CYLINDER HEAD GASKET REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the cylinder head gasket removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of ECM

  • Learning values save

  • Learning values write

 Engine starting
Code registration (Immobiliser system) Engine start function See the Service Bulletin for the registration method.
Replacement of engine assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting
Clear Crank Time Compensation Data Engine starting
Replacement of crankshaft position sensor plate Clear Crank Time Compensation Data Crank time compensation data compensation amount is same as before replacement, affecting crank time compensation data
Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

    for AC60F:

  • Replacement of automatic transmission assembly

 Reset memory

  • Large shift shock

  • Engine overruns

Click here


    for AC60F:

  • Replacement of automatic transmission fluid

 ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

    for 4WD:

  • Front wheel alignment adjustment

  • Clearing zero point calibration data

  • Yaw rate and acceleration sensor zero point calibration

 VSC malfunctioning

Click here

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B003QVR

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. REMOVE CAMSHAFT


  2. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

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

    Click here

  4. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  5. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B003NZUN01

      Uniformly loosen the 10 cylinder head set bolts in several passes in the sequence shown in the illustration. Then remove the 10 cylinder head set bolts and 6 cylinder head set bolt spacers.

      Note


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

      • Be careful not to drop the cylinder head set bolt spacers into the cylinder head sub-assembly.

    2. Lift the cylinder head sub-assembly from the ring pins on the cylinder block sub-assembly, and place the cylinder head sub-assembly on wooden blocks on a bench.

      Note

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

      Tech Tips

      If the cylinder head sub-assembly is difficult to lift, use a screwdriver to pry between the cylinder head sub-assembly and cylinder block sub-assembly.

  6. REMOVE CYLINDER HEAD GASKET

  7. INSPECT CYLINDER HEAD SET BOLT

    Click here