### Cylinder Head

#### REMOVAL & INSTALLATION

NOTE: To prevent distortion or warping of the cylinder head, allow the engine to cool completely before removing the head bolts.

##### 200SX (Z Series Engine)

1. Crank the engine until the No. 1 piston is at TDC of the compression stroke, disconnect the battery, and drain the cooling system.
2. Remove the radiator hoses and the heater hoses. Unbolt the alternator mounting bracket and move the alternator to one side, if necessary.
3. If the car is equipped with air conditioning, unbolt the compressor and place it to one side. Do not disconnect the compressor lines. Severe injury could result.

   Fig. 1: Cylinder head bolt loosening sequence — 200SX Z series engine

   Fig. 2: Cylinder head bolt torque sequence — 200SX Z series engine

   Fig. 3: Wood wedge dimensions — 9 in. (229mm) x 15 in. (38mm) — used to hold chain in place

   Fig. 4: Wedge the chain with a wooden block (arrow). If you don't, you will be fishing for the chain in the engine

   Fig. 5: Matchmark the timing chain to camshaft sprocket

4. Remove the power steering pump.
5. Mark and remove the spark plug wires and spark plugs.
6. Disconnect the throttle linkage, the air cleaner or its intake hose assembly. Release the fuel pressure (refer to the necessary service procedures). Disconnect the fuel line, the return fuel line and any other vacuum lines or electrical leads.

   NOTE: A good rule of thumb when disconnecting the rather complex engine wiring of today's automobiles is to put a piece of masking tape on the wire or hose and one the connection you removed the wire or hose from, then mark both pieces of tape 1, 2, 3, etc. When replacing wiring, simply match the pieces of tape.

7. Remove the EGR tube from around the rear of the engine.
8. Remove the exhaust air induction tubes from the exhaust manifold.
9. Unbolt the exhaust manifold from the exhaust pipe.
10. Remove the intake manifold supports from under the manifold if so equipped. Remove the PCV valve from around the rear of the engine if necessary.
11. Remove the valve cover.
12. Mark the relationship of the camshaft sprocket to the timing chain with paint or chalk. If this is done, it will not be necessary to locate the factory timing marks. Before removing the camshaft sprocket, it will be necessary to wedge the chain in place so that it will not fall down into the front cover. The factory procedure is to wedge the timing chain in place with the wooden wedge. The problem with this procedure is that it may allow the chain tensioner to move out far enough to cock itself against the chain. If this happens, you'll find that the chain won't go back over the sprocket after you've put the sprocket back on. In this case, you'll have to remove the front cover and push the tensioner back. After you've wedged the chain, unbolt the camshaft sprocket and remove it.
13. Working from both ends in, loosen the cylinder head bolts and remove them. Remove the bolts securing the cylinder head to the front cover assembly.
14. Lift the cylinder head off the engine block. It may be necessary to tap the head lightly with a rubber mallet to loosen it.

    To install:

15. Thoroughly clean the cylinder block and head surfaces and check both for warpage.
16. Fit the new head gasket. Don't use sealant. Make sure that no open valves are in the way of raised pistons, and do not rotate the crankshaft or camshaft separately because of possible damage which might occur to the valves.
17. Temporarily tighten the two center right and left cylinder head bolts to 14 ft. lbs.
18. Install the camshaft sprocket together with the timing chain to the camshaft. Make sure the marks you made earlier line up with each other. If you get into trouble, see Timing Chain Removal and Installation for timing procedures.
19. Install the cylinder head bolts and torque them to 20 ft. lbs., then 40 ft. lbs., then 58 ft. lbs. in the order (sequence) shown in the illustration.
20. Clean and regap the spark plugs then install them in the cylinder head. DO NOT OVER TORQUE THE SPARK PLUGS.
21. Install the valve cover with a new gasket.
22. Install the intake manifold supports to the manifold if so equipped. Install the PCV valve if it was removed.
23. Connect the exhaust pipe to exhaust manifold (use NEW exhaust gasket).
24. Install the exhaust air induction tubes to the exhaust manifold.
25. Install the EGR tube from around the rear of the engine.
26. Connect the throttle linkage, the air cleaner or its intake hose assembly (fuel injection). Reconnect the fuel line, the return fuel line and any other vacuum lines or electrical leads.
27. Install the power steering pump if so equipped and correctly adjust the drive belt.
28. Install the air conditioning compressor and correctly adjust the drive belt.
29. Install the alternator mounting bracket, alternator, electrical connections to the alternator and adjust the drive belt.
30. Reconnect the heater and radiator hoses.

