CYLINDER HEAD GASKET (w/o DPF) REMOVAL

CAUTION:

When replacing an injector (including interchanging injectors between cylinders), common rail, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.


  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. REMOVE ENGINE ASSEMBLY


    1. Remove the engine assembly from the vehicle Click here.

  4. CHECK INJECTOR COMPENSATION CODE

    A015A64E02

    Note


    • When a fuel injector is replaced, the new fuel injector compensation code must be input into the ECM. When the ECM is replaced, all of the existing fuel injector compensation codes must be input into the new ECM.

    • Fuel injector compensation codes are unique, 30 digit, alphanumeric values printed on the head portion of each fuel injector. If an incorrect fuel injector compensation code is input into the ECM, the engine assembly may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.


    1. After replacing fuel injector(s) with new one(s), input compensation code(s) of fuel injector(s) into ECM as follows:

      Tech Tips


      • Each fuel injector has different fuel injection characteristics. In order to optimize the fuel injections, the ECM uses the compensation codes to balance the different fuel injections between each fuel injector.

      • When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set. This is to inform you that registration of a fuel injector compensation code(s) is/are required. Manually clear the DTC upon completion of the compensation code registration.


      1. Input the compensation code(s), which is/are imprinted on the head portion(s) of the new fuel injector(s), into the intelligent tester.

      2. Input the new compensation code(s) into the ECM using the tester.

      3. Turn the tester off and turn the ignition switch off.

      4. Wait for at least 30 seconds.

      5. Turn the ignition switch to ON and turn the tester on.

      6. Clear DTC P1601 stored in the ECM using the tester Click here.

    2. Register compensation code.

      A0157BSE04

      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

        Note

        Do not start the engine.

      3. Turn the tester on.

      4. A0156CME01

        Enter the following menus: Powertrain / Engine / Utility / Injector Compensation.

      5. Press Next.

      6. A015DGLE01

        Press Next again to proceed.

      7. A0155RYE01

        Select "Set Compensation Code".

      8. Press Next.

      9. A015A0R

        Select the number of the cylinder corresponding to the fuel injector compensation code that you want to read.

      10. Press Next.

      11. A0156MFE01

        Register compensation code.


        1. Press Input.

        2. A0158O4

          Manually input the cylinder compensation code using the keyboard on the tester screen. The code is a 30 digit, alphanumeric value printed on the injector head portion.

          Tech Tips

          Each fuel injector compensation code is unique. The compensation code for each selected cylinder must be input into the tester correctly.

        3. Confirm that the compensation code for the selected cylinder is correct, and then press OK.

      12. A015CD0E01

        Check that the compensation code displayed on the screen is correct by comparing it with the 30 digit alphanumeric value on the head portion of the fuel injector.

        Note

        If an incorrect fuel injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

        Tech Tips


        • If a wrong compensation code is input or read, return to the Input Value screen by pressing Input.

        • The saving process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and repeat this operation.

      13. Press Next to register the compensation code in the ECM.

        Tech Tips


        • If the registration process fails, the compensation code may be incorrect. Check the compensation code again.

        • If the input compensation code fails to register even though it is input correctly, there may be a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and restart this operation.

      14. A015AQWE01

        If you want to continue with other compensation code registrations, press Next. To finish the registration, press Cancel.

      15. Turn the ignition switch off and then turn the tester off.

      16. Wait for at least 30 seconds.

      17. Turn the ignition switch to ON and then turn the tester on.

      18. Clear DTC P1601 stored in the ECM using the tester Click here.

  5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE


    1. A015AXC

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 5 wire harness clamps.

    3. A015E2Z

      Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.

  6. REMOVE GENERATOR ASSEMBLY


    1. A015ABF

      Remove the nut and bolt, and disconnect the generator positive (+) cable.

    2. A015E66

      Remove the 3 bolts, 2 nuts and generator.

  7. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01578C

      Remove the 2 bolts and No. 1 engine oil level dipstick guide.

  8. DISCONNECT NO. 2 VENTILATION HOSE

    A0159XJE01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  9. DISCONNECT NO. 2 TURBO WATER HOSE

    A015C6G

  10. DISCONNECT BREATHER PLUG RH


    1. A015ATR

      Disconnect the hose.

