CYLINDER HEAD GASKET(w/o 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.

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 ENGINE ASSEMBLY


    1. Remove the engine assembly from the vehicle Click here.

  4. CHECK INJECTOR COMPENSATION CODE

    Click here

  5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE

    Click here

  6. REMOVE GENERATOR ASSEMBLY

    Click here

  7. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  8. DISCONNECT NO. 2 VENTILATION HOSE

    Click here

  9. DISCONNECT NO. 2 TURBO WATER HOSE

    Click here

  10. DISCONNECT BREATHER PLUG RH

    Click here

  11. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  12. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE

    Click here

  13. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 1 TURBOCHARGER STAY

    Click here

  15. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY

    Click here

  16. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH

    Click here

  17. DISCONNECT NO. 3 VENTILATION HOSE

    Click here

  18. DISCONNECT BREATHER PLUG LH

    Click here

  19. DISCONNECT NO. 2 TURBO WATER HOSE

    Click here

  20. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  22. REMOVE FRONT WATER BY-PASS JOINT

    Click here

  23. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  24. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE

    Click here

  25. REMOVE NO. 2 TURBOCHARGER STAY

    Click here

  26. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY

    Click here

  27. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

    Click here

  28. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET

    Click here

  29. REMOVE AIR TUBE SUPPORT

    Click here

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

    Click here

  31. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)

    Click here

  32. REMOVE ENGINE MOUNTING BRACKET RH

    Click here

  33. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  34. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

  35. REMOVE TURBOCHARGER WIRE

    Click here

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

    Click here

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

    Click here

  38. REMOVE ENGINE MOUNTING BRACKET LH

    Click here

  39. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    Click here

  40. REMOVE COMPRESSOR BRACKET

    Click here

  41. REMOVE STIFFENER INSULATOR RH (w/ Intercooler)

    Click here

  42. DISCONNECT NO. 1 OIL COOLER HOSE

    Click here

  43. DISCONNECT NO. 2 OIL COOLER HOSE

  44. REMOVE CRANKSHAFT PULLEY

    Click here

  45. REMOVE TIMING GEAR COVER SPACER (w/ Intercooler)

    Click here

  46. REMOVE OIL FILTER ELEMENT

    Click here

  47. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  48. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  50. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  51. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  52. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  53. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

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

    Click here

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

    Click here

  56. REMOVE WATER INLET

    Click here

  57. REMOVE THERMOSTAT

    Click here

  58. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)

    Click here

  59. REMOVE FAN BRACKET SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  62. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  63. DISCONNECT INLET WATER HOSE

    Click here

  64. REMOVE STARTER ASSEMBLY

    Click here

  65. REMOVE STARTER HOSE BRACKET


    1. B001YOU

      Remove the 2 bolts and starter hose bracket.

  66. REMOVE CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. B001YN2

      Remove the 2 bolts and clutch flexible hose bracket.

  67. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

    Click here

  68. REMOVE WATER OUTLET

    Click here

  69. REMOVE WATER OUTLET PIPE

    Click here

  70. REMOVE NO. 1 GLOW PLUG CONNECTOR

    Click here

  71. REMOVE GLOW PLUG ASSEMBLY

    Click here

  72. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)

    Click here

  73. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  74. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)

    Click here

  75. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)

    Click here

  76. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)

    Click here

  77. REMOVE NOZZLE HOLDER SEAL RH

    Click here

  78. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  79. REMOVE NOZZLE HOLDER GASKET RH

    Click here

  80. REMOVE OIL SEPARATOR ASSEMBLY

    Click here

  81. REMOVE NOZZLE HOLDER SEAL LH

    Click here

  82. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  83. REMOVE NOZZLE HOLDER GASKET LH

    Click here

  84. REMOVE FUEL INJECTOR RH

    Click here

  85. REMOVE FUEL INJECTOR LH

    Click here

  86. REMOVE WATER PUMP ASSEMBLY

    Click here

  87. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B001XFXE01
      *1 Nut

      Remove the 4 nuts and 16 bolts.

    2. Using a screwdriver, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

      B001X66
    3. B001ZOP

      Remove the O-ring from the timing gear case.