    NOTE: It is always wise to drain the crankcase oil after the cylinder head has been installed to avoid coolant contamination.

31. Refill the cooling system. Adjust the valves.
32. Start engine, run engine to normal operating temperature, check for the correct coolant level.
33. Check for leaks and roadtest vehicle for proper operation.

##### 200SX (CA20E and CA18ET Engines), Stanza and Stanza Wagon (CA20E)

1. Relieve the fuel system pressure, disconnect the negative battery cable and drain the cooling system.
2. Remove the air intake pipe.
3. Remove the cooling fan and radiator shroud.
4. Remove the alternator drive belt, power steering pump drive belt and the air conditioner compressor drive belt, if equipped.
5. Position the No. 1 cylinder at TDC of the compression stroke and remove the upper and lower timing belt covers.
6. Loosen the timing belt tensioner and return spring, then remove the timing belt.

   NOTE: When the timing belt has been removed, do not rotate the crankshaft and the camshaft separately, because the valves will hit the tops of the pistons.

7. Remove the exhaust manifold.
8. Remove the camshaft pulley.
9. Remove the water pump pulley.
10. Remove the crankshaft pulley.
11. Remove the alternator adjusting bracket.
12. Remove the water pump.
13. Remove the oil pump.
14. Loosen the cylinder head bolts in sequence and in several steps.
15. Remove the cylinder head and manifold as an assembly.

    To install:

16. Clean the cylinder head gasket surfaces.
17. Lay the cylinder head gasket onto the block and lower the head onto the gasket.
18. Install the cylinder head bolts. When installing the bolts, tighten the two center bolts temporarily to 15 ft. lbs. and install the head bolts loosely. They will be torqued after the timing belt and front cover are installed.
19. Install the oil pump.
20. Install the water pump.
21. Install the alternator adjusting bracket.
22. Install the crankshaft, water pump and camshaft pulleys.
23. Install the exhaust manifold.

    NOTE: Before installing the timing belt, be certain the crankshaft pulley key is near the top and that the camshaft knock pin or sprocket aligning mark is at the top.

24. Install the timing belt and timing belt covers. After the timing belt and covers have been installed, torque all the head bolts in the torque sequence provided. Tighten all bolts to 22 ft. lbs. (29 Nm). Re-tighten all bolts to 58 ft. lbs. (78 Nm). Loosen all bolts completely and then re-tighten them once again to 22 ft. lbs. (29 Nm). Tighten all bolts to a final torque of 54–61 ft. lbs. (74–83 Nm) or if using an angle torque wrench, give all bolts a final turn to 75–80 degrees except bolt No. 8 which is 83–88 degrees. No. 8 bolt is longer.

    NOTE: Newer models use cupped washers on the cylinder head bolts, always make sure that the flat side of the washer is facing downward before tightening the cylinder head bolts.

25. Install the drive belts.
26. Install the cooling fan and radiator shroud.
27. Fill the cooling system to the proper level and connect the negative battery cable.
28. Make all the necessary engine adjustments. Road test the vehicle for proper operation.

    Fig. 6: Cylinder head bolt loosening sequence — 200SX CA series engine

    Fig. 7: Cylinder head bolt torque sequence — 200SX CA series engine. Bolt No 8 is the longest

    Fig. 8: Set the CA series engines No. 1 cylinder at TDC on the compression stroke The key-way on the crankshaft sprocket will be almost at 12:00 position

    Fig. 9: CA series engines camshaft knock pin position for cylinder head assembly

    Fig. 10: Cupped washer installation — cylinder head installation

##### 200SX (VG30E Engine)

NOTE: To remove or install the cylinder head, you'll need a special hex head wrench ST10120000 (J24239–01) or equivalent. The collector assembly and intake manifold have special bolt sequence for removal and installation. The distributor assembly is located in the cylinder head mark and remove it if necessary.

NOTE: See note at 200SX VG30E "Camshaft Removal And Installation'' before starting this procedure.

1. Release the fuel pressure. See the procedure in this section for timing belt removal. Set the engine to Top Dead Center and then remove the timing belt.

