CYLINDER HEAD (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

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

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  2. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. REMOVE TIMING BELT

    Click here

  4. REMOVE CAMSHAFTS

    Click here

  5. REMOVE COMMON RAIL ASSEMBLY

    Click here

  6. REMOVE EGR COOLER ASSEMBLY

    Click here

  7. REMOVE INJECTOR ASSEMBLY

    Click here

  8. REMOVE GLOW PLUG ASSEMBLY

    Click here

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (for LHD)


    1. Disconnect the wire harness from the wire harness clamp bracket.

    2. A01KI96

      Remove the 2 bolts and wire harness clamp bracket.

    3. A01KG1H

      Remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring from the engine oil level dipstick guide.

  10. SEPARATE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    A01KHTU

    1. Remove the 4 bolts and disconnect the cooler compressor.

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

    A01KELJ

    1. Remove the 4 bolts and No. 1 compressor mounting bracket.

  12. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  13. REMOVE EXHAUST MANIFOLD

    A01KHVE

    1. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

  14. REMOVE INTAKE MANIFOLD STAY


    1. A01KHHD

      Remove the 2 bolts and intake manifold stay.

  15. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A01KI8G

      Remove the No. 1 intake manifold insulator from the intake manifold.

  16. REMOVE INTAKE MANIFOLD


    1. A01KEVY

      Remove the 7 bolts, 2 nuts and intake manifold.

    2. Remove the gasket.

  17. REMOVE VACUUM CONTROL VALVE SET

    A01KGXZ

    1. Remove the 2 connectors and 3 vacuum hoses.

    2. A01KFXZ

      Remove the 2 bolts and vacuum control valve set.

  18. REMOVE SWIRL CONTROL VALVE ASSEMBLY


    1. A01KESJ

      Remove the 4 bolts, 2 nuts and swirl control valve.

    2. Remove the gasket.

  19. REMOVE CYLINDER BLOCK INSULATOR


    1. A01KF3S

      Remove the cylinder block insulator from the cylinder head.

  20. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A01KEGEE01

    1. Uniformly loosen the 18 cylinder head bolts in several passes in the sequence shown in the illustration. Then remove the 18 cylinder head bolts and 18 washers.

      Note

      Head warpage or cracking could result from removing the bolts in an incorrect order.

    2. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a workbench.

      Note

      Be careful not to damage the contact surfaces of the cylinder head or cylinder block.

      Tech Tips

      If the cylinder head is difficult to lift, use a screwdriver to pry between the cylinder head and block.

  21. REMOVE CYLINDER HEAD GASKET