CYLINDER HEAD GASKET > REMOVAL

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1. Remove the engine assembly (Click here).
   

1. Remove the 2 bolts and the No. 1 turbo insulator.
   

1. Remove the bolt, nut and the No. 2 turbocharger stay.
   

1. Remove the 2 bolts and manifold stay.
   

1. Remove the 11 nuts and the turbocharger with the exhaust manifold.
   

2. Remove the 2 gaskets from the cylinder head and cylinder block.
   

3. Remove the 2 nuts and the turbo oil inlet pipe from the turbocharger.
   

4. Remove the gasket from the turbocharger.
   

1. Remove the 2 bolts, nut and generator.
   

1. Remove the bolt and the generator bracket.
   

1. Disconnect the vacuum transmitting hose.
   

2. Disconnect the No. 1 vacuum transmitting hose.
   

3. Disconnect the 2 vacuum hoses and No. 1 oil hose.
   

4. Disconnect the No. 2 oil cooler hose.
   

5. Disconnect the No. 2 water by-pass hose.
   

6. Remove the 4 bolts, 2 nuts and the EGR with cooler pipe assembly.
   

7. Remove the 2 gaskets from the cylinder head and the electric EGR control valve.
   

1. Disconnect the vacuum hose.
   

2. Remove the 2 bolts and the No. 1 EGR cooler bracket.
   

1. Disconnect the vacuum hose from the vacuum pump.
   

2. Remove the bolt and harness bracket.
   

1. Disconnect the No. 4 water by-pass hose.
   

2. Disconnect the No. 3 water by-pass hose.
   

3. Remove the 2 bolts and the electric EGR control valve.
   

4. Remove the gasket from the intake air connector.
   

1. Remove the 2 bolts, 2 nuts and the intake air connector with the diesel throttle body.
   

2. Remove the gasket from the cylinder head.
   

1. Remove the nut and both sides of the No. 2 injection pipe clamp.
   

1. Remove the 2 nuts and both sides of the No. 1 injection pipe clamp.
   

1. Using a union nut wrench (17 mm), separate the union nut from the injector first.
   

2. Then remove the union nut from the common rail, and remove the injection pipe.
   

   Text in Illustration 

   *1	No. 1 Injection Pipe
   *2	No. 2 Injection Pipe
   *3	No. 3 Injection Pipe

3. After removing the injection pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.
   

HINT:

Perform the same procedure as for injection pipe No. 1.

HINT:

Perform the same procedure as for injection pipe No. 1.

1. Remove the 4 screw grommets.
   

2. Remove the 4 nuts and the No. 1 glow plug connector.
   

1. Remove the 4 glow plugs.
   

1. Remove the No. 2 intake manifold insulator.
   

1. Remove the 3 nozzle leakage pipe set clamps.
   

1. Remove the retainer spring disconnect the nozzle leakage pipe.
   

2. Pull up the lock bush as shown in the illustration and remove the nozzle leakage pipe.
   

   Text in Illustration 

   *1

   Lock Bush

   NOTICE:

   Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.

1. Remove the 4 bolts, 4 washers, and 4 nozzle holder clamps.
   

   Text in Illustration 

   *1	Washer
   *2	Nozzle holder clamp
   *3	Nozzle holder clamp seat

1. Remove the 4 nozzle holder clamp seats from the cylinder head.
   

1. