CYLINDER HEAD 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.


  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )
  2. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly 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.

      B007OT1E01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -
    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block drain cock plug (on the engine oil cooler cover), and drain the engine coolant.

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
  3. 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 oil pan drain plug.

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

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

    Click here

  5. REMOVE COMMON RAIL ASSEMBLY


  6. REMOVE EGR COOLER ASSEMBLY


  7. REMOVE INJECTOR ASSEMBLY


  8. REMOVE GLOW PLUG ASSEMBLY


  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY


  10. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

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


    1. B007ULA

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

  12. REMOVE CYLINDER BLOCK INSULATOR


    1. B007SPW

      Remove the cylinder block insulator from the cylinder head.

  13. REMOVE MANIFOLD STAY


    1. B007QXUE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and manifold stay.

  14. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ DPF)


    1. Remove the No. 1 intake manifold insulator from the intake manifold.

  15. REMOVE INTAKE MANIFOLD (w/ DPF)


    1. B007UNO

      Remove the 7 bolts, 2 nuts and intake manifold.

    2. Remove the gasket.

  16. REMOVE VACUUM SWITCHING VALVE SET (w/ DPF)


    1. B007P8L

      Remove the 2 connectors and 3 vacuum hoses.

    2. B007OJR

      Remove the 2 bolts and vacuum control valve set.

  17. REMOVE SWIRL CONTROL VALVE ASSEMBLY (w/ DPF)


    1. B007Q4H

      Remove the 4 bolts, 2 nuts and swirl control valve.

    2. Remove the gasket.

  18. REMOVE INTAKE MANIFOLD (w/o DPF)


    1. B007TI0

      Remove the 4 bolts, 2 nuts and intake manifold.

    2. Remove the gasket.

  19. REMOVE EXHAUST MANIFOLD


    1. B007QBL

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

  20. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B007W31E01

      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 the bolts in an incorrect order.

    2. Lift 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 or cylinder block.

      Tech Tips

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

  21. REMOVE CYLINDER HEAD GASKET