CYLINDER HEAD REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. DRAIN ENGINE COOLANT

    A003F1ME01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir cap while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

    3. Loosen the cylinder block drain plug and drain the coolant.

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. REMOVE RADIATOR HOSE INLET

  4. DISCONNECT HEATER WATER HOSE INLET A

  5. DISCONNECT FUEL HOSE

  6. REMOVE TIMING BELT

    Click here

  7. SEPARATE AIR CLEANER HOSE NO.2


    1. Loosen the bolt, and disconnect the air cleaner hose No.2.

  8. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Disconnect the ventilation hose.

    2. Disconnect the turbo pressure sensor connector.

    3. A003FXV

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

  9. REMOVE VENTURI ASSEMBLY


    1. A003I6AE01

      Disconnect the throttle open switch connector.

    2. A003G5UE01

      Disconnect the throttle control motor connector.

    3. Remove the venturi and gasket.

  10. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. Remove the 3 bolts and exhaust manifold heat insulator No.1.

  11. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Long Wheelbase)


    1. Remove the 4 bolts, 2 compression springs.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front No.2 and 2 gaskets.

  12. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)


    1. Remove the 4 bolts, 2 nuts, 2 compression springs.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front No.2 and 2 gaskets.

  13. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Long Wheelbase)


    1. Loosen the clamp bolt, and separate the exhaust pipe support bracket No.1 from the exhaust pipe sub-assembly front No.1.

    2. Remove the 3 bolts, exhaust pipe sub-assembly front No.1 and gasket from the exhaust manifold.

  14. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Super Long Wheelbase)


    1. Loosen the clamp bolt, and separate the exhaust pipe support bracket No.1 from the exhaust pipe sub-assembly front No.1.

    2. Remove the 3 bolts, exhaust pipe sub-assembly front No.1 and gasket from the exhaust manifold.

  15. REMOVE INJECTION PIPE SET


    1. Loosen the 8 union nuts of the 4 injection pipes.

    2. Remove the 2 nuts, 2 upper pipe clamps, and 4 injection pipes with lower pipe clamps.

  16. REMOVE GLOW PLUG NO.1 CONNECTOR


    1. Remove the vehicle's side wire harness, glow plug screw grommets and nuts, and disconnect the glow plug No.1 connector.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Disconnect the ventilation hose.

    2. Remove the 9 bolts, nut, cylinder head cover and gasket.

  18. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003B08E02

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

      Note

      Head warpage or cracking could result from removing 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 bench.

  19. REMOVE CYLINDER HEAD GASKET