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 injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

Click here


    for 2KD-FTV:

  • Replacement of diesel throttle body assembly

 Perform initialization -

Click here

Replacement of timing belt Mode reset operation

  • Does not illuminate when replacement is necessary

  • Illuminates when replacement is not necessary

Click here

CAUTION:

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

B0026TA

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 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)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. PRECAUTION

    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

  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

  3. DRAIN ENGINE OIL

    Click here

  4. REMOVE INTAKE MANIFOLD

    Click here

  5. REMOVE GLOW PLUG ASSEMBLY

    Click here

  6. REMOVE INJECTOR ASSEMBLY

    Click here

  7. REMOVE COMMON RAIL ASSEMBLY

    Click here

  8. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  9. REMOVE FAN SHROUD

    Click here

  10. DISCONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  11. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  12. REMOVE NO. 1 TIMING BELT COVER

    Click here

  13. REMOVE TIMING BELT

    Click here

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

    Click here

  15. REMOVE CAMSHAFT TIMING PULLEY


    1. B0028DN

      Remove the bolt of the camshaft timing pulley while holding the intake camshaft sub-assembly with a wrench.

      Note

      Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

    2. Remove the camshaft timing pulley from the intake camshaft sub-assembly.

  16. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and No. 2 timing belt cover from the cylinder head sub-assembly and timing gear cover.

  17. REMOVE CAMSHAFT SUB-ASSEMBLY

    Click here

  18. REMOVE VALVE LIFTER

    Click here

  19. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B00247LN01

      Uniformly loosen the 18 cylinder head set bolts in several passes in the sequence shown in the illustration. Then remove the 18 cylinder head set bolts and 18 washers.

      Note

      Cylinder head warpage or cracking could result from removing bolts in the incorrect order.

    2. Lift the cylinder head sub-assembly from the dowels 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.

  20. REMOVE CYLINDER HEAD GASKET