioner bracket
     
    Camshaft gears
     
    Rear timing belt cover
     
    Exhaust manifold pipe heat shield
     
    Front exhaust manifold pipe-to-rear exhaust manifold pipe fasteners
     
    Rear exhaust manifold pipe nuts, pull the manifold pipe down and discard the gasket
     
    Exhaust Gas Recirculation (EGR)-to-exhaust manifold pipe
     
    Exhaust camshaft
     
    Cylinder head bolts
     
    Cylinder head
     
    Exhaust manifold from the cylinder head
     

  10.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm), if removed
     
    New cylinder head gasket with the part number imprint facing the top of the engine
     
    Cylinder head
     

  2.  
  3. Torque the new cylinder head bolts, in sequence, as follows:
    1. 18 ft. lbs. (25 Nm).
    2.  
    3. 90 degree turn.
    4.  
    5. 90 degree turn.
    6.  
    7. 90 degree turn.
    8.  
    9. 15 degree turn.
    10.  

  4.  
  5. Install or connect the following:

    Exhaust camshaft
     
    Rear timing belt cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Camshaft gears and torque the bolts to 37 ft. lbs. (50 Nm) plus a 60 degree turn plus another 15 degree turn
     
    Timing belt tensioner bracket and torque the bolts to 30 ft. lbs. 940 Nm)
     
    Timing belt
     
    Front timing belt cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Rear camshaft cover and torque the bolts to 71 inch lbs. (8 Nm)
     
    Exhaust manifold pipe to the manifold
     
    Exhaust manifold pipe heat shield
     
    EGR-to-exhaust manifold pipe and torque the nut to 18 ft. lbs. (25 Nm)
     
    Coolant bridge and torque the bolt to 22 ft. lbs. (33 Nm)
     
    Engine ventilation chamber and torque the bolts to 71 inch lbs. (8 Nm)
     
    Intake manifold spacer and torque the bolts to 25 ft. lbs. (20 Nm)
     
    Intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Intake plenum and torque the bolts to 71 inch lbs. (8 Nm)
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Fill the cooling system.
  10.  
  11. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
  12.  
  13. Start the engine, check for leaks, and repair if necessary.
  14.  

3.5L Engine
Left Side
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the oil dipstick tube.
  4.  
  5. Remove the oil fill cap.
  6.  
  7. Remove the Positive Crankcase Ventilation (PCV) valve and bolt.
  8.  
  9. Disconnect the ignition wring harness from the ignition coils and retaining bracket.
  10.  
  11. Remove the wiring harness bracket bolt from the cylinder head.
  12.  
  13. Remove the bolts the ignition coils.
  14.  
  15. Remove the bolts, grommets, valve cover and gasket.
  16.  
  17. Remove the seals, if required.
  18.  
  19. Remove the timing belt.
  20.  
  21. Remove the coolant bridge.
  22.  
  23. Disconnect the left bank Oxygen (O 2 S) sensors.
  24.  
  25. Remove the cylinder head bolts.
  26.  
  27. Remove the cylinder head and gasket.
  28.  

To install:

  1. Install a new gasket and the cylinder head.
  2.  
  3. Install the cylinder head bolts and tighten in the following sequence:
    1. First pass: 29 ft. lbs. (39 Nm).
    2.  
    3. Second pass: 51 ft. lbs. (69 Nm).
    4.  
    5. Final pass: 72 ft. lbs. (98 Nm).
    6.  

  4.  
  5. Connect the left bank O 2 S sensors.
  6.  
  7. Install the coolant bridge.
  8.  
  9. Install the timing belt.
  10.  
  11. Install new seals, new gasket and the cover
  12.  
  13. Install new grommets and the bolts, tighten the bolts in sequence as follows:
    1. First pass: 53 inch lbs. (6 Nm).
    2.  
    3. Final pass: 106 inch lbs. (12 Nm).
    4.  

  14.  
  15. Install the ignition coils and tighten the bolts to 106 inch lbs. (12 Nm).
  16.  
  17. Install the wiring harness bracket bolt to the cylinder head and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  20.  
  21. Install the oil dipstick tube and new O-rings.
  22.  
  23. Install a new O-rings, the PCV valve and bolt. Tighten the bolt to 106 inch lbs. (12 Nm.
  24.  
  25. Install a new O-ring and the oil fill cap.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-3.5L engine



    Click image to see an enlarged view

    Fig. Valve cover bolt tightening sequence-3.5L engine

  26.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the oil dipstick tube.
  4.  
  5. Remove the oil fill cap.
  6.  
  7. Remove the Positive Crankcase Ventilation (PCV) valve and bolt.
  8.  
  9. Disconnect the ignition wring harness from the ignition coils and retaining bracket.
  10.  
  11. Remove the wiring harness bracket bolt from the cylinder head.
  12.  
  13. Remove the bolts the ignition coils.
  14.  
  15. Remove the bolts, grommets, valve cover and gasket.
  16.  
  17. Remove the seals, if required.
  18.  
  19. Remove the timing belt.
  20.  
  21. Remove the coolant bridge.
  22.  
  23. Disconnect the left bank Oxygen (O 2 S) sensors.
  24.  
  25. Remove the cylinder head bolts.
  26.  
  27. Remove the cylinder head and gasket.
  28.  

To install:

  1. Install a new gasket and the cylinder head.
  2.  
  3. Install the cylinder head bolts and tighten in the following sequence:
    1. First pass: 29 ft. lbs. (39 Nm).
    2.  
    3. Second pass: 51 ft. lbs. (69 Nm).
    4.  
    5. Final pass: 72 ft. lbs. (98 Nm).
    6.  

