CYLINDER HEAD 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.


  1. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

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

  2. REMOVE TIMING BELT

    Click here

  3. REMOVE EGR COOLER ASSEMBLY

    Click here

  4. REMOVE INJECTOR ASSEMBLY

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  5. REMOVE COMMON RAIL ASSEMBLY

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  6. REMOVE GLOW PLUG ASSEMBLY

    Click here

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  8. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  9. REMOVE CAMSHAFT

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  10. REMOVE CYLINDER BLOCK INSULATOR


    1. A01BA4G

      Remove the cylinder block insulator from the cylinder head.

  11. REMOVE MANIFOLD STAY


    1. A01BH2C

      Remove the 2 bolts and manifold stay.

  12. REMOVE INTAKE MANIFOLD


    1. A01BDGB

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

  13. REMOVE EXHAUST MANIFOLD


    1. A01BGE3

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

  14. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01BCAVE01

      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.

      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 or cylinder block.

  15. REMOVE CYLINDER HEAD GASKET