CYLINDER HEAD (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  5. REMOVE INTAKE MANIFOLD

    Click here

  6. REMOVE GLOW PLUG ASSEMBLY

    Click here

  7. REMOVE INJECTOR ASSEMBLY

    Click here

  8. REMOVE COMMON RAIL ASSEMBLY

    Click here

  9. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  10. REMOVE FAN SHROUD

    Click here

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

    Click here

  12. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. Remove the 4 bolts and No. 1 viscous heater bracket.

  13. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Remove the 4 bolts and disconnect the cooler compressor.

      Tech Tips

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

  14. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


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

  15. REMOVE EXHAUST MANIFOLD


    1. A01DXWR

      Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

    2. Remove the gasket.

  16. REMOVE TIMING BELT

    Click here

  17. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Note

      Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  18. REMOVE NO. 2 TIMING BELT COVER


    1. Remove the 4 bolts, nut and No. 2 timing belt cover.

  19. REMOVE CYLINDER BLOCK INSULATOR


    1. A01E2IC

      Remove the cylinder block insulator from the cylinder head.

  20. REMOVE CAMSHAFT


    1. A01DX0VE03
      Text in Illustration
      *1 Key Groove

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

    2. A01E0JJE01

      Uniformly loosen the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

    3. Remove the 15 bearing cap bolts, 5 bearing caps, oil seal and 2 camshafts.

  21. REMOVE VALVE LIFTER


    1. Remove the valve lifters.

      Tech Tips

      Arrange the valve lifters in the correct order.

  22. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01E1AUE01

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

      Note

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

    2. Remove the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a workbench.

      Note

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

      Tech Tips

      If the cylinder head is difficult to remove, use a screwdriver to pry between the cylinder head and block.

  23. REMOVE CYLINDER HEAD GASKET