CYLINDER HEAD GASKET REMOVAL


  1. DISCONNECT BATTERY NEGATIVE TERMINAL

  2. DRAIN COOLANT

  3. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)


    1. A01KHOR

      Remove the seat track cover.

    2. Remove the 4 bolts.

    3. Remove the front seat assembly RH.

  4. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  5. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

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  6. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and the engine service hole sub-cover.

  7. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1

  8. REMOVE RADIATOR ASSEMBLY

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  9. DISCONNECT HEATER WATER INLET HOSE A (W/ HEATER)

  10. DISCONNECT REAR HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (W/ HEATER)

  11. DISCONNECT WATER BY-PASS HOSE (w/ ACSD)

  12. DISCONNECT WATER BY-PASS HOSE NO.2 (w/ ACSD)

  13. REMOVE TIMING BELT

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  14. REMOVE ENGINE HANGER NO.2

  15. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1

  16. REMOVE EXHAUST FRONT PIPE ASSEMBLY NO.2

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  17. REMOVE EXHAUST PIPE ASSEMBLY FRONT

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  18. REMOVE THROTTLE CONTROL CABLE SUPPORT

    Tech Tips

    Remove the throttle control cable support with the accelerator flexible wire connect.

  19. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.1

  20. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.2

  21. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.3

  22. REMOVE INJECTION PIPE SUB-ASSEMBLY NO.4

  23. DISCONNECT ENGINE WIRE

  24. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Remove the 3 nuts and bolt, intake air connector and gasket.

  25. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  26. REMOVE CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No. 2)


    1. Remove the 4 nuts, plate washers, cylinder head cover No. 2 and cylinder head cover silencer.

  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.

  28. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01KG2LE01

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

  29. REMOVE CYLINDER HEAD GASKET