   NOTE: Do not rotate either the crankshaft or camshaft from this point onward, or the valves could be bent by hitting the pistons.

2. Drain the coolant from the engine. Then, disconnect all the vacuum hoses and water hoses connected to the intake collector.

   Fig. 11: To remove the collector (VG30E engine), loosen the arrowed bolts

   Fig. 12: To remove the cylinder head (VG30E engine), loosen the bolts in numerical order

   Fig. 13: Torquing pattern for the right side cylinder head — VG30E engine

   Fig. 14: Torquing pattern for the left side cylinder head — VG30E engine

   Fig. 15: Torquing pattern for the intake manifold — VG30E engine

3. Remove the collector cover and the collector. Refer to the section Intake Manifold Removal And Installation for correct bolt removal sequence.
4. Remove the intake manifold and fuel tube assembly.
5. Remove the exhaust collector bracket. Remove the exhaust manifold covers. Disconnect the exhaust manifold when it connects to the exhaust pipe (three bolts).
6. Remove the camshaft pulleys and the rear timing cover securing bolts.
7. Loosen cylinder head bolts a little at a time in numerical order.
8. Remove the cylinder head with the exhaust manifold attached. If you need to remove the exhaust manifold, refer to the procedure in this section.

   To install:

9. Check the positions of the timing marks and camshaft sprockets to make sure they have not shifted.
10. Install the head with a new gasket. Apply clean engine oil to the threads and seats of the bolts and install the bolts with washers in the correct position. Note that bolts 4, 5, 12, and 13 are 127mm long. The other bolts are 106mm long.
11. Torque the bolts according to the pattern for the cylinder head on each side in the following stages:
    1. Torque all bolts, in order, to 22 ft. lbs.
    2. Torque all bolts, in order, to 43 ft. lbs.
    3. Loosen all bolts completely.
    4. Torque all bolts, in order, to 22 ft. lbs.
    5. Torque all bolts, in order, to 40–47 ft. lbs. If you have a special wrench available that torques bolts to a certain angle, torque them 60–65°tighter rather than going to 40–47 ft. lbs.
12. Install the rear timing cover bolts. Install the camshaft pulleys. Make sure the pulley marked R3 goes on the right and that marked L3 goes on the left.
13. Align the timing marks if necessary and then install the timing belt and adjust the belt tension.
14. Install the front upper and lower belt covers.
15. Make sure that the rocker cover bolts, trays and washers are free of oil. Then, install the rocker covers.
16. Install the intake manifold and fuel tube. Torque NUTS as follows:
    1. Torque in numbered order to 26–43 in. lbs.
    2. Torque in numbered order to 17–20 ft. lbs.
17. Torque the BOLTS on the intake manifold as follows:
    1. Torque in numbered order to 26–43 inch lbs.
    2. Torque in numbered order to 12–14 ft. lbs.
18. Install the exhaust manifold if removed from the cylinder head.
19. Connect the exhaust manifold to the exhaust pipe connection (replace the exhaust pipe gasket). Install the exhaust collector bracket.
20. Install the collector and collector cover. Refer to the section for Intake Manifold Removal And Installation for the correct torque pattern.
21. Connect all the vacuum hoses and water hoses to the intake collector.
22. Refill the cooling system. Start the engine check the engine timing. After the engine reaches the normal operating temperature check for the correct coolant level.
23. Roadtest the vehicle for proper operation.

##### 240SX (KA24E Engine)1990–92 Stanza (KA24E Engine)

NOTE: After finishing this procedure allow the rocker cover to cylinder head rubber plugs to dry for 30 minutes before starting the engine. This will allow the liquid gasket sealer used to seal these plugs to dry completely.

1. Drain coolant from the radiator and remove drain plug from the cylinder block. Release the fuel pressure.
2. Remove the power steering drive belt, power steering pump, idler pulley and power steering brackets.
3. Mark and disconnect all the vacuum hoses, spark plug wires and electrical connections to gain access to cylinder head. Remove the air induction hose from the collector assembly.
4. Disconnect the accelerator bracket. If necessary mark the position and remove the accelerator cable wire end from the throttle drum.
5. Remove the bolts that hold intake manifold collector to the intake manifold. Remove and position the collector assembly to the side.
6. Remove the bolts that hold intake manifold to the cylinder. Remove the intake manifold. Unplug the exhaust gas sensor and remove the exhaust cover and exhaust pipe at exhaust manifold connection. Remove the exhaust manifold from the cylinder head.
7. Remove the rocker cover. If cover sticks to the cylinder head, tap it with a rubber hammer.

