CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING BELT

    Click here

  2. REMOVE AIR CLEANER PIPE

  3. REMOVE AIR CLEANER HOSE NO.2

  4. REMOVE EXHAUST PIPE ASSEMBLY FRONT

    Click here

  5. REMOVE REAR HEATER WATER INLET HOSE A (FROM ENGINE)

  6. REMOVE AIR HOSE NO.1

  7. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  8. REMOVE AIR HOSE NO.3

  9. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

  10. REMOVE RADIATOR HOSE OUTLET

  11. REMOVE INTAKE AIR CONNECTOR


    1. A01KGL2

      Disconnect the connector and hose.


      1. Disconnect the throttle control motor connector.

      2. Disconnect the throttle full switch connector.

      3. Disconnect the Intake air temp. sensor connector.

      4. Disconnect the vacuum hose.

    2. Remove the 2 bolts, 2 nuts, gasket and intake air connector with diesel throttle body assembly.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Disconnect the 4 injector connectors.

    2. Remove the 2 bolts and disconnect the engine wire protector.

    3. Remove the 4 injection pipes Click here.

    4. Remove the 4 nozzle holder seals.

    5. A01KINQ

      Remove the 10 bolts, 2 nuts, cylinder head cover and the cylinder head cover gasket.

    6. A01KGGW

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  13. REMOVE INJECTOR ASSEMBLY

    Click here

  14. REMOVE CAMSHAFT TIMING PULLEY


    1. A01KF8M

      Hold the hexagonal wrench head portion of the camshaft with a wrench, and remove the No.1 camshaft timing pulley bolt.

    2. A01KFEQE01

      Using SST, remove the No.1 camshaft timing pulley.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061 )

    3. Remove the set key.

  15. REMOVE TIMING BELT NO.2 COVER

  16. REMOVE EGR PIPE SUB-ASSEMBLY NO.1


    1. Remove the 2 nuts.

    2. Remove the EGR control valve, EGR pipe sub-assembly and 2 gaskets.

  17. REMOVE VSV ASSEMBLY


    1. Remove the 2 bolts and VSV assembly.

  18. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01KGCJE01

      Using SST, remove the oil filter.

      SST
      09228-10002

      Tech Tips

      As the oil in the filter flows out through the drain hose, place the drain oil container under the drain hose.

    2. Clean the oil filter contact surface on the oil filter mounting.

    3. Lubricate the filter rubber gasket with clean engine oil.

  19. REMOVE INTAKE MANIFOLD


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

  20. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01KICG

    1. Remove the bolt and injection pipe clamp No. 2.

    2. Using a union wrench 17mm, loosen the fuel inlet union of common rail side.

    3. Using a union wrench 17 mm, loosen the fuel inlet pipe union of pump side.

    4. Remove the inlet pipe sub-assembly.

      Note

      After removing the fuel pipe, affix the gum tape to the pump, common rail, and the whole injector installation area of the cylinder head cover for preventing dust.

  21. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2

    A01KHU4

    1. Disconnect the fuel hose from the nozzle leakage pipe assembly No. 2.

    2. Remove the 2 bolts, 2 union bolts, check valve, nozzle leakage pipe assembly No. 2 and 3 gaskets.

  22. REMOVE COMMON RAIL ASSEMBLY

    A01KHS5

    1. Disconnect the sensor connectors.

    2. Remove the 3 bolts and common rail assembly.

      Note


      • Do not disassemble the pressure limiter.

      • Do not reuse the fuel pressure sensor.

  23. REMOVE CAMSHAFT


    1. A01KFXNE01
      Text in Illustration
      *1 key Groove
      *a Upward

      Set the key groove of the camshaft, facing upward by turning the camshaft with a wrench.

    2. A01KHD2E01

      Uniformly loosen and remove the 15 bolts in several passes, in the sequence shown.

    3. Remove the 5 camshaft bearing caps.

    4. Remove the 2 camshafts and oil seal.

  24. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01KEAPE01

      Uniformly loosen and remove the 18 cylinder head bolts, in several passes, in the sequence shown.

      Note

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

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

      Tech Tips

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

      Note

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

  25. REMOVE CYLINDER HEAD GASKET

  26. REMOVE SEMICIRCULAR PLUG