  88. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. B001ZCAE04
      *1 Wooden Block

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  89. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

    2. Turn the crankshaft clockwise to set the No. 1 cylinder to TDC.

    3. With the crankshaft key 45° counterclockwise from the top position, check that the timing marks of the RH and LH camshaft timing gears are aligned. If not as specified, turn the crankshaft 1 revolution (360°) and align the timing marks as shown below.

      B00202ME04
      *1 Top
      *2 Key

    4. Remove the 2 crankshaft pulley set bolts.

  90. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001Y05

      Using a T30 "TORX" wrench, remove the 2 screws and crankshaft position sensor plate.

  91. REMOVE PUMP DRIVE SHAFT GEAR


    1. B001YCTE01

      Using SST, hold the pump drive shaft gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and pump drive shaft gear.

  92. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      B001ZSME02
      *1 Stopper Plate
    4. B001W1S

      Remove the 2 bolts and No. 1 chain tensioner.

  93. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    B001XAX

  94. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B001XUH

      Remove the 2 bolts and No. 1 chain vibration damper.

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

    B001Z4M

  96. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      B001VVQE02
      *1 Stopper Plate
    4. B001Z8I

      Remove the 2 bolts and No. 2 chain tensioner.

  97. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    B001ZYT

  98. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B001WGZ

      Remove the 2 bolts and No. 2 chain vibration damper.

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


    1. B001WY1E03

      Using SST, hold the No. 2 camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts, No. 2 camshaft timing sprocket and No. 2 timing chain.

  100. REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. Using SST, hold the idle gear.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the nut.

      B001XUCE03
      *1 w/ Intercooler:
      *2 w/o Intercooler:

  101. REMOVE IDLE GEAR ASSEMBLY


    1. B001YVH

      w/ Intercooler:

      Using a 8 mm x 1.25 pitch service bolt with a length of 15 mm or more, fix the idle gear in place.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. B001Z1KE03
      *1 w/ Intercooler:
      *2 w/o Intercooler:

      Remove the 2 bolts, idle gear thrust plate and idle gear.

  102. REMOVE NO. 1 IDLE GEAR SHAFT

    B001Z32

  103. REMOVE FUEL SUPPLY PUMP DRIVE GEAR


    1. B00202SE02

      Using SST, remove the fuel supply pump drive gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031 )

  104. REMOVE FUEL PUMP MOTOR WIRE

    Click here

  105. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. B001WXP

      Using a 6 mm hexagon wrench, remove the hexagon bolt. Then remove the 2 nuts and fuel supply pump.

    2. Remove the O-ring.

  106. REMOVE V-BANK SILENCER

    B001XGZ

  107. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. B001YQHE01
      *1 Nut

      Remove the 22 bolts, 2 nuts and timing gear case shown in the illustration.

    2. B001ZZ8

      Remove the 2 O-rings and timing gear case gasket.

  108. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. B001X5L

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B001ZSK

      Loosen the 2 union bolts.

    3. B001Y2AE02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. B001VUM

      Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

    5. B001WQI

      Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. B001W9F

      Remove the No. 1 and No. 2 camshafts.

  109. REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. B001X5L

      Using an 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B001Z1W

      Loosen the 2 union bolts.

    3. B001ZP4E02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. B001YZF

      Remove the 2 union bolts, and No. 3 and No. 4 oil feed pipes.

    5. B001VK9

      Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. B001W9E

      Remove the No. 3 and No. 4 camshafts.

  110. REMOVE NO. 2 CAMSHAFT BEARING CAP

    B001ZYR

  111. REMOVE NO. 5 CAMSHAFT BEARING CAP

    B001WTI

  112. REMOVE NO. 1 VALVE ROCKER ARM


    1. B001WME

      Remove the 16 No. 1 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  113. REMOVE NO. 2 VALVE ROCKER ARM


    1. B001X9L

      Remove the 16 No. 2 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  114. REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY


    1. B001XJ4

      Remove the 16 No. 1 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  115. REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY


    1. B001Y5C

      Remove the 16 No. 2 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  116. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. B001ZLAE02

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  117. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. B001Z0OE02

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  118. REMOVE NO. 1 CYLINDER HEAD GASKET

  119. REMOVE NO. 2 CYLINDER HEAD GASKET