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CYLINDER HEAD GASKET(w/ DPF) REMOVAL

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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.

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PROCEDURE


  1. Click here

    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. Click here

    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. Click here

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

    (Click here)

  4. Click here

    CHECK INJECTOR COMPENSATION CODE

    Click here

  5. Click here

    REMOVE GENERATOR ASSEMBLY

    Click here

  6. Click here

    REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET

    Click here

  7. Click here

    REMOVE AIR TUBE SUPPORT

    Click here

  8. Click here

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

    Click here

  9. Click here

    REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  10. Click here

    REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  11. Click here

    REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  12. Click here

    REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

  13. Click here

    REMOVE TURBOCHARGER WIRE

    Click here

  14. Click here

    REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  15. Click here

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

    Click here

  16. Click here

    REMOVE ENGINE MOUNTING BRACKET LH

    Click here

  17. Click here

    REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    Click here

  18. Click here

    REMOVE COMPRESSOR BRACKET

    Click here

  19. Click here

    REMOVE STIFFENER INSULATOR RH

    Click here

  20. Click here

    DISCONNECT NO. 1 OIL COOLER HOSE

    Click here

  21. Click here

    DISCONNECT NO. 2 OIL COOLER HOSE

  22. Click here

    REMOVE CRANKSHAFT PULLEY

    Click here

  23. Click here

    REMOVE TIMING GEAR COVER SPACER

    Click here

  24. Click here

    REMOVE OIL FILTER ELEMENT

    Click here

  25. Click here

    REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  26. Click here

    REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  27. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  28. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  29. Click here

    REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  30. Click here

    REMOVE CAMSHAFT POSITION SENSOR

    Click here

  31. Click here

    REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  32. Click here

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

    Click here

  33. Click here

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

    Click here

  34. Click here

    REMOVE WATER INLET

    Click here

  35. Click here

    REMOVE THERMOSTAT

    Click here

  36. Click here

    REMOVE TIMING GEAR COVER INSULATOR

    Click here

  37. Click here

    REMOVE FAN BRACKET SUB-ASSEMBLY

    Click here

  38. Click here

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

    Click here

  39. Click here

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

    Click here

  40. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  41. Click here

    DISCONNECT INLET WATER HOSE

    Click here

  42. Click here

    REMOVE STARTER ASSEMBLY

    Click here

  43. Click here

    REMOVE STARTER HOSE BRACKET


    1. B001Y5L

      Remove the 2 bolts and starter hose bracket.

  44. Click here

    REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

    Click here

  45. Click here

    REMOVE WATER OUTLET

    Click here

  46. Click here

    REMOVE WATER OUTLET PIPE

    Click here

  47. Click here

    REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  48. Click here

    REMOVE GLOW PLUG ASSEMBLY

    Click here

  49. Click here

    REMOVE VACUUM PUMP ASSEMBLY

    Click here

  50. Click here

    REMOVE CYLINDER HEAD COVER INSULATOR RH

  51. Click here

    REMOVE FUEL INJECTOR RH

    Click here

  52. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  53. Click here

    REMOVE NO. 2 FUEL PUMP BRACKET

    Click here

  54. Click here

    REMOVE CYLINDER HEAD COVER INSULATOR LH

  55. Click here

    REMOVE FUEL INJECTOR LH

    Click here

  56. Click here

    REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  57. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  58. Click here

    REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Click here

  59. Click here

    REMOVE FUEL INJECTOR SEAL

    Click here

  60. Click here

    REMOVE WATER PUMP ASSEMBLY

    Click here

  61. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  62. Click here

    REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  63. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  64. Click here

    REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  65. Click here

    REMOVE PUMP DRIVE SHAFT GEAR

    Click here

  66. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Click here

  67. Click here

    REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    Click here

  68. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER

    Click here

  69. Click here

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

    Click here

  70. Click here

    REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  71. Click here

    REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    Click here

  72. Click here

    REMOVE NO. 2 CHAIN VIBRATION DAMPER

    Click here

  73. Click here

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

    Click here

  74. Click here

    REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT

    Click here

  75. Click here

    REMOVE IDLE GEAR ASSEMBLY

    Click here

  76. Click here

    REMOVE NO. 1 IDLE GEAR SHAFT

    Click here

  77. Click here

    REMOVE FUEL SUPPLY PUMP DRIVE GEAR

    Click here

  78. Click here

    REMOVE FUEL PUMP MOTOR WIRE

    Click here

  79. Click here

    REMOVE FUEL SUPPLY PUMP ASSEMBLY

    Click here

  80. Click here

    REMOVE V-BANK SILENCER

    Click here

  81. Click here

    REMOVE TIMING GEAR CASE SUB-ASSEMBLY

    Click here

  82. Click here

    REMOVE NO. 1 AND NO. 2 CAMSHAFTS

    Click here

  83. Click here

    REMOVE NO. 3 AND NO. 4 CAMSHAFTS

    Click here

  84. Click here

    REMOVE NO. 2 CAMSHAFT BEARING CAP

    Click here

  85. Click here

    REMOVE NO. 5 CAMSHAFT BEARING CAP

    Click here

  86. Click here

    REMOVE NO. 1 VALVE ROCKER ARM

    Click here

  87. Click here

    REMOVE NO. 2 VALVE ROCKER ARM

    Click here

  88. Click here

    REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY

    Click here

  89. Click here

    REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY

    Click here

  90. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  91. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  92. Click here

    REMOVE NO. 1 CYLINDER HEAD GASKET

  93. Click here

    REMOVE NO. 2 CYLINDER HEAD GASKET