   NOTE: After removing the rocker cover matchmark the timing chain with the camshaft sprocket with paint or equivalent. This step is very important for the correct installation of the timing chain to sprocket.

8. Set No.1 cylinder piston at TDC on its compression stroke. Remove the No.1 spark plug and make sure that the piston is UP.
9. Loosen the camshaft sprocket bolt. Do not turn engine when removing the bolt.
10. Support the timing chain with a block of wood as illustrated.
11. Remove the camshaft sprocket.
12. Remove the front cover to cylinder head retaining bolts.

    NOTE: The cylinder head bolts should be loosened in two or three steps in the correct order to prevent head warpage or cracking.

13. Remove the cylinder head bolts in the correct order.

    To install:

14. Confirm that the No. 1 is at TDC on its compression stroke as follows:
    1. Align timing mark with 0 mark on the crankshaft pulley.
    2. Make sure the distributor rotor head is set at No. 1 on the distributor cap.
    3. Confirm that the knock pin on the camshaft is set at the top position.
15. Install the cylinder head with a new gasket and torque the head bolts in numerical order in 5 steps (a, b, c, d, e). Do not rotate crankshaft and camshaft separately, or valves will hit the piston heads.
    1. Torque all bolts to 22 ft. lbs.
    2. Torque all bolts to 58 ft. lbs.
    3. Loosen all bolts completely.
    4. Torque all bolts to 22 ft. lbs.
    5. Torque all bolts to 54–61 ft. lbs., or if you are using an angle wrench, turn all bolts 80–85°clockwise.
16. Remove the block of wood holding timing chain in the correct location. Position the timing chain on the camshaft sprocket by aligning each matchmark. Install the camshaft sprocket to the camshaft.
17. Tighten the camshaft sprocket bolt and the front cover to cylinder head retaining bolts.
18. Install the intake manifold and collector assembly with new gaskets. Refer to the Intake Manifold Removal and Installation procedures.
19. Install the exhaust manifold with new gaskets. Refer to the Exhaust Manifold Removal and Installation procedures.
20. Apply liquid gasket to the rubber plugs and install the rubber plugs in the correct location in the cylinder head.
21. Install the rocker cover with new gasket in place. Tighten the retaining bolts in the correct order.
22. Reconnect the accelerator bracket and cable if removed.
23. Connect all the vacuum hoses, and electrical connections that were removed to gain access to cylinder head. Reconnect the air induction hose to collector assembly.
24. Clean and regap the spark plugs if necessary. Install the spark plugs and spark plug wires in the correct location. DO NOT OVERTIGHTEN!
25. Install the power steering brackets, idler pulley, and power steering pump. Install the drive belt and adjust the belt.
26. Install the drain plug in the cylinder block. Refill the cooling system.
27. Start the engine, after the engine reaches the normal operating temperature check for the correct coolant level.
28. Roadtest the vehicle for proper operation.

    Fig. 16: Support the timing chain with a block of wood

    Fig. 17: Remove the front cover-to-cylinder head retaining bolts

    Fig. 18: Loosen cylinder head bolts in this order — KA24E and KA24DE series engines

    Fig. 19: Align timing mark with 0 on the timing scale

    Fig. 20: View of rotor at No. 1 cylinder firing location

    Fig. 21: Matchmark timing chain with camshaft sprocket

    Fig. 22: Confirm knock pin on camshaft is set at the top position

    Fig. 23: Torque cylinder head bolts in this order — KA24E and KA24DE series engines

    Fig. 24: Installing rubber plugs in the correct manner

    Fig. 25: Correct rocker cover bolt torque sequence

##### 240SX (KA24DE Engine)

1. Release the fuel system pressure.
2. Disconnect the negative battery cable and drain the cooling system. Drain the engine oil.
3. Remove all vacuum hoses, fuel lines, wires, electrical connections as necessary.
4. Remove the front exhaust pipe and AIV. pipe.
5. Remove the air duct, cooling fan with coupling and radiator shroud.
6. Remove the fuel injector tube assembly with injectors.
7. Disconnect and mark spark plug wires. Remove the spark plugs.
8. Set No. 1 piston at TDC on compression stroke. Remove the rocker cover assembly.
9. Mark and remove the distributor assembly.
10. Remove the cam sprocket, brackets and camshafts. These parts should be reassembled in their original position. Bolts should be loosened in 23 steps––refer to the service procedures and illustrations in this section.
11. Loosen cylinder head bolts in two or three steps in sequence.
12. Remove the cam sprocket cover. Remove the upper chain tensioner and upper chain guides.
13. Remove the upper timing chain and idler sprocket bolt. Lower timing chain will not disengaged from the crankshaft sprocket.
14. Remove the cylinder head with the intake manifold, collector and exhaust manifold assembly.

