CYLINDER HEAD GASKET REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERYTERMINAL

    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.

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

  2. REMOVE FRONT BUMPER LOWER COVER

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  4. DRAIN ENGINE COOLANT

    Click here

  5. DRAIN ENGINE OIL

    Click here

  6. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER


    1. Remove the exhaust manifold with turbocharger Click here.

  7. REMOVE INTAKE MANIFOLD


    1. Remove the intake manifold Click here.

  8. REMOVE GLOW PLUG ASSEMBLY


    1. Remove the glow plugs Click here.

  9. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  11. REMOVE COMMON RAIL ASSEMBLY

    Click here

  12. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

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


    1. B001FVS

      Disconnect the vacuum hose.

    2. Remove the bolt and No. 3 vacuum transmitting pipe.

  14. REMOVE NOZZLE HOLDER SEAL


    1. B001ET3

      Using a small screwdriver, remove the 4 holder seals by prying between each holder seal and the cutout part of the cylinder head cover.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. B001E0H

      Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.

    2. B001HEI

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  16. REMOVE INJECTOR ASSEMBLY

    Click here

  17. REMOVE TIMING BELT


    1. Remove the timing belt Click here.

  18. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  19. REMOVE CAMSHAFT TIMING PULLEY


    1. B001DCE

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  20. REMOVE NO. 2 TIMING BELT COVER


    1. B001FZZ

      Remove the 4 bolts, nuts and No. 2 timing belt cover.

  21. REMOVE CYLINDER BLOCK INSULATOR


    1. B001H9G

      Remove the cylinder block insulator from the cylinder head.

  22. REMOVE CAMSHAFT

    Click here

  23. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B001E6KE02

      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 bolts in the incorrect order.

    2. Remove 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 remove, use a screwdriver to pry between the cylinder head and block.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

  24. REMOVE CYLINDER HEAD GASKET