CYLINDER HEAD 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 under "REMOVE TIMING BELT" Click here.

  3. REMOVE INJECTOR ASSEMBLY

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

  4. REMOVE COMMON RAIL ASSEMBLY

    A01BFUS

    1. Disconnect the 2 connectors from the common rail.

    2. Disconnect the fuel hose.

    3. A01BEK0

      Remove the 2 bolts and remove the common rail.

  5. REMOVE MANIFOLD STAY

    A01BEOH

    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

    A01BE1N

    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

    A01BFOP

    1. Remove the No. 2 intake manifold Insulator.

  8. REMOVE GLOW PLUG ASSEMBLY

    A01BB48

    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

    A01BAG7

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

  12. SEPARATE TAIL EXHAUST PIPE ASSEMBLY (for Long Wheelbase)

    A01BI3O

    1. Remove the 2 bolts and 2 nuts, and separate the tail exhaust pipe.

    2. A01BHA3

      Remove the gasket.

  13. SEPARATE CENTER EXHAUST PIPE ASSEMBLY (for Super Long Wheelbase)

    A01BB6L

    1. Remove the 2 bolts and 2 nuts, and separate the center exhaust pipe.

    2. A01BHA3

      Remove the gasket.

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    A01BH7S

    1. Remove the 2 bolts and the 2 compression springs.

    2. Remove the hanger and the front exhaust pipe.

    3. A01BAYV

      Remove the gasket.

  15. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFYF

      Remove the 2 hose clamps, bolt and compressor outlet elbow.

  16. DISCONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01BBX8

      Disconnect the turbocharger motor connector.

  17. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01BHN9

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  18. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01BETM

      Disconnect the turbocharger stroke sensor connector.

  19. REMOVE VENTILATION PIPE SUB-ASSEMBLY


    1. A01BHQ5

      Remove the bolt and ventilation pipe sub-assembly.

  20. REMOVE NO. 1 TURBO INSULATOR


    1. A01BEFA

      Remove the 2 bolts and turbo insulator.

  21. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01BG6A

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

  22. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01BC20

      Loosen the 2 clips and disconnect the 2 turbo water hoses.

  23. REMOVE TURBINE OUTLET ELBOW


    1. A01BE8V

      Remove the 3 nuts, turbine outlet elbow and gasket.

  24. REMOVE TURBOCHARGER STAY


    1. A01BCUS

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

  25. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BCPXE01

      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, If mistakenly loosened, replace the turbocharger.

  26. REMOVE EXHAUST MANIFOLD

    A01BFQG

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

  27. REMOVE CAMSHAFT TIMING PULLEY

    A01BBTF

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

    2. A01BDDQE01

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-05010, 09957-04010 )
      09955-04150
    3. A01BFILE02

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

  28. REMOVE NO. 2 TIMING BELT COVER


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

  29. REMOVE CYLINDER BLOCK INSULATOR

  30. REMOVE NO. 2 CAMSHAFT

    A01BHKIE02

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

    2. A01BHPHE01

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

    3. Remove the 5 bearing caps.

    4. A01BD22

      Remove the No. 2 camshaft.

  31. REMOVE CAMSHAFT

    A01BGX8

    1. Remove the camshaft.

  32. REMOVE CAMSHAFT SETTING OIL SEAL

    A01BCDE

    1. Remove the oil seal from the camshaft.

  33. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A01BCAVE01

    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 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.

  34. REMOVE CYLINDER HEAD GASKET