Cylinder Head Assembly: Service and Repair
REMOVAL1. Remove intake manifold as outlined in Intake Manifold.
2. Remove drive belts.
3. Remove A/C compressor without disconnecting A/C pressure lines, position compressor aside.
4. Remove alternator and idler pulley brackets.
Fig. 5 Lefthand Exhaust Manifold Tightening Sequence:
5. Remove oil level gauge support and left exhaust manifold retaining bolts in reverse order of tightening, Fig. 5.
6. Remove power steering pump and bracket.
Fig. 6 Righthand Exhaust Manifold Tightening Sequence:
7. Remove right exhaust manifold retaining bolts in reverse order of manifold tightening, Fig. 6.
8. Remove both rocker covers, then the upper chain guides.
Fig. 7 No. 1 Piston At TDC:
9. Remove upper front covers, then set No. 1 piston at TDC of compression stroke by rotating crankshaft, Fig. 7.
Fig. 8 Camshaft Sprocket Mating Marks:
10. Rotate crankshaft until mating marks on camshaft sprockets are set at position, Fig. 8.
11. Remove crank angle sensor, then the chain tensioners.
12. Remove camshaft sprockets and VTC assemblies.
Fig. 9 Righthand Exhaust Camshaft Loosening Sequence:
13. Remove right side exhaust camshaft, camshaft brackets and rocker arms in order, Fig. 9.
Fig. 10 Lefthand Exhaust Camshaft Loosening Sequence:
14. Remove left side exhaust camshaft, camshaft brackets and rocker arms in order, Fig. 10.
15. Remove cylinder head outside bolts.
Fig. 11 Righthand Cylinder Head Loosening Sequence:
Fig. 12 Lefthand Cylinder Head Loosening Sequence:
16. Using sequence shown in Figs. 11 and 12, loosen cylinder head bolts in two or three steps.
17. Remove cylinder head.
INSTALLATION
1. Turn crankshaft until No. 1 piston is at approximately 120° before TDC on compression stroke to prevent any interference of valve and pistons.
2. Apply a continuous bead of liquid gasket to cylinder head mating surface of cylinder block.
3. Install cylinder heads with new gaskets.
Fig. 13 Righthand Cylinder Head Bolt Tightening Sequence:
Fig. 14 Lefthand Cylinder Head Bolt Tightening Sequence:
4. Using sequence shown in Figs. 13 and 14, tighten cylinder head bolts as follows:
a. Torque all bolts to 29 ft. lbs.
b. Using suitable angle wrench, turn all bolts marked "CRA" 65-70° clockwise.
c. Using suitable angle wrench, turn all bolts marked "CRB" 70-75° clockwise.
d. If angle wrench is not available, torque all bolts to 90 ft. lbs.
e. Loosen all bolts completely.
f. Torque all bolts to 25-33 ft. lbs.
g. Using suitable angle wrench, turn all bolts marked (1) 65-70 degrees clockwise.
h. Using suitable angle wrench, turn all bolts marked (2) 70-75 degrees clockwise.
i If angle wrench is not available, torque all bolts to 87-94 ft. lbs.
j. Install cylinder head outside bolts.
5. Install exhaust camshafts as follows:
a. Left and right camshafts have identification marks, (96E RE) indicates righthand camshaft and (96E LE) indicates lefthand camshaft.
Fig. 15 Exhaust Camshaft Keys Position:
b. Position righthand camshaft key at approximately 10 o'clock, Fig. 15.
c. Position lefthand camshaft key at approximately 12 o'clock, Fig. 15.
d. Install camshaft brackets in their original position.
e. Prior to installing lefthand exhaust camshaft end bracket, remove all remaining liquid gasket from mating surface of bracket and cylinder head, and completely clean any oil stains.
Fig. 16 Liquid Gasket Application:
f. Apply a continuous bead of liquid gasket to mating surface of lefthand exhaust camshaft bracket as shown in Fig. 16, then install bracket.
Fig. 17 Righthand Exhaust Camshaft Bolt Tightening Sequence:
Fig. 18 Lefthand Exhaust Camshaft Bolt Tightening Sequence:
g. Using sequence shown in Figs. 17 and 18, tighten brackets to specification.
6. Install righthand VTC assembly, then the righthand camshaft sprocket.
Fig. 19 Righthand Upper Timing Chain, VTC Assembly & Camshaft Sprocket Alignment:
7. Line up mating marks on righthand upper timing chain with mating marks on righthand VTC assembly and righthand camshaft sprocket, Fig. 19.
Fig. 20 Chain Tensioner Hook Setting:
8. Before installing righthand upper chain tensioner, press-in sleeve until hook can be engaged on pin. Make sure that hook used to retain chain tensioner is released, Fig. 20.
Fig. 21 Chain Tensioner Identification:
9. Install righthand chain tensioner, refer to Fig. 21 to ensure correct tensioner is installed.
10. Turn crankshaft clockwise to set No. 1 piston at TDC of compression stroke.
11. Install lefthand VTC assembly, then the lefthand camshaft sprocket.
Fig. 22 Lefthand Upper Timing Chain, VTC Assembly & Camshaft Sprocket Alignment:
12. Line up mating marks on lefthand upper timing chain with mating marks on lefthand VTC assembly and lefthand camshaft sprocket, Fig. 22.
Fig. 23 Upper Timing Chains Alignment:
13. Install lefthand chain tensioner, then ensure upper timing chains are in correct position as shown in Fig. 23.
Fig. 24 Crank Angle Sensor Positioning Maxima W/VE30DE Engine:
14. Install crank angle sensor, ensure position of camshaft and rotor position of crank angle sensor are as shown in Fig. 24.
15. Remove all traces of liquid gasket from mating surfaces and grooves of both upper timing chain covers.
16. Remove any remaining liquid gasket from mating surface of cylinder head.
17. Apply a continuous bead of liquid gasket to mating surface of both upper covers as shown in Fig. 16, then install both covers.
18. Install both upper chain guides.
19. Remove all traces of liquid gasket from rocker cover and cylinder head mating surfaces.
20. Apply a continuous bead of liquid gasket to mating surface of rocker cover gaskets and cylinder heads as shown in Fig. 16.
Fig. 25 Righthand Rocker Cover Tightening Sequence:
Fig. 26 Lefthand Rocker Cover Tightening Sequence:
21. Using sequence shown in Figs. 25 and 26, tighten rocker cover bolts as follows:
a. Torque nuts 1, 2, 12, 11, 9, 14 in that order to 35 inch lbs.
b. Torque nuts 1-14 in sequence to 7 ft. lbs.
22. Install remaining parts in reverse order of removal.