CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE EGR COOLER ASSEMBLY (w/ EGR System)

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  2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  3. INSTALL ENGINE TO ENGINE STAND (w/o EGR System)

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  4. REMOVE ENGINE MOTOR CABLE CLAMP BRACKET (w/o EGR System)

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  5. REMOVE FUEL INJECTOR ASSEMBLY

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  6. REMOVE FUEL INJECTOR SET

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  7. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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  8. REMOVE NO. 6 WATER BY-PASS HOSE (w/o EGR System)


    1. A000OR9

      Slide the clip and disconnect the No. 6 water by-pass hose from the water by-pass pipe.

  9. REMOVE NO. 5 WATER BY-PASS HOSE (w/o EGR System)


    1. A000RJ5

      Slide the clip and disconnect the No. 5 water by-pass hose from the water by-pass pipe.

  10. REMOVE WATER BY-PASS PIPE (w/o EGR System)


    1. A000NBL

      Remove the nut, bolt and water by-pass pipe from the cylinder head sub-assembly.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

  11. REMOVE NO. 9 WATER BY-PASS HOSE


    1. A000OUW

      Slide the clip and disconnect the No. 9 water by-pass hose from the cylinder head sub-assembly.

  12. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A000P6GE02
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Remove the 2 bolts and disconnect the No. 2 water by-pass pipe.

  13. REMOVE SPARK PLUG

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  14. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      Tech Tips

      Be sure to keep the removed parts for each installation position separate.

  15. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Be sure to keep the removed parts for each installation position separate.

  16. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the valve stem ends.

      Tech Tips

      Be sure to keep the removed parts for each installation position separate.

  17. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A000RE7E01

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head set bolts in the sequence shown in the illustration. Remove the 10 cylinder head set bolts and plate washers.

      Note


      • Be careful not to drop the plate washers into the cylinder head sub-assembly.

      • Cylinder head sub-assembly warpage or cracking could result from removing cylinder head set bolts in an incorrect order.

      Tech Tips

      Be sure to keep the removed parts for each installation position separate.

    2. Remove the cylinder head sub-assembly.

  18. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block sub-assembly.

  19. INSPECT CYLINDER HEAD SET BOLT

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  20. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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