    2. Detach the clamp and remove the breather plug RH.

  11. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015DQXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  12. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE

    A015952

  13. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01596N

      Disconnect the water hose.

    2. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.

  14. REMOVE NO. 1 TURBOCHARGER STAY


    1. A015AVN

      Remove the 2 bolts and No. 1 turbocharger stay.

  15. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY


    1. A0156CB

      Disconnect the hose.

    2. Remove the union bolt, bolt, No. 1 ventilation tube and gasket.

  16. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH


    1. A015B3D

      Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.

    2. Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.

      A015A4VE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    3. Remove the gasket.

    4. A015D0F

      w/ DPF:

      Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.

    5. Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.

      A0155TWE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    6. Remove the gasket from the No. 1 turbocharger.

  17. DISCONNECT NO. 3 VENTILATION HOSE

    A015CQ4E01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  18. DISCONNECT BREATHER PLUG LH


    1. A01562TE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the hose.

    2. w/o DPF:

      Detach the clamp.

    3. Remove the breather plug LH.

  19. DISCONNECT NO. 2 TURBO WATER HOSE

    A0157W9

  20. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015ASCE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  21. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015D12

      Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.

  22. REMOVE FRONT WATER BY-PASS JOINT


    1. A0157D8

      Remove the front water by-pass joint and gasket.

  23. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015C38

      Disconnect the water hose.

    2. Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.

  24. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE

    A0156TV

  25. REMOVE NO. 2 TURBOCHARGER STAY


    1. A015A3Y

      Remove the 2 bolts and No. 2 turbocharger stay.

  26. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY


    1. Disconnect the hose.

      A0155F8E01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Remove the union bolt, bolt, No. 2 ventilation tube and gasket.

  27. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH


    1. A0158JX

      Disconnect the 2 connectors from the turbocharger.

    2. A015674

      Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.

    3. Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.

      A015D0BE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    4. Remove the gasket.

    5. A015AVS

      w/ DPF:

      Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.

    6. A015BQJE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

    7. Remove the gasket from the turbocharger.

  28. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET


    1. A015DI3

      Remove the 2 bolts and No. 1 intake air connector bracket.

  29. REMOVE AIR TUBE SUPPORT


    1. A015AHS

      Remove the 2 bolts and air tube support.

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


    1. A015CMG

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  31. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A0155EP

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 4 vacuum transmitting pipe.

  32. REMOVE ENGINE MOUNTING BRACKET RH


    1. A0158ZJ

      Remove the 4 bolts and engine mounting bracket RH.

  33. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

    A015B29

  34. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A0155C7

      Detach the 2 wire harness clamps.

    2. A0157EH

      Remove the bolt and No. 2 intake air connector bracket.

  35. REMOVE TURBOCHARGER WIRE


    1. A015787

      Detach the 3 wire harness clamps.

    2. Remove the 2 bolts and turbocharger wire.

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


    1. A01578D

      w/ Intercooler:

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe.

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


    1. A015CRL

      Remove the union bolt, 2 bolts, No. 2 water by-pass pipe and gasket.

  38. REMOVE ENGINE MOUNTING BRACKET LH


    1. A015CB7

      Remove the 4 bolts and engine mounting bracket LH.

  39. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

    A015BW0

  40. REMOVE COMPRESSOR BRACKET


    1. A015BRQ

      Remove the bolt and compressor bracket.

  41. REMOVE STIFFENER INSULATOR RH (w/ Intercooler)


    1. A0156XQ

      Remove the 2 bolts and stiffener insulator RH.

  42. DISCONNECT NO. 1 OIL COOLER HOSE

    A015BCRE01
    Text in Illustration
    *1 No. 1 Oil Cooler Hose
    *2 No. 2 Oil Cooler Hose

  43. DISCONNECT NO. 2 OIL COOLER HOSE

  44. REMOVE CRANKSHAFT PULLEY

    Note

    A015BCNE02

    This procedure is intended for removal/installation of the crankshaft pulley only. Do not use this procedure for removal/installation of the flywheel or the drive plate and ring gear.

