Does the power steering pump have to be removed in order to remover cylinder head on 1997 caviled

Removal

1. Drain engine cooling system.

1. Disconnect battery ground cable (14301) .

1. Remove engine air cleaner (ACL) (9600) including air cleaner outlet tube (9B659) .

1. Loosen drive belt tensioner (6B209). Remove drive belts (8620) .

1. If LH cylinder head (6049) is being removed, perform the following:
   1. Remove oil filler cap (6766) .
   1. Remove power steering pump front mounting bracket retaining bolts.
   1. Remove generator (GEN) (10346) and belt idler pulley (8678).
   1. Remove power steering pump/generator bracket retaining bolts. Leave hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.

1. If RH cylinder head is being removed, perform the following:
   1. Remove drive belts .
   1. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor (19703) aside.
   1. Remove positive crankcase ventilation valve (PCV valve) (6A666) .

1. Remove upper intake manifold (9424) .

1. Remove valve cover retaining bolts.

1. Remove fuel injection supply manifold (9F792).

1. Remove lower intake manifold as outlined.

1. Remove exhaust manifolds (9430) as outlined.

1. Loosen rocker arm seat retaining bolts enough to allow rocker arm (6564) to be lifted off the push rod (6565) and rotate to one side.

1. Remove push rods . Identify position of each push rod . Push rods should be installed in their original position during assembly.

1. Remove cylinder head retaining bolts and discard.

1. Remove cylinder heads .

1. Remove and discard old head gaskets (6051) .

Installation

1. NOTE: Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.
   Clean cylinder head, intake manifold , valve cover (6582) and head gasket surfaces. If cylinder head was removed for head gasket replacement, check flatness and sealing areas for scratches of cylinder head and cylinder block gasket surfaces. Refer to Section 03-00 for procedure.
2. Position new head gaskets onto cylinder block (6010) using cylinder head to block dowels (6A008) for alignment.
   
   Head Gasket
   
   
   
   
   
3. Position cylinder heads onto cylinder block .
4. CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.
   -ft).
   
5. For 3.8L non-SC engine, tighten cylinder head retaining bolts in numerical sequence in three steps as follows:
   1. 20 Nm (15 Lb-Ft)
   1. 40 Nm (29 Lb-Ft)
   1. 50 Nm (37 Lb-Ft)
6. CAUTION: Do not loosen all of the bolts at the same time, only work on one bolt at a time or possible damage to engine or leakage may occur.
   In sequence, loosen retaining bolts two to three revolutions and retighten bolts one at a time in the following manner:
   1. Long bolts:
      • 15-25 Nm (11-18 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
   1. Short bolts:
      • 10-20 Nm (7-15 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
      
      
      
      
      
      Item Part Number Description 1 6010 Cylinder Block 2 - Locating Pin (2 Req'd) 3 N802515-S Cylinder Head Bolt (4 Req'd Each Side) 4 6049 Cylinder Head 5 N802516-S Cylinder Head Bolt (4 Req'd Each Side) 6 6A008 Cylinder Head to Block Dowel
7. NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check as outlined.
   Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A and install push rods in their original position.
8. For each valve, rotate crankshaft (6303) until valve tappet (6500) rests on the heel (base circle) of the camshaft lobe, before tightening rocker arm seat retaining bolts to 7-15 Nm (5-11 lb-ft) maximum.
9. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A. Final-tighten the rocker arm seat bolts to 30-40 Nm (22-30 lb-ft). For final tightening, camshaft (6250) may be in any position.
   
10. Install exhaust manifolds as outlined.
11. Install lower intake manifold as outlined.
12. Install fuel injection supply manifold .
13. Position valve cover and new valve cover gasket (6584) on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 Nm (7-9 lb-ft).
14. Install upper intake manifold .Install spark plugs (12405) , if removed.
15. Connect ignition wires to the spark plugs .
16. If LH cylinder head is being installed, perform the following:
    1. Install oil filler cap.
    1. Install generator/power steering pump mounting bracket.
    1. Install generator .
    1. Install main accessory drive belt tensioner .
    1. Install power steering pump (3A674) .
1. Install power steering pump support bracket.If RH cylinder head is being installed, perform the following:
17. 1. Install positive crankcase ventilation valve .
    1. If equipped with A/C, install A/C compressor mounting brackets (2882) and A/C compressor .
18. Install drive belt and tighten to specification.
19. Connect battery ground cable .
20. Install air cleaner outlet tube.