  4.  
  5. Connect the left bank O 2 S sensors.
  6.  
  7. Install the coolant bridge.
  8.  
  9. Install the timing belt.
  10.  
  11. Install new seals, new gasket and the cover.
  12.  
  13. Install new grommets and the bolts, tighten the bolts in sequence as follows:
    1. First pass: 53 inch lbs. (6 Nm).
    2.  
    3. Final pass: 106 inch lbs. (12 Nm).
    4.  

  14.  
  15. Install the ignition coils and tighten the bolts to 106 inch lbs. (12 Nm).
  16.  
  17. Install the wiring harness bracket bolt to the cylinder head and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  20.  
  21. Install the oil dipstick tube and new O-rings.
  22.  
  23. Install a new O-rings, the PCV valve and bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
  24.  
  25. Install a new O-ring and the oil fill cap.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-3.5L engine



    Click image to see an enlarged view

    Fig. Valve cover bolt tightening sequence-3.5L engine

  26.  

Right Side
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the vacuum brake booster hose.
  4.  
  5. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  6.  
  7. Disconnect the Intake Air Temperature (IAT) sensor connector.
  8.  
  9. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
  10.  
  11. Disconnect the EVAP purge hose from the purge valve.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Disconnect the fuel injector connectors.
  16.  
  17. Remove the wiring harness bracket bolt from the valve rocker arm cover.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Remove the bolts, grommets, valve cover and gasket.
  22.  
  23. Remove the seals, if required.
  24.  
  25. Remove the timing belt.
  26.  
  27. Remove the coolant bridge.
  28.  
  29. Disconnect the right bank Oxygen (O 2 S) sensors.
  30.  
  31. Remove the cylinder head bolts.
  32.  
  33. Remove the cylinder head and gasket.
  34.  

To install:

  1. Install a new gasket and the cylinder head.
  2.  
  3. Install the cylinder head bolts and tighten in the following sequence:
    1. First pass: 29 ft. lbs. (39 Nm).
    2.  
    3. Second pass: 51 ft. lbs. (69 Nm).
    4.  
    5. Final pass: 72 ft. lbs. (98 Nm).
    6.  

  4.  
  5. Connect the right bank O 2 S sensors.
  6.  
  7. Install the coolant bridge.
  8.  
  9. Install the timing belt.
  10.  
  11. Install new seals, new gasket and the cover
  12.  
  13. Install new grommets and the bolts, tighten the bolts in sequence as follows:
    1. First pass: 53 inch lbs. (6 Nm).
    2.  
    3. Final pass: 106 inch lbs. (12 Nm).
    4.  

  14.  
  15. Install the ignition coils and tighten the bolts to 106 inch lbs. (12 Nm).
  16.  
  17. Install the wiring harness bracket bolt to the cylinder head and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Connect the fuel injector connectors.
  20.  
  21. Install the intake manifold.
  22.  
  23. Connect the EVAP purge hose.
  24.  
  25. Connect the IAT sensor connector.
  26.  
  27. Connect the MAP sensor connector.
  28.  
  29. Connect the vacuum brake booster hose.
  30.  
  31. Connect the ECT sensor connector.
  32.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the vacuum brake booster hose.
  4.  
  5. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  6.  
  7. Disconnect the Intake Air Temperature (IAT) sensor connector.
  8.  
  9. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
  10.  
  11. Disconnect the EVAP purge hose from the purge valve.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Disconnect the fuel injector connectors.
  16.  
  17. Remove the wiring harness bracket bolt from the valve rocker arm cover.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Remove the bolts, grommets, valve cover and gasket.
  22.  
  23. Remove the seals, if required.
  24.  
  25. Remove the timing belt.
  26.  
  27. Remove the coolant bridge.
  28.  
  29. Disconnect the right bank Oxygen (O 2 S) sensors.
  30.  
  31. Remove the cylinder head bolts.
  32.  
  33. Remove the cylinder head and gasket.
  34.  

To install:

  1. Install a new gasket and the cylinder head.
  2.  
  3. Install the cylinder head bolts and tighten in the following sequence:
    1. First pass: 29 ft. lbs. (39 Nm).
    2.  
    3. Second pass: 51 ft. lbs. (69 Nm).
    4.  
    5. Final pass: 72 ft. lbs. (98 Nm).
    6.  

  4.  
  5. Connect the right bank O 2 S sensors.
  6.  
  7. Install the coolant bridge.
  8.  
  9. Install the timing belt.
  10.  
  11. Install new seals, new gasket and the cover.
  12.  
  13. Install new grommets and the bolts, tighten the bolts in sequence as follows:
    1. First pass: 53 inch lbs. (6 Nm).
    2.  
    3. Final pass: 106 inch lbs. (12 Nm).
    4.  

  14.  
  15. Install the ignition coils and tighten the bolts to 106 inch lbs. (12 Nm).
  16.  
  17. Install the wiring harness bracket bolt to the cylinder head and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Connect the fuel injector connectors.
  20.  
  21. Install the intake manifold.
  22.  
  23. Connect the EVAP purge hose.
  24.  
  25. Connect the IAT sensor connector.
  26.  
  27. Connect the MAP sensor connector.
  28.  
  29. Connect the vacuum brake booster hose.
  30.  
  31. Connect the ECT sensor connector.
  32.  

 
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