    Text in Illustration
    *1 Service Hole
    *2 Protrusion

    1. Install the 2 bolts to the bolt holes of the crankshaft rear side.

    2. Using a bar, turn the crankshaft until the crankshaft pulley service hole is a little to the left of bottom dead center.

    3. Install a 14 mm x 1.5 pitch service bolt with a length of 70 mm or more to the crankshaft pulley service hole, and hold the crankshaft using the timing chain cover protrusion.

    4. Remove the 3 bolts and crankshaft pulley.

      Note

      If the crankshaft pulley cannot be removed, temporarily install a bolt to the crankshaft so that the pulley does not fall, and lightly tap the outer edge of the mass damper with a plastic-faced hammer to remove the pulley. Do not tap the pulley V-ribbed belt ribs, as the crankshaft may be damaged.

  45. REMOVE TIMING GEAR COVER SPACER (w/ Intercooler)


    1. A0155DM

      Remove the 2 bolts and timing gear cover spacer.

  46. REMOVE OIL FILTER ELEMENT


    1. A015AKI

      Remove the oil filter drain plug.

    2. A015A6BE04

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    3. Remove the O-ring from the oil filter drain plug and install it to the drain pipe.

    4. A015691E01

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

    5. Remove the oil filter drain pipe.

    6. Apply a light coat of engine oil to a new O-ring, and install it to the oil filter drain plug.

    7. A015AKI

      Install the oil filter drain plug to the oil filter cap.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    8. A015CT2E01

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Tech Tips

      Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap ribs are vertical, engine oil drains from the gap between the oil filter cap and oil pan.

    9. A015AAWE05

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

  47. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01576F

      Disconnect the 2 wire harness clamps.

    2. A01586O

      Remove the 3 bolts, 2 nuts and oil filter bracket.

    3. A015CNA

      Remove the 2 O-rings.

  48. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01587A

      Remove the 4 bolts and engine oil level sensor.

    2. Remove the gasket.

  49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0156L3

      Remove the 10 bolts and 2 nuts.

    2. A015D2G

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

      Note

      Be careful not to damage the contact surfaces of the No. 1 and No. 2 oil pans.

  50. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A015DAB

      Remove the 2 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  51. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A015A12E02

      Remove the 20 bolts, 2 nuts and oil reflector plate.

      Note

      If the oil reflector plate is deformed, replace it.

      Tech Tips

      Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

    2. A0158AK

      Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A015970

      Remove the 3 O-rings.

    4. A015BZW

      Remove the cylinder block oil hole gasket.

  52. REMOVE CAMSHAFT POSITION SENSOR

    A015CJR

    1. Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  53. REMOVE CRANKSHAFT POSITION SENSOR

    A015B82

    1. Disconnect the sensor wire harness clamp.

    2. Remove the bolt and sensor.

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

    A01560B

    1. Disconnect the connector and detach the clamp.

    2. Using pliers, grip the claws of the clips and slide the 2 clips.

    3. Disconnect the 2 heater hoses.

    4. Remove the 2 bolts and heater assembly.

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


    1. A0155QF

      Remove the bolt and No. 1 idler pulley bracket.

  56. REMOVE WATER INLET


    1. A015CD1

      Disconnect the No. 2 oil cooler hose from the water pump and clamp.

    2. A015E4I

      Remove the 4 bolts and water inlet.

  57. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  58. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)


    1. A015B15

      w/o Viscous Heater:

      Remove the 2 bolts and timing gear cover insulator.

    2. A015BZO

      w/ Viscous Heater:

      Remove the timing gear cover insulator.

  59. REMOVE FAN BRACKET SUB-ASSEMBLY


    1. A015AIZ

      Remove the 4 bolts and fan bracket.

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


    1. A0159CU

      Remove the bolt, cover, No. 2 idler pulley and collar.

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


    1. A015C5N

      Remove the 3 bolts and idler pulley bracket.

  62. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A015AA4

      Remove the 3 bolts and V-ribbed belt tensioner bracket.

    2. A0156FA

      Remove the bolt and No. 1 idler pulley.

    3. A01597P

      Remove the 5 bolts and V-ribbed belt tensioner.

  63. DISCONNECT INLET WATER HOSE

    A0156YW

  64. REMOVE STARTER ASSEMBLY


    1. A015DCB

      Detach the harness clamp and disconnect the wire harness.