    To install:

15. Check all components for wear. Replace as necessary. Clean all mating surfaces and replace the cylinder head gasket.
16. Install cylinder head. Tighten cylinder head in the following sequence:
    1. Tighten all bolts in sequence to 22 ft. lbs.
    2. Tighten all bolts in sequence to 59 ft. lbs.
    3. Loosen all bolts in sequence completely.
    4. Tighten all bolts in sequence to 1825 ft. lbs.
    5. Tighten all bolts to 86 to 91 degrees clockwise, or if an angle wrench is not available, tighten all bolts to in sequence to 5562 ft. lbs.
17. Install upper timing chain assemble in the correct position. Align all timing marks.
18. Install all other components in the reverse order of the removal procedure. Refill and check all fluid levels. Road test the vehicle for proper operation.

##### Stanza (CA20 Engine)

Fig. 26: Removal and installation bolt torque sequence — Stanza CA20 series

Fig. 27: Make sure the crankshaft pulley key is near the top position — CA series engines

1. Disconnect the negative battery cable and drain the cooling system.
2. Support vehicle safely, remove the right front wheel.
3. Remove all spark plugs. Tag and disconnect all lines, hoses and wires which may interfere with cylinder removal.
4. Position the No. 1 cylinder at TDC of the compression stroke and remove the dust cover and the under cover.
5. Remove the alternator drive belt, power steering pump drive belt and air conditioning compressor drive belt if so equipped.
6. Remove the crankshaft pulley.
7. Support engine and remove right side engine insulator and mounting bracket.
8. Remove front upper and lower timing belt covers.
9. Loosen timing belt tensioner and return spring, then remove the timing belt.

   NOTE: When the timing belt has been removed, do not rotate the crankshaft and the camshaft separately, because the valves will hit the piston heads.

10. Remove rocker shafts with rocker arms and securing bolts. The bolts should be loosened in two or three stages.
11. Remove camshaft sprocket.
12. Disconnect exhaust pipe from the exhaust manifold.
13. Remove cylinder head together with manifolds as an assembly. The bolts should be loosened in two or three stages in sequence.

    To install:

14. Thoroughly clean both the cylinder block and head mating surfaces. Avoid scratching either.
15. Install a new head gasket on the block and the cylinder head with manifolds attached as an assembly. When installing the bolts tighten the two center bolts temporarily to 15 ft. lbs. and install the head bolts loosely. After the timing belt and front cover have been installed, torque all the head bolts in the torque sequence. Tighten all bolts to 22 ft. lbs. Retighten all bolts to 58 ft. lb. Loosen all bolts completely and then retighten them once again to 22 ft. lbs. Tighten all bolts to a final torque of 54–61 ft. lbs.

    NOTE: Newer models utilize cupped washers, always make sure that the flat side of the washer is facing downward before tightening the cylinder head bolts. Before installing the timing belt, be certain that the crankshaft pulley key is near the top and that the camshaft knock pin or sprocket aligning mark is at the top.

16. Reconnect exhaust pipe to exhaust manifold.
17. Install the camshaft sprocket.
18. Install the rocker shafts with rocker arms and securing bolts. The bolts should be tighten in two or three stages from the center to the ends.
19. Install timing belt and tensioner.
20. Install the front upper and lower timing belt covers and the right side engine insulator and mounting bracket.
21. Install the crankshaft pulley. Install and adjust, the alternator drive belt, power steering pump drive belt and air conditioning compressor drive belt if so equipped.
22. Install the dust and under covers.
23. Install all spark plugs. Reconnect all lines, hoses and wires that were removed.
24. Install the right front wheel.
25. Connect the negative battery cable and refill the cooling system.
26. Start engine, check engine timing and for oil or water leaks.
27. Road test for proper operation.