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	w/o DPF Click here w/ DPF Click here
	for RC61: Performing iMT installation information reset	iMT system DTCs are output	Click here
	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	w/o DPF Click here w/ DPF Click here
Replacement of engine assembly	Clear Crank Time Compensation Data	Engine starting	w/o DPF Click here w/ DPF Click here
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	w/o DPF Click here w/ DPF Click here
Replacement of injector assembly	Injector compensation code registration Pilot quantity learning	Engine starting	w/o DPF Click here w/ DPF Click here
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	-	w/o DPF Click here w/ DPF Click here
for AC60E: Replacement of automatic transmission assembly	Reset memory	Large shift shock Engine overruns	Click here
for AC60E: 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	Click here
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	Click here
w/ Automatic Headlight Beam Level Control System: The vehicle height changes due to replacement of suspension components or after performing such operations as removal and reinstallation	Headlight leveling ECU assembly initialization	Headlight leveling function	Click here
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.

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 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

REMOVE CAMSHAFT

Click here
REMOVE TIMING CHAIN COVER ASSEMBLY

Click here
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Click here
REMOVE VALVE LASH ADJUSTER ASSEMBLY

Click here
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. 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.
REMOVE CYLINDER HEAD GASKET

Click here
INSPECT CYLINDER HEAD SET BOLT

Click here