    2. Disconnect the starter connector.

    3. Remove the nut and disconnect the starter wire.

    4. A015CX5

      Disconnect the 2 starter hoses.

    5. A0158Q9

      Remove the 2 bolts and starter.

  65. REMOVE STARTER HOSE BRACKET


    1. A0158Q5

      Remove the 2 bolts and starter hose bracket.

  66. REMOVE CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. A0157L4

      Remove the 2 bolts and clutch flexible hose bracket.

  67. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET


    1. A015BEV

      Remove the 2 bolts and No. 2 intercooler support bracket.

  68. REMOVE WATER OUTLET


    1. A015A30

      Disconnect the engine coolant temperature sensor connector.

    2. Remove the 2 bolts, disconnect the water outlet from the No. 2 water hose joint, and remove the water outlet and gasket.

  69. REMOVE WATER OUTLET PIPE


    1. A015BJ2

      Remove the 4 bolts, water outlet pipe and 2 gaskets.

  70. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. Remove the 2 screw grommets and 2 nuts, and disconnect the 2 wire harnesses.

    2. A015DN4E01
      Text in Illustration
      *a RH
      *b LH

      Remove the 8 screw grommets, 8 nuts and 2 glow plug connectors.

  71. REMOVE GLOW PLUG ASSEMBLY


    1. A01580TE01
      Text in Illustration
      *a RH
      *b LH

      Using a 10 mm deep socket wrench, remove the 8 glow plugs.

      Tech Tips

      Before removing the glow plugs, thoroughly clean off all dirt, sand, etc.

  72. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)


    1. A015COX

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  73. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A015BP2

      w/ Intercooler:

      Disconnect the 2 vacuum hoses.

    2. A0159UD

      Remove the 3 bolts and vacuum transmitting pipe.

  74. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)


    1. A015B6D

      Remove the 3 bolts and cylinder head cover silencer.

  75. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)


    1. A0158CR

      Remove the 3 bolts and cylinder head cover silencer.

  76. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler)


    1. A0155AS

      Remove the 3 bolts and vacuum pump.

    2. Remove the 2 O-rings.

  77. REMOVE NOZZLE HOLDER SEAL RH


    1. A015BTY

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

  78. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A015CK9

      Remove the 18 bolts, cylinder head cover and gasket.

  79. REMOVE NOZZLE HOLDER GASKET RH


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

  80. REMOVE OIL SEPARATOR ASSEMBLY


    1. A0157GO

      Remove the 3 bolts, oil separator and gasket.

  81. REMOVE NOZZLE HOLDER SEAL LH


    1. A0158R5

      Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

      Tech Tips

      Tape the screwdriver tip before use.

  82. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A015DOO

      Remove the 17 bolts, cylinder head cover and gasket.

  83. REMOVE NOZZLE HOLDER GASKET LH


    1. A015CGN

      Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

  84. REMOVE FUEL INJECTOR RH


    1. A015DUS

      Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

      Text in Illustration
      A015CC1 Union Bolt

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01575P

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  85. REMOVE FUEL INJECTOR LH


    1. A015CZW

      Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

      Text in Illustration
      A015CC1 Union Bolt

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A015AEN

      Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.

  86. REMOVE WATER PUMP ASSEMBLY


    1. A0158CT

      Remove the 9 bolts, 2 nuts, water pump and gasket.

  87. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0157BME01

      Remove the 4 nuts and 16 bolts.

    2. Using a screwdriver, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.

      Tech Tips

      Tape the screwdriver tip before use.

      A015DZK
    3. A0157K4

      Remove the O-ring from the timing gear case.

  88. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A0157T3E01

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  89. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

    2. Turn the crankshaft clockwise to set the No. 1 cylinder to TDC.

    3. With the crankshaft key 45° counterclockwise from the top position, check that the timing marks of the RH and LH camshaft timing gears are aligned. If not as specified, turn the crankshaft 1 revolution (360°) and align the timing marks as shown below.

      A0157BOE01

    4. Remove the 2 crankshaft pulley set bolts.

  90. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A015AJD

      Using a T30 "TORX" wrench, remove the 2 screws and crankshaft position sensor plate.

