CYLINDER HEAD GASKET REMOVAL


  1. REMOVE ENGINE UNDER COVER

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. Remove the drain plug and gasket from the oil pan and drain engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not loosen the radiator drain cock plug and engine drain plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E02
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap sub-assembly, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  5. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH

  6. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH

  7. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. A01CGLT

      Remove the bolt and 3 nuts.

    2. Remove the radiator reserve tank assembly.

  8. REMOVE FENDER SIDE APRON SUB-ASSEMBLY LH

  9. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH

  10. REMOVE VACUUM RESERVOIR SUB-ASSEMBLY

  11. REMOVE INJECTOR DRIVER ASSEMBLY


    1. Disconnect the 2 injector driver connectors.

    2. A01CHLQ

      Disconnect the wire harness clamp and connector from the injector driver assembly.

    3. Remove the 2 bolts and injector driver assembly.

  12. REMOVE NO. 2 INTAKE PIPE


    1. A01CHOY

      Remove the 3 bolts, loosen the 2 hose bands, and remove the No. 2 intake pipe and No. 1 air hose.

  13. REMOVE NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. A01CH0N

      Disconnect the connector (w/ Cab tilt warning).

    2. A01CJGK

      Remove the 4 nuts and air cleaner case.

    3. A01CIIG

      Remove the 2 bolts and No. 1 air hose assembly.

    4. A01CIY0

      Remove the 8 bolts and No. 3 cab mounting bracket.

  14. REMOVE NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CJ0J

      Disconnect the hose band.

    2. A01CGN2

      Remove the bolt.

    3. A01CJ8T

      Disconnect the turbo pressure sensor connector and wire harness clamp, and remove the bolt.

    4. A01CJ3X

      Loosen the hose band and remove the No. 1 intake air pipe with No. 4 air hose.

  15. REMOVE NO. 2 AIR HOSE

  16. REMOVE INTERCOOLER ASSEMBLY


    1. A01CISR

      Remove the 4 bolts and intercooler assembly.

  17. REMOVE FAN


    1. Loosen the 4 nuts.

    2. Remove the fan and generator V belt Click here.

    3. Remove the 4 nuts and fan.

  18. REMOVE FAN PULLEY


    1. A01CI13

      Remove the fan pulley.

  19. DISCONNECT INLET RADIATOR HOSE


    1. Disconnect the inlet radiator hose.

  20. SEPARATE OUTLET RADIATOR HOSE


    1. Disconnect the outlet radiator hose.

  21. SEPARATE HEATER HOSE


    1. A01CJFI

      Remove the 5 bolts and separate the heater hose.

  22. SEPARATE NO. 4 RADIATOR BRACKET


    1. A01CIT5

      Remove the 3 bolts and separate the No. 4 radiator bracket.

  23. SEPARATE NO. 3 RADIATOR BRACKET


    1. A01CJBO

      Remove the 3 bolts and separate the No. 3 radiator bracket.

  24. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly with the fan shroud.

  25. REMOVE GENERATOR ASSEMBLY


    1. A01CI5J

      Remove the terminal cap and nut, and disconnect the wire harness from terminal B.

    2. Disconnect the connector from the generator.

    3. Disconnect the 3 wire harness clamps.

    4. A01CGO2

      Remove the 4 bolts, generator belt adjusting bar and generator assembly.

  26. REMOVE EXHAUST RETARDER ASSEMBLY


    1. A01CIBFE01

      Disconnect the vacuum hose.

    2. A01CHNOE01

      Remove the 4 bolts and exhaust retarder assembly.

    3. Remove the 2 gaskets from the exhaust retarder assembly.

  27. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01CHG1

      Remove the bolt.

    2. A01CI20E01

      Remove the 3 nuts and front exhaust pipe assembly.

    3. Remove the gasket.

  28. DISCONNECT FUEL HOSE


    1. A01CIXU

      Disconnect the 2 fuel hoses.

  29. DISCONNECT WIRE HARNESS


    1. Disconnect the wire harness.

  30. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Disconnect the water by-pass hose.

    2. Remove the 6 bolts, EGR cooler sub-assembly, bracket and 2 gaskets.

  31. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Remove the oil filler cap sub-assembly.

  32. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

      Remove the 2 bolts and cylinder head cover sub-assembly.

  33. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CGZM

      Remove the wire harness.

