CYLINDER HEAD (w/o DPF) REMOVAL


  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. REMOVE TIMING BELT

    Refer to the procedures up to "REMOVE TIMING BELT" Click here.

  3. REMOVE INJECTOR ASSEMBLY

    Refer to the procedures up to "REMOVE INJECTOR ASSEMBLY" Click here.

  4. REMOVE COMMON RAIL ASSEMBLY


    1. A01KHC7

      Disconnect the 2 connectors from the common rail.

    2. Disconnect the fuel hose.

    3. A01KI1X

      Remove the 2 bolts and remove the common rail.

  5. REMOVE MANIFOLD STAY

    A01KGL0

    1. Separate the 3 vacuum hoses and gas filter.

    2. Remove the 4 bolts and remove the manifold stay.

  6. REMOVE NO. 1 GLOW PLUG CONNECTOR

    A01KIEP

    1. Remove the screw grommet and nut and separate the wire harness from the No. 1 glow plug connector.

    2. Remove the 4 screw grommets and 4 nuts and remove the No.1 glow plug connector.

  7. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    A01KILK

    1. Remove the No. 2 intake manifold Insulator.

  8. REMOVE GLOW PLUG ASSEMBLY

    A01KIIK

    1. Remove the 4 glow plugs.

  9. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

  10. REMOVE FUEL COOLER


    1. Remove the 2 bolts and fuel cooler.

  11. REMOVE INTAKE MANIFOLD

    A01KHW9

    1. Remove the 2 nuts and 4 bolts, then remove the intake manifold and gasket.

  12. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    A01KHYR

    1. Remove the 2 nuts and the 2 bolts from the center exhaust pipe.

    2. A01KIGB

      Remove the gasket from the front exhaust pipe.

    3. Remove the 2 bolts and the 2 compression springs from the turbine outlet elbow.

    4. Remove the 2 hooks and the front exhaust pipe.

    5. A01KI40

      Remove the gasket from the turbine outlet elbow.

  13. DISCONNECT NO. 1 AIR HOSE


    1. A01KHAW

      Loosen the hose clamp and disconnect the No. 1 air hose .

  14. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01KEB4

      Remove the hose clamp and bolt shown in the illustration and remove the compressor outlet elbow with No. 2 air hose.

  15. DISCONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01KHOK

      Disconnect the turbocharger motor connector from the turbocharger.

  16. REMOVE NO. 2 AIR CLEANER HOSE


    1. A01KF86

      Loosen the hose clamp and remove the NO. 2 air cleaner hose.

  17. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01KEZH

      Disconnect the turbocharger stroke sensor connector from the turbocharger.

  18. SEPARATE ENGINE WIRE HARNESS (for LHD)


    1. A01KG9Q

      Remove the 2 bolts and separate the engine wire harness with bracket.

  19. SEPARATE ENGINE WIRE HARNESS (for RHD)


    1. A01KIQT

      Remove the 2 bolts and separate the engine wire harness with bracket.

  20. REMOVE VENTILATION PIPE SUB-ASSEMBLY


    1. A01KGB4

      Remove the bolt and ventilation pipe sub-assembly.

  21. REMOVE NO. 1 TURBO INSULATOR


    1. A01KGR2

      Remove the 2 bolts and turbo insulator No. 1.

  22. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01KG7W

      Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

  23. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01KHWT

      Loosen the 2 clamps and disconnect No. 1 turbo water hose.

  24. REMOVE TURBINE OUTLET ELBOW


    1. A01KEND

      Remove the 3 nuts, turbine outlet elbow and gasket.

  25. REMOVE TURBOCHARGER STAY


    1. A01KFD3

      Remove the 2 bolts and nut and remove the turbocharger stay.

  26. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KEC7E01

      Remove the 2 bolts, 2 nuts and union bolt, then remove the turbo oil inlet pipe sub-assembly and gasket.

      Note

      Do not loosen the nut labeled A.

  27. REMOVE OIL LEVEL GAUGE GUIDE (for LHD)


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

    3. Remove the O-ring from the oil level gauge guide.

  28. REMOVE EXHAUST MANIFOLD

    A01KG97

    1. Remove the 8 nuts, and then remove the exhaust manifold.

  29. REMOVE CAMSHAFT TIMING PULLEY

    A01KGL6

    1. Remove the bolt from the camshaft timing pulley while holding the camshaft with a wrench.

    2. A01KIA4E06
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
    3. A01KGB9E02

      Rotate the crankshaft approximately 90° counterclockwise from the TDC position to lower the piston.

  30. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and timing belt cover.

  31. REMOVE CYLINDER BLOCK INSULATOR

  32. REMOVE NO.2 CAMSHAFT

    A01KICNE04

    1. Face the key groove of the camshaft upward by turning the camshaft with a wrench.

      Text in Illustration
      *1 Key Groove
      *a Upward
    2. A01KI8RE01

      Uniformly loosen the 15 bearing cap bolts in several steps in the sequence shown in the illustration.

    3. Remove the 5 bearing caps.

    4. A01KF8Y

      Remove the No. 2 camshaft.

  33. REMOVE CAMSHAFT

    A01KI9C

    1. Remove the camshaft.

  34. REMOVE CAMSHAFT SETTING OIL SEAL

    A01KESS

    1. Remove the oil seal from the camshaft.

  35. 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 bolts in the incorrect order.

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

      Tech Tips

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

      Note

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

  36. REMOVE CYLINDER HEAD GASKET