  91. REMOVE PUMP DRIVE SHAFT GEAR


    1. A015E0QE01

      Using SST, hold the pump drive shaft gear.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and pump drive shaft gear.

  92. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      A015DRSE01
    4. A0156GR

      Remove the 2 bolts and No. 1 chain tensioner.

  93. REMOVE NO. 1 CHAIN TENSIONER SLIPPER

    A01564K

  94. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0157D9

      Remove the 2 bolts and No. 1 chain vibration damper.

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

    A0158HA

  96. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

    2. Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

    3. Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

      A015DO1E01
    4. A0155BH

      Remove the 2 bolts and No. 2 chain tensioner.

  97. REMOVE NO. 2 CHAIN TENSIONER SLIPPER

    A0159DL

  98. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A015943

      Remove the 2 bolts and No. 2 chain vibration damper.

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


    1. A015DE3E01

      Using SST, hold the No. 2 camshaft timing sprocket.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts, No. 2 camshaft timing sprocket and No. 2 timing chain.

  100. REMOVE FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. Using SST, hold the idle gear.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the nut.

      A015CQOE01

  101. REMOVE IDLE GEAR ASSEMBLY


    1. A015E4V

      w/ Intercooler:

      Using a 8 mm x 1.25 pitch service bolt with a length of 15 mm or more, fix the idle gear in place.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A015DZSE01

      Remove the 2 bolts, idle gear thrust plate and idle gear.

  102. REMOVE NO. 1 IDLE GEAR SHAFT

    A0155P3

  103. REMOVE FUEL SUPPLY PUMP DRIVE GEAR


    1. A015ACQE01

      Using SST, remove the fuel supply pump drive gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031 )

  104. REMOVE FUEL PUMP MOTOR WIRE


    1. A01556N

      Disconnect the 2 connectors and remove the bolt and fuel pump motor wire.

  105. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A015AH6

      Using a 6 mm hexagon wrench, remove the hexagon bolt. Then remove the 2 nuts and fuel supply pump.

    2. Remove the O-ring.

  106. REMOVE V-BANK SILENCER

    A0159OE

  107. REMOVE TIMING GEAR CASE SUB-ASSEMBLY


    1. A015BY5E01

      Remove the 22 bolts, 2 nuts and timing gear case shown in the illustration.

    2. A0155LX

      Remove the 2 O-rings and timing gear case gasket.

  108. REMOVE NO. 1 AND NO. 2 CAMSHAFTS


    1. A015ATK

      Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A015CNE

      Loosen the 2 union bolts.

    3. A0155JBE01

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. A015BGX

      Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

    5. A0158S7

      Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. A015D13

      Remove the No. 1 and No. 2 camshafts.

  109. REMOVE NO. 3 AND NO. 4 CAMSHAFTS


    1. A015ATK

      Using an 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A0158I9

      Loosen the 2 union bolts.

    3. A0157SVE01

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    4. A015AUW

      Remove the 2 union bolts, and No. 3 and No. 4 oil feed pipes.

    5. A015B34

      Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    6. A0155KE

      Remove the No. 3 and No. 4 camshafts.

  110. REMOVE NO. 2 CAMSHAFT BEARING CAP

    A0157IH

  111. REMOVE NO. 5 CAMSHAFT BEARING CAP

    A0158PF

  112. REMOVE NO. 1 VALVE ROCKER ARM


    1. A01590K

      Remove the 16 No. 1 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  113. REMOVE NO. 2 VALVE ROCKER ARM


    1. A0159GD

      Remove the 16 No. 2 valve rocker arms.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  114. REMOVE NO. 1 VALVE LASH ADJUSTER ASSEMBLY


    1. A01585A

      Remove the 16 No. 1 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  115. REMOVE NO. 2 VALVE LASH ADJUSTER ASSEMBLY


    1. A01590A

      Remove the 16 No. 2 valve lash adjusters.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  116. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A015DH8E01

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  117. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A0158EKE01

      Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

      Note


      • Be careful not to drop washers into the cylinder head.

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

  118. REMOVE NO. 1 CYLINDER HEAD GASKET

  119. REMOVE NO. 2 CYLINDER HEAD GASKET