CYLINDER HEAD GASKET REMOVAL

PROCEDURE

  1. PRECAUTION

    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 contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354E03

      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

    • 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 hereClick 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 hereClick hereClick here

  3. REMOVE CAMSHAFT AND NO. 2 CAMSHAFT

    Click here

  4. REMOVE EXHAUST MANIFOLD

    Click here

  5. REMOVE EGR VALVE BRACKET

    Click here

  6. REMOVE NO. 2 TURBO INSULATOR

    Click here

  7. DISCONNECT RADIATOR RESERVOIR ASSEMBLY

    1. A319788

      Remove the 2 bolts and disconnect the radiator reservoir assembly.

  8. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    1. A318380

      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. A318379C01

      *a

      Wooden Block

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

    4. Support the engine slightly.

    5. A318496

      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. REMOVE GLOW PLUG ASSEMBLY

    Click here

  10. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    1. A318383

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

    2. A318384E05

      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 bolts.

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

  11. REMOVE CYLINDER HEAD GASKET

    1. Remove the cylinder head gasket from the cylinder block.