CYLINDER HEAD GASKET(w/ DPF) REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. PRECAUTION

   Note

   After turning the engine 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.

   
   

   1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

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

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4. CHECK INJECTOR COMPENSATION CODE

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5. REMOVE GENERATOR ASSEMBLY

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6. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET

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7. REMOVE AIR TUBE SUPPORT

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

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

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10. REMOVE ENGINE MOUNTING BRACKET RH

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11. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

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12. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET

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13. REMOVE TURBOCHARGER WIRE

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

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

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16. REMOVE ENGINE MOUNTING BRACKET LH

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17. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

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18. REMOVE COMPRESSOR BRACKET

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19. REMOVE STIFFENER INSULATOR RH

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20. DISCONNECT NO. 1 OIL COOLER HOSE

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21. DISCONNECT NO. 2 OIL COOLER HOSE

22. REMOVE CRANKSHAFT PULLEY

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23. REMOVE TIMING GEAR COVER SPACER

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24. REMOVE OIL FILTER ELEMENT

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25. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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26. REMOVE ENGINE OIL LEVEL SENSOR

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27. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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28. REMOVE OIL STRAINER SUB-ASSEMBLY

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29. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

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30. REMOVE CAMSHAFT POSITION SENSOR

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31. REMOVE CRANKSHAFT POSITION SENSOR

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

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

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34. REMOVE WATER INLET

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35. REMOVE THERMOSTAT

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36. REMOVE TIMING GEAR COVER INSULATOR

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37. REMOVE FAN BRACKET SUB-ASSEMBLY

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

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

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40. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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41. DISCONNECT INLET WATER HOSE

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42. REMOVE STARTER ASSEMBLY

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43. REMOVE STARTER HOSE BRACKET

    
    

    1. 

       Remove the 2 bolts and starter hose bracket.

44. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET

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45. REMOVE WATER OUTLET

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46. REMOVE WATER OUTLET PIPE

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47. REMOVE NO. 1 GLOW PLUG CONNECTOR

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48. REMOVE GLOW PLUG ASSEMBLY

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49. REMOVE VACUUM PUMP ASSEMBLY

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50. REMOVE CYLINDER HEAD COVER INSULATOR RH

51. REMOVE FUEL INJECTOR RH

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52. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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53. REMOVE NO. 2 FUEL PUMP BRACKET

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54. REMOVE CYLINDER HEAD COVER INSULATOR LH

55. REMOVE FUEL INJECTOR LH

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56. REMOVE OIL SEPARATOR ASSEMBLY

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57. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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58. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

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59. REMOVE FUEL INJECTOR SEAL

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60. REMOVE ENGINE WATER PUMP ASSEMBLY

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61. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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62. REMOVE FRONT CRANKSHAFT OIL SEAL

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63. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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64. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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65. REMOVE PUMP DRIVE SHAFT GEAR

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66. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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67. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

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68. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

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70. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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71. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

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72. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

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74. REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT

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75. REMOVE IDLE GEAR ASSEMBLY

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76. REMOVE NO. 1 IDLE GEAR SHAFT

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77. REMOVE FUEL SUPPLY PUMP DRIVE GEAR

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78. REMOVE FUEL PUMP MOTOR WIRE

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79. REMOVE FUEL SUPPLY PUMP ASSEMBLY

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80. REMOVE V-BANK SILENCER

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81. REMOVE TIMING GEAR CASE SUB-ASSEMBLY

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82. REMOVE NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT

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83. REMOVE NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT

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84. REMOVE NO. 2 CAMSHAFT BEARING CAP

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85. REMOVE NO. 5 CAMSHAFT BEARING CAP

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

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87. REMOVE NO. 2 VALVE ROCKER ARM SUB-ASSEMBLY

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88. REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY

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89. REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY

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90. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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91. REMOVE CYLINDER HEAD LH

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92. REMOVE CYLINDER HEAD GASKET

93. REMOVE NO. 2 CYLINDER HEAD GASKET