Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Caution: – When installing camshafts, camshaft bracket, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. – Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, and camshaft bracket. – - – - Do not put Hydraulic Lash Adjusters (HLA) upside down, otherwise air will enter HLA, causing it to make a noise. Do not disassemble HLA. Attach tags to HLA so as not to mix them up. HLA should be immersed in engine oil. Removal: 1. Remove intake manifold collector. 2. Remove injector pipe assembly. 3. Remove valve covers. 4. Remove timing belt.5. Remove idler pulley and its stud bolt. 6. Remove intake manifold. 7. Disconnect front exhaust tube from exhaust manifold. 8. Remove cylinder head with exhaust manifold. Note: Cylinder head bolts should be loosened in two or three steps.

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Fig. 82: Removing/Installing Cylinder Head Gasket REMOVAL SERVICE POINT << A >> CYLINDER HEAD ASSEMBLY REMOVAL Use special tool MD998051 to loosen each bolt two or three steps in the order shown in the illustration. Fig. 83: Removing Cylinder Head Fig. 84: Identifying Cylinder Head Gasket On Cylinder Block With Identification Mark At Front Top INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION 1. Degrease the cylinder head and cylinder block gasket mounting surfaces. 2. Make sure that the gasket has the proper identification mark for the engine.

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Cylinder Head Cover Removal 1. Remove the fuel pump fuse. 2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed. 3. Disconnect the negative battery cable. 4. Drain the engine coolant. 5. Remove the intake manifold.
6. Remove the coolant reservoir. 7. Remove the front support bracket retaining bolt and the front support
bracket. 8. Remove the air filter housing. 9. Remove the rear support bracket retaining bolts and the rear support bracket.

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

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Remove outer (upper) timing chain. See TIMING CHAINS . Remove idler sprocket and shaft. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 30 . Remove camshafts. 2. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 31 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. Inspection (240SX, Altima & Frontier) 1. Inspect timing chain roller links. Replace timing chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD (EXCEPT 1997 PICKUP) table under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely. Installation (240SX, Altima & Frontier) 1. Install cylinder head and NEW gasket. Tighten cylinder head bolts in sequence shown. See Fig. 31 . See TORQUE SPECIFICATIONS . 2. Install upper timing chain. See TIMING CHAINS . Tighten all fasteners to specification. See TORQUE SPECIFICATIONS