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CYLINDER HEAD GASKET REMOVAL

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Note:

  • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

  • When working on the fuel circuit, protect the generator assembly against dirt contamination.

    Cover the generator assembly with suitable materials.

    Failure to comply with this procedure may result in a generator assembly malfunction.

  • A01IPPME01

    After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

    SST
    PZ4TB-04941-79
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  1. Click here

    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. Click here

    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. Click here

    REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

    (Click here)

  4. Click here

    REMOVE EXHAUST MANIFOLD

    (Click here)

  5. Click here

    REMOVE EGR VALVE BRACKET


    1. A01IUT2

      Remove the 2 bolts and EGR valve bracket from the cylinder head sub-assembly.

  6. Click here

    REMOVE NO. 1 TURBO INSULATOR


    1. A01IPTS

      Remove the 3 bolts and No. 1 turbo insulator.

  7. Click here

    DISCONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A01IOGO

      Remove the 2 bolts and disconnect the radiator reservoir assembly.

  8. Click here

    REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH


    1. A01IQHU

      Detach the clamp to disconnect the air conditioner tube and accessory assembly.

    2. Detach the 2 clamps to disconnect the suction pipe sub-assembly.

    3. A01IU9IE01

      Place a wooden block between a jack and the oil pan sub-assembly.

      Table 1. Text in Illustration
      *a Wooden Block

    4. Support the engine slightly.

    5. A01ING4

      Remove the 4 bolts, 3 nuts and engine mounting insulator sub-assembly RH.

      Tip:

      Supporting the engine slightly makes the engine mounting insulator sub-assembly RH easier to remove.

  9. Click here

    REMOVE GLOW PLUG ASSEMBLY


    1. Disconnect the 4 connectors from the glow plug assemblies.

    2. A01IUCDE01

      Using SST, remove the 4 glow plug assemblies.

      SST
      PZ4TB-04910-68
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    REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01ISZN

      Using an E10 "TORX" socket wrench, remove the 5 bolts.

    2. A01IT19E01

      Using an E18 "TORX" socket wrench, uniformly loosen the 10 cylinder head bolts in several steps in the sequence shown in the illustration.

      Note:

      Do not reuse the cylinder head bolt.

    3. Remove the 10 cylinder head bolts and cylinder head sub-assembly.

  11. Click here

    REMOVE CYLINDER HEAD GASKET