Power Steering Pump Removal & Installation 2.2L Engine To Remove:

1. Remove the upper cooling fan shroud.
2. Position a fluid catch pan under the power steering pump.
3. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan. NOTE: On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.
   
4. Remove the drive belt from the pulley.
5. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump. NOTE: When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   Installing the pilot bolt
   
   Removing the power steering pump pulley
   
   Installing the power steering pump pulley
   
   
6. Unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
7. Remove the front mounting bolts and the rear bracket nuts from the studs on the engine.
8. Remove the rear brace mounting bolt.
9. Remove the power steering pump from the vehicle.

To Install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 22 ft. lbs. (30 Nm).
2. Install the rear bracket bolt and nuts. Tighten the retainers to 22 ft. lbs. (30 Nm) on 1994 - 97 models and 37 ft. lbs. (50 Nm) on 1998 and later models.
3. Install the A/C compressor.
4. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end. NOTE: When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   
5. Properly install the drive belt.
6. Remove the caps, then connect the feed and return hoses to the pump.
7. Properly refill and bleed the power steering system.
8. Test drive the vehicle.

4.3L Engine To Remove:

1. Remove the upper cooling fan shroud.
2. Remove the drive belt.
3. Remove the fan and clutch from the water pump.
4. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.
5. Safely raise and support the vehicle.
6. Remove the shield from the steering linkage.
7. Position a fluid catch pan under the power steering pump.
8. Disconnect the return hose from the power steering pump, then drain the excess fluid into the catch pan.
9. Safely lower the vehicle.
10. Disconnect the pressure hose from the pump and cap the open line.
11. Remove the filler neck tube.
12. Remove the power steering pump mounting nuts and bolts.
13. Remove the power steering pump from the vehicle.

NOTE: When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
Installing the pilot bolt

Removing the power steering pump pulley

Installing the power steering pump pulley

To Install:

1. Position the pump to the vehicle.
   • Tighten the front retaining bolts to 37 ft. lbs. (50 Nm) and the nuts to 31 ft. lbs. (41 Nm).
2. Install the filler neck tube.
   • Tighten the bolt to 15 ft. lbs. (20 Nm).
3. Connect the pressure hose to the pump.
4. Safely raise and support the vehicle.
5. Connect the return hose to the vehicle.
6. Install the shield on the steering linkage and lower the vehicle.
7. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end. NOTE: When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   
8. Install the fan and clutch on the water pump.
9. Properly install the drive belt. NOTE: Be sure to secure any hoses which may get in the way or rub other components.
   
10. Install the upper fan shroud.
11. Properly refill and bleed the power steering system.
12. Test drive the vehicle.

4.3L Engine

1. Position a fluid catch pan under the power steering pump.
   
2. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan.
   
   NOTE

   On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.
   
   

3. Remove the drive belt from the pulley.
   
4. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.
   
   NOTE

   When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   

Installing the pilot bolt

Removing the power steering pump pulley

Installing the power steering pump pulley

1. On most models, it may be necessary to unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
   
2. If equipped, unfasten the power steering filler tube bolt and remove the filler tube.
   
3. Remove the rear brace retainers and the brace.
   
4. Remove the power steering pump-to-bracket bolts and then remove the pump from the vehicle.
   

To install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 37 ft. lbs. (50 Nm).
   
2. If equipped, install the rear brace and tighten the retainers to 31 ft. lbs. (41 Nm).
   
3. If removed, install the A/C compressor.
   
4. If removed, install the filler tube and its retainer. Tighten the retainer to 15 ft. lbs. (20 Nm).
   

Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end.

NOTE

When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.


Properly install the drive belt and, if applicable, adjust the tension.

1. NOTE

1. Be sure to secure any hoses which may get in the way or rub other components.

1. Remove the caps, then connect the feed and return hoses to the pump.
   
2. Properly refill and bleed the power steering system.
   
3. Test drive the vehicle.
   

Cylinder Head Removal & Installation 5.7L Engine To Remove:

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the air cleaner assembly.
4. Remove the upper radiator hose.
5. Remove both heater hoses.
6. Disconnect spark plug wires at distributor cap.
7. Remove distributor cap.
8. Remove the coolant bypass hose from the water pump.
9. Remove the drive belt. NOTE: It is not necessary to evacuate the A/C refrigerant.
   
