CYLINDER HEAD GASKET(w/ DPF) REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

When replacing an injector (including interchanging injectors between cylinders), common rail, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.

Note

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH AND NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

    Click here

  4. CHECK INJECTOR COMPENSATION CODE

    Click here

  5. REMOVE GENERATOR ASSEMBLY

    Click here

  6. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET

    Click here

  7. REMOVE AIR TUBE SUPPORT

    Click here

  8. REMOVE NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  10. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  11. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  12. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

  13. REMOVE TURBOCHARGER WIRE

    Click here

  14. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  16. REMOVE ENGINE MOUNTING BRACKET LH

    Click here

  17. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    Click here

  18. REMOVE COMPRESSOR BRACKET

    Click here

  19. REMOVE STIFFENER INSULATOR RH

    Click here

  20. DISCONNECT NO. 1 OIL COOLER HOSE

    Click here

  21. DISCONNECT NO. 2 OIL COOLER HOSE

  22. REMOVE CRANKSHAFT PULLEY

    Click here

  23. REMOVE TIMING GEAR COVER SPACER

    Click here

  24. REMOVE OIL FILTER ELEMENT

    Click here

  25. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  26. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  27. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  28. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  29. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  30. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  31. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  32. REMOVE VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

    Click here

  33. REMOVE NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  34. REMOVE WATER INLET

    Click here

  35. REMOVE THERMOSTAT

    Click here

  36. REMOVE TIMING GEAR COVER INSULATOR

    Click here

  37. REMOVE FAN BRACKET SUB-ASSEMBLY

    Click here

  38. REMOVE NO. 2 IDLER PULLEY (w/ Viscous Heater)

    Click here

  39. REMOVE NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  40. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  41. DISCONNECT INLET WATER HOSE

    Click here

  42. REMOVE STARTER ASSEMBLY

    Click here

  43. REMOVE STARTER HOSE BRACKET


    1. B001Y5L

      Remove the 2 bolts and starter hose bracket.

  44. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

    Click here

  45. REMOVE WATER OUTLET

    Click here

  46. REMOVE WATER OUTLET PIPE

    Click here

  47. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  48. REMOVE GLOW PLUG ASSEMBLY

    Click here

  49. REMOVE VACUUM PUMP ASSEMBLY

    Click here

  50. REMOVE CYLINDER HEAD COVER INSULATOR RH

  51. REMOVE FUEL INJECTOR RH

    Click here

  52. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  53. REMOVE NO. 2 FUEL PUMP BRACKET

    Click here

  54. REMOVE CYLINDER HEAD COVER INSULATOR LH

  55. REMOVE FUEL INJECTOR LH

    Click here

  56. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  57. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  58. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Click here

  59. REMOVE FUEL INJECTOR SEAL

    Click here

  60. REMOVE WATER PUMP ASSEMBLY

    Click here

  61. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  62. REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  63. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  64. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  65. REMOVE PUMP DRIVE SHAFT GEAR

    Click here

  66. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  67. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    Click here

  68. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  69. REMOVE NO. 1 CAMSHAFT TIMING SPROCKET AND NO. 1 TIMING CHAIN

    Click here

  70. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  71. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    Click here

  72. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  73. REMOVE NO. 2 CAMSHAFT TIMING SPROCKET AND NO. 2 TIMING CHAIN

    Click here

  74. REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT

    Click here

  75. REMOVE IDLE GEAR ASSEMBLY

    Click here

  76. REMOVE NO. 1 IDLE GEAR SHAFT

    Click here

  77. REMOVE FUEL SUPPLY PUMP DRIVE GEAR

    Click here

  78. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  79. REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  80. REMOVE V-BANK SILENCER

    Click here

  81. REMOVE TIMING GEAR CASE SUB-ASSEMBLY

    Click here

  82. REMOVE NO. 1 AND NO. 2 CAMSHAFTS

    Click here

  83. REMOVE NO. 3 AND NO. 4 CAMSHAFTS

    Click here

  84. REMOVE NO. 2 CAMSHAFT BEARING CAP

    Click here

  85. REMOVE NO. 5 CAMSHAFT BEARING CAP

    Click here

  86. REMOVE NO. 1 VALVE ROCKER ARM

    Click here

  87. REMOVE NO. 2 VALVE ROCKER ARM

    Click here

  88. REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY

    Click here

  89. REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY

    Click here

  90. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  91. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  92. REMOVE NO. 1 CYLINDER HEAD GASKET

  93. REMOVE NO. 2 CYLINDER HEAD GASKET