CYLINDER HEAD GASKET REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

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

    3. Wipe the oil pan and oil pan drain plug.

    4. Install a new gasket and the oil pan drain plug.

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

  5. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly, radiator drain cock plug or 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. A01CGQLE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug
      *4 Radiator Reservoir Assembly

      Loosen the radiator drain cock plug and engine drain plug.

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

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    3. Tighten the radiator drain cock plug by hand.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  6. REMOVE RADIATOR ASSEMBLY

    Click here

  7. REMOVE GENERATOR ASSEMBLY

    Click here

  8. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  9. REMOVE COMMON RAIL ASSEMBLY

    Click here

  10. REMOVE GLOW PLUG ASSEMBLY (for Cold Area Specification Vehicles)

    Click here

  11. REMOVE INTAKE MANIFOLD

    Click here

  12. REMOVE INJECTOR ASSEMBLY

    Click here

  13. REMOVE FENDER SIDE APRON SUB-ASSEMBLY LH


    1. Remove the 6 bolts and fender side apron sub-assembly LH.

  14. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH


    1. Remove the 6 bolts and fender side apron sub-assembly RH.

  15. REMOVE AIR HOSE ASSEMBLY


    1. A01CH5L

      Slide the clamp and disconnect the ventilation hose from the air hose assembly.

    2. Loosen the 2 hose clamps.

    3. Remove the bolt and air hose assembly.

  16. REMOVE AIR CLEANER ASSEMBLY


    1. A01CITM

      Remove the 4 nuts and air cleaner assembly from the No. 1 air cleaner stay.

  17. REMOVE AIR CLEANER STAY


    1. A01CIZT

      Remove the 3 nuts, No. 1 air cleaner stay and No. 2 air cleaner stay.

  18. REMOVE EXHAUST BRAKE WITH BRACKET SOLENOID ASSEMBLY


    1. Disconnect the connector from the exhaust brake solenoid with bracket assembly.

    2. A01CHWI

      Slide the 2 clips and disconnect the exhaust retarder hose and solenoid hose from the exhaust brake solenoid with bracket assembly.

    3. Remove the 2 bolts and exhaust brake solenoid with bracket assembly.

  19. REMOVE STARTER RELAY ASSEMBLY


    1. A01CIGK

      Remove the terminal cap.

    2. Remove the 2 nuts and disconnect the 2 lead wires.

    3. Detach the wire harness clamp and disconnect the connector.

    4. Remove the 2 nuts and starter relay assembly.

  20. REMOVE INJECTOR DRIVER ASSEMBLY


    1. Disconnect the 3 injector driver assembly connectors.

    2. A01CJ3W

      Remove the 2 bolts and injector driver assembly.

  21. DISCONNECT RELAY BLOCK


    1. A01CIP4

      Remove the 2 bolts and nut, and disconnect the relay block.

  22. REMOVE RELAY BLOCK BRACKET ASSEMBLY


    1. A01CJG4

      Remove the 2 bolts, 2 nuts and relay block bracket assembly.

  23. REMOVE REAR ENGINE SIDE SHUTTER


    1. Remove the 4 bolts and rear engine side shutter from the rear cab mounting bracket sub-assembly.

  24. REMOVE REAR CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. A01CJ7ME01
      Text in Illustration
      *a LH
      *b RH

      Remove the 8 bolts and rear cab mounting bracket sub-assembly.

  25. REMOVE NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY


    1. A01CGLK

      Remove the nut and nozzle leakage clamp.

    2. Remove the 2 union bolts, 2 gaskets and No. 3 nozzle leakage pipe sub-assembly.

  26. DISCONNECT OIL PUMP TO GEAR BOX TUBE


    1. A01CIOP

      Remove the union bolt and gasket.

    2. Remove the 4 bolts and disconnect the oil pump to gear box tube.

  27. REMOVE RADIATOR PIPE SUB-ASSEMBLY


    1. A01CHDF

      Remove the 2 bolts and radiator pipe sub-assembly.

    2. Remove the O-ring.

  28. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CGQT

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

    2. Remove the 6 O-rings.

  29. 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 valve rocker arms and that there is no free play in the No. 4 cylinder valve rocker arms.

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

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


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

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

      Note

      If the valve adjusting screws are not loosened, the No. 1 valve rocker shaft sub-assembly may bend when the valve rocker arm support bolts are loosened.

    2. A01CGKLE01

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

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

  31. REMOVE VALVE PUSH ROD

    Tech Tips

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

  32. REMOVE VALVE LIFTER

    Tech Tips

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

  33. REMOVE VALVE BRIDGE

    Tech Tips

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

  34. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01CITFE01

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

    2. Lift and remove the cylinder head sub-assembly from the cylinder block.

  35. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket.

  36. INSPECT CYLINDER HEAD SET BOLT


    1. A01CGS1E05
      Text in Illustration
      *a Measurement Length

      Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Standard length
      126 mm (4.96 in.)
      Maximum length
      129 mm (5.07 in.)

      If the length is more than the maximum, replace the cylinder head set bolt.

  37. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A01CHJTE07
      Text in Illustration
      *a Cylinder Block Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

      Using a straightedge and feeler gauge, measure the warpage on the cylinder block side and the intake manifold side and exhaust manifold side.

      Maximum warpage
      0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the cylinder head sub-assembly.

    2. Using a dye penetrant, check the cylinder head sub-assembly for cracks.

      If there are cracks, replace the cylinder head sub-assembly.