10. Remove the A/C compressor from the mounting bracket and set it aside.
11. Remove the wiring bracket from the rear of the cylinder head.
12. Disconnect the accessory bracket and slide forward.
13. Remove the upper and lower intake manifold.
14. Remove the exhaust manifolds.
15. Remove the valve rocker arms and pushrods.
16. Remove the power steering pump pulley.
17. Disconnect the electrical connector from the power steering pump.
18. Remove nuts attaching the power steering pump to the engine.
19. Remove power steering pump mounting bracket bolts and nut.
20. Slide power steering pump/bracket assembly forward and remove stud.
21. Set power steering pump/bracket assembly aside.
22. Disconnect the wiring bracket from rear of the right cylinder head.
23. Remove the generator.
24. Remove the oil indicator tube bracket bolt.
25. Remove the generator mounting bracket.
26. Remove the sixteen cylinder head bolts.
27. Remove cylinder heads and gaskets.
28. Clean all sealing surfaces.

To Install:
Right Side NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the generator mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the generator mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the generator.
16. Install the oil indicator tube bracket bolt.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Left Side To Install:
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).
NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
NOTE: Do not use any type of sealant on the cylinder head gasket (unless specified).

1. Clean the cylinder head bolt holes with a thread chaser and compressed air.
2. Check the cylinder head locating pins for proper installation.
3. Place a new cylinder head gasket over the engine block dowel pins.
4. Install the cylinder head to the engine block.
5. Apply sealant (GM P/N 12346004 or equivalent) to cylinder head bolt threads.
6. Install the cylinder head bolts.
   
   
7. Tighten the cylinder head bolts in sequence on the first pass.
   • Torque to: 22 ft. lbs. (30 Nm)
8. Using a torque angle meter, tighten the long bolts (1, 2, 5, 6, 9, 10 and 13) on the second pass in sequence to 75°.
9. Using a torque angle meter, tighten the medium bolts (14 and 17) on the second pass in sequence to 65°.
10. Using a torque angle meter, tighten the short bolts (3, 4, 7, 8, 11, 12, 15 and 16) on the second pass in sequence to 55°.
11. Install the valve rocker arms and pushrods.
12. Install the power steering pump mounting bracket stud.
    • Torque to: 15 ft. lbs. (20 Nm)
13. Loosely assemble the mounting bracket over the stud.
14. Install all nuts and bolts finger tight.
    • Torque to: 30 ft. lbs. (41 Nm)
15. Install the power steering pump pulley.
16. Connect the electrical connector to the power steering pump.
17. Install the exhaust manifold.
18. Install the lower intake manifold.
19. Install the valve rocker arm covers.
20. Install the wiring bracket to the rear of the cylinder head.
21. Connect the accessory bracket.
22. Install the A/C compressor.
23. Install the drive belt.
24. Install the distributor cap.
25. Connect the spark plug wires to the distributor cap.
26. Install both heater hoses.
27. Install the upper radiator hose.
28. Install the air cleaner assembly.
29. Refill the engine coolant.
30. Connect the negative battery cable.

Check this procedure...

1. Tighten the first design cylinder head bolts as follows:
   1. M11 bolts 1st pass: in sequence to 22 ft. lbs. (30 Nm).
   2. M11 bolts 2nd pass: in sequence + 90 degrees.
   3. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
   4. M11 bolts (9 and 10): + 50 degrees.
   5. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      
2. Tighten the second design cylinder head bolts as follows:
   1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
   2. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
   3. M11 bolts (1-10): + 70 degrees.
   4. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines (click for zoom)


Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm). The bolts must be tightened once, then be tightened again in sequence in the following order:

1. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16), plus 55 degrees.
2. Step 2: Medium length bolt: (14, 17), plus 65 degrees.
3. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13), plus 75 degrees.