    2. Remove the 2 bolts and No. 2 cylinder head cover sub-assembly.

    3. Remove the cushions, spacers and gasket.

  34. REMOVE DIESEL THROTTLE BODY


    1. A01CHFJ

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH93

      Remove the 2 bolts, 2 nuts and diesel throttle body.

  35. REMOVE VENTURI ASSEMBLY


    1. Remove the bolt and bracket from the venturi assembly.

    2. Remove the 4 bolts, 2 nuts and venturi assembly from the intake manifold.

  36. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CIEE

      Disconnect the 3 connectors, 4 wire harness clamps and bolt.

  37. REMOVE EGR VALVE BRACKET


    1. A01CGLD

      Remove the 4 bolts and bracket.

  38. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CHT5

      Remove the 3 bolts and 2 union bolts.

    2. Remove the water by-pass pipe and gasket.

  39. REMOVE INJECTION PIPE CLAMP


    1. A01CGTY

      Remove the 2 nuts.

    2. Remove the oil level gauge.

    3. Remove the oil level gauge guide and O-ring, and then remove the 2 injection pipe clamps.

  40. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick guide and O-ring.

  41. REMOVE INJECTOR ASSEMBLY


    1. A01CHN3

      Using a union nut wrench (17 mm), loosen the 8 union nuts and remove the injection pipe sub-assembly.

    2. A01CGVZ

      Remove the 5 hollow screws and 5 gaskets, and then remove the nozzle leakage pipe.

      Tech Tips

      After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating the injectors.

    3. A01CIVM

      Using a small screwdriver, remove the 4 holder seals.

    4. A01CGOO

      Remove the 4 bolts and the 4 nozzle holder clamps.

      Note

      Arrange the holder clamps and bolts in the correct order.

    5. Remove the 4 injectors.

      Note

      Arrange the injectors in the correct order.

    6. Attach tags to identify the cylinder (#1 to #4) to the injector assemblies so that each injector assembly can be inserted into the correct cylinder during installation.

    7. Remove the gasket from each injector.

    8. A01CI6EE02
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each injector.

  42. REMOVE GENERATOR BELT ADJUSTING BAR


    1. Remove the 2 bolts and generator belt adjusting bar.

  43. REMOVE GENERATOR BRACKET SUB-ASSEMBLY


    1. A01CHR0

      Disconnect the connector clamp.

    2. Remove the 3 bolts and generator bracket.

  44. REMOVE RADIATOR PIPE


    1. A01CIP1

      Remove the 2 bolts, radiator pipe and O-ring.

  45. REMOVE GLOW PLUG GROUND WIRE


    1. Remove the 4 screw grommets.

    2. Remove the 4 nuts.

    3. Remove the wire harness and 3 glow plug ground wires.

  46. REMOVE GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, remove the 4 glow plugs.

  47. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here.

  48. REMOVE WATER PIPE SUB-ASSEMBLY


    1. A01CIX4

      Remove the 3 bolts, clamp and water pipe sub-assembly.

    2. Remove the O-ring.

  49. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Remove the 6 bolts and water by-pass pipe sub-assembly.

    2. Remove the 2 O-rings.

  50. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CJ11E04
      Text in Illustration
      *1 Timing Mark

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips


      • Make sure that there is free play in the No. 1 cylinder rocker arms and that there is no free play in the No. 4 cylinder rocker arms.

      • If not, turn the crankshaft 1 revolution (360°) to set the No. 1 cylinder to TDC/compression.

  51. REMOVE NO. 1 VALVE ROCKER SHAFT SUB-ASSEMBLY


    1. A01CI9IE02
      Text in Illustration
      *1 Adjusting Screw
      *2 Lock Nut

      Loosen the lock nuts at the top of the rocker arms and completely loosen the adjusting screws.

      Note

      If the adjusting screws are not loosened, the rocker shaft may bend when the rocker arm support bolts are loosened.

    2. A01CGKLE01

      Loosen the rocker arm support bolts in the order shown in the illustration.

    3. Remove the 5 bolts and No. 1 valve rocker shaft sub-assembly.

  52. REMOVE VALVE PUSH ROD

    Tech Tips

    Organize the parts so that each part location can be remembered for reassembly.

  53. REMOVE VALVE BRIDGE

    Tech Tips

    Organize the parts so that each part location can be remembered for reassembly.

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01CHHQE01

      Loosen the cylinder head bolts in the order shown in the illustration and remove the bolts.

    2. Lift and remove the cylinder head from the cylinder block.

  55. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket.