CYLINDER HEAD GASKET REMOVAL


  1. REMOVE EXHAUST MANIFOLD


    1. Remove the exhaust manifold Click here.

  2. REMOVE TIMING BELT


    1. Remove the timing belt Click here.

  3. REMOVE DIESEL THROTTLE BODY


    1. Remove the diesel throttle body Click here.

  4. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A00JVDC

      Remove the 4 bolts and idle pulley bracket.

    2. A00K12L

      Disconnect the connector.

    3. Remove the 3 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the cooler compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  5. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A0095XF

      Remove the bolt and disconnect the generator.

    2. A009AZVE01

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  6. DISCONNECT HEATER WATER HOSE SUB-ASSEMBLY


    1. A00K0B7E01
      Text in Illustration
      *A for Rear Heater

      Remove the bolt and disconnect the heater water hoses.

  7. REMOVE INJECTION PIPE SET


    1. A00JY0JE03
      Text in Illustration
      *1 Union Nut Wrench
      *a for Injection Nozzle Side
      *b for Injection Pump Side

      Using a union nut wrench, loosen the 8 union nuts of the 4 injection pipes.

    2. Remove the 2 nuts, 2 upper pipe clamps and 4 injection pipes with 2 lower pipe clamps.

  8. DISCONNECT WIRE HARNESS


    1. Remove the terminal cap.

    2. A0097AO

      Remove the nut and generator wire.

    3. Disconnect the generator connector and cooler compressor connector.

    4. Detach the 4 wire harness clamps.

    5. for RHD:


      1. A0096PA

        Detach the 5 wire harness clamps.

    6. A0099ET

      for LHD:


      1. Detach the 4 wire harness clamps.

      2. A0099E2

        Detach the 3 wire harness clamps.

  9. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)


    1. A00JYUM

      Remove the bolt and wiring harness clamp bracket.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 9 bolts, nut, cylinder head cover and gasket.

  11. REMOVE CAMSHAFT


    1. A00JXC5E03
      Text in Illustration
      *1 Upward
      *2 Key Groove

      Turn the camshaft with a wrench so that the key groove faces upward.

    2. A00JVTYE04

      Uniformly loosen and remove the 10 bearing cap bolts in several steps in the sequence shown in the illustration.

    3. Remove the 5 bearing caps and camshaft.

      Tech Tips

      Arrange the bearing caps in the correct order.

  12. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A009APUE02

      Uniformly loosen and remove the 18 cylinder head bolts in several steps in the sequence shown.

      Note

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

    2. Lift the cylinder head from the dowels on the cylinder block to remove it, and place the cylinder head on wooden blocks on a workbench.

      Note

      Do not damage the contact surfaces of the cylinder head and cylinder block.

      Tech Tips

      If the cylinder head is difficult to lift off, pry between the cylinder head and block with a screwdriver.

  13. INSPECT CYLINDER HEAD SET BOLT


    1. A0099DUE05
      Text in Illustration
      *a Measuring Point
      *b Elongated Thread

      Using a vernier caliper, measure the minimum outer diameter of the elongated thread at the measuring point.

      Standard outer diameter
      11.80 to 12.00 mm (0.465 to 0.472 in.)
      Minimum outer diameter
      11.60 mm (0.457 in.)

      If the diameter is less than the minimum, replace the cylinder head set bolt.

  14. REMOVE CYLINDER HEAD GASKET