Fig. Cylinder head bolt tightening sequence-5.0L and 5.7L engines

1990–95 VEHICLES

1. Disconnect the battery ground.
2. Drain the cooling system. CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
   
3. Disconnect the hoses at the thermostat housing.
4. Remove the air cleaner.
5. Remove the rocker arm cover as outlined earlier in this section.
6. Remove the rocker arms. Keep them in order!
7. Remove the pushrods. Keep them in order!
8. Remove the power steering pump bracket.
9. Suspend the pump out of the way.
10. Remove the intake and exhaust manifolds.
11. Remove the air conditioning compressor drive belt.
12. Loosen the alternator drive belt.
13. Remove the compressor/alternator bracket mounting bolt.
14. Unbolt the compressor and suspend it out of the way. DO NOT DISCONNECT THE REFRIGERANT LINES!
15. Remove the spark plugs.
16. Disconnect the temperature sending unit wire. Fig. 6: Disconnect the coolant hoses at the thermostat housing
    Fig. 7: Disconnect the coolant hoses at the thermostat housing
    Fig. 8: Remove the cylinder head–to–block bolts
    Fig. 9: Cylinder head bolt removed from the head
    Fig. 10: Removing the cylinder head from the engine block
    
    
17. Remove the head bolts.
18. Lift the head off the engine and place it on a clean workbench.
19. Remove the head gasket. To install:
    
20. Thoroughly clean the gasket mating surfaces. Remove all traces of old gasket material. Remove all carbon deposits from the combustion chambers. Lay a straightedge across the head and check for flatness. Total deviation should not exceed 0.001 in. (0.025mm). NOTE: The cylinder head gasket used on the 2.5L engine is a composition gasket. The gasket is to be installed dry. Do not use gasket sealing compound on the gasket.
    
21. Fabricate 2 cylinder head alignment dowels from 2 used cylinder head bolts. Cut the head of the longest bolt off below the hex head. Then cut a slot in the top of the dowel to allow easier removal with a screwdriver.
22. Install one dowel in bolt hole No. 10 and the other dowel in bolt hole No. 8.
23. Place the cylinder head gasket over the dowels with the numbers facing up.
24. Place the cylinder head over the dowels.
25. Coat the threads of bolt No. 7 only, with Loctite PST sealant or equivalent.
26. Install all head bolts except Nos. 8 and 10.
27. Tighten the bolts in the sequence shown in the illustration to the following:
    1. Tighten bolts 1 through 10 in sequence to 22 ft. lbs. (30 Nm).
    2. Tighten bolts 1 through 10 in sequence to 45 ft. lbs. (61 Nm).
    3. Recheck bolts 1 through 10 in sequence to verify that they are 45 ft. lbs. (61 Nm).
    4. Tighten bolts 1 through 6 in sequence to 110 ft. lbs. (149 Nm).
    5. Tighten bolt 7 to 100 ft. lbs. (136 Nm).
    6. Tighten bolts 8 through 10 to 110 ft. lbs. (149 Nm). NOTE: During the final tightening sequence, bolt No. 7 will be tightened to a lower torque than the rest of the bolts. Do not overtighten bolt No. 7.
       
28. Connect the temperature sending unit wire.
29. Install the spark plugs.
30. Install the compressor.
31. Install the compressor/alternator bracket mounting bolt.
32. Adjust the alternator drive belt.
33. Install the air conditioning compressor drive belt.
34. Install the intake and exhaust manifolds.
35. Install the power steering pump bracket.
36. Install the pushrods. Keep them in order!
37. Install the rocker arms. Keep them in order!
38. Thoroughly clean the mating surfaces of the head and rocker cover and install as outlined earlier in this section.
39. Install the air cleaner.
40. Connect the hoses at the thermostat housing.
41. Connect the battery ground.
42. Fill the cooling system.

1. Disconnect the negative battery cable.
   
2. If necessary, remove the air cleaner duct and the air cleaner.
   
3. Remove the drive belt from the air conditioning compressor, if equipped.
   
4. Loosen power steering pump belt adjustment as follows:
   
   1. Loosen the pivot and mounting bolts.
      
   2. Loosen the idler pulley locknut and turn the adjusting nut counterclockwise to remove the power steering belt.
      
5. Loosen the power steering hoses at the pump and remove the bolts holding the power steering pump to the bracket.
   
6. Disconnect and plug the power steering hoses and remove the pump from the vehicle.
   

To install:

1. Using new O-rings, connect the power steering hoses to the steering pump.
   
2. Install the power steering pump and secure it with its mounting bolts. Tighten the front and rear mounting bolts to specifications.
   
3. Install the remaining components in the reverse order from which they were removed.
   
4. Connect the negative battery cable.
   
5. Fill the power steering system, start the engine and turn the steering wheel from side-to-side to bleed air from system
   

If you have a hydor booster the power steering pump runs your power brakes, make sure power steering level is at max, to replace master cylinder, unscrew both brake line, then unbolt both nut that hold master cylinder 15mm nut's, remove master cylinder, fill new master cylinder with DOT 3 brake fluid, bench bleed new master cylinder, new master cylinder will come with a bleeder kit, before installing, then install new one.

CYLINDER HEAD REMOVAL

2.5L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Drain cooling system and engine oil.
   
3. Relieve the fuel system pressure.
   
4. 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
     
5. Support the engine from above and below with a suitable jack and hoist.
   
6. 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
     
7. Loosen the cylinder head bolts in the sequence shown and remove the cylinder head.
   

Removing the front suspension member—Altima


Cylinder head bolt removal sequence—2.5L engine–Altima and Sentra


Cylinder head bolt tightening sequence—2.5L engine–Altima and Sentra

To install:

1. Clean the gasket surfaces.
   
2. Using new head gaskets, install the cylinder heads.
   NOTE If possible, replacement of the head bolts is suggested.
   
   
3. If replacement of the head bolts is not possible, perform the following bolt measurement:
   
   • Measure the diameter of the head bolt 0.43 in. (11mm) from the bottom of the bolt.
     
   • Measure the diameter of the head bolt 2.17 in. (55mm) from the bottom of the bolt.
     
   • Whenever the size difference between the 2 measurements exceeds 0.0091 in. (0.23mm) the head bolts must be replaced.
     
4. Apply clean engine oil to the bolt threads and seating surfaces and tighten the cylinder head bolts in sequence as follows:
   
   • Step 1: 72 ft. lbs. (98 Nm).
     
   • Step 2: Loosen all the bolts completely.
     
   • Step 2: 29 ft. lbs. (33 Nm).
     
   • Step 4: Plus 75–80 degrees clockwise.
     
   • Step 5: Plus 75–80 degrees clockwise.
     
5. Install the front suspension member and tighten the bolts to the specifications shown in the illustration.
   
6. 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
     
7. Fill the cooling system and engine oil
   
8. Start the vehicle, check for leaks and repair if necessary.
   

2.2L (VIN 4) Engine

1. Before servicing the vehicle, refer to the precautions section.
   
2. Relieve the fuel system pressure.
   
3. Drain the cooling system.
   
4. Remove or disconnect the following:
   
   • Accessory drive belt
     
   • Air cleaner outlet duct
     
   • Engine mount
     
   • Intake manifold
     
   • Exhaust manifold
     
   • Engine Coolant Temperature (ECT) sensor electrical connector
     
   • Power steering pump
     
   • Radiator inlet pipe
     
   • Spark plug wires
     
   • Rocker arm cover
     
   
   NOTE Whenever valve train components are removed, keep them in order for installation purposes.
   
   
   • Rocker arms and pushrods
     
   • Lifters
     
   • Alternator rear brace and the alternator
     
   • Power steering pump
     
   • Radiator inlet pipe
     
   • Ignition coil assembly
     
   • Accessory bracket
     
   • Spark plug wires
     
   • Cylinder head bolts
     
   
   WARNING Two sizes of bolts are used; note the location of each.
   
   
   • Cylinder head
     
5. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
   

Cylinder head torquing sequence—2.2L (VIN 4) engine

1. Install or connect the following:
   
   • Cylinder head with a new gasket and new cylinder head bolts. Torque the long bolts, in sequence to 46 ft. lbs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm) plus an additional 90 degree turn on all the bolts.
     
   • Lifters
     
   • Pushrods and rocker arms. Torque nuts to 22 ft. lbs. (30 Nm).
     
   • Rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
   • Spark plug wires
     
   • Accessory bracket
     
   • Ignition coil assembly
     
   • Radiator inlet pipe
     
   • Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
   • ECT sensor electrical connector
     
   • Exhaust manifold. Torque the nuts to 118 inch lbs. (13 Nm).
     
   • Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
   • Intake manifold. Torque the bolts to 17 ft. lbs. (24 Nm).
     
   • Engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     
   • Air cleaner outlet duct
     
   • Accessory drive belt
     
   • Negative battery cable
     
2. Refill and bleed the cooling system.
   
3. Start the vehicle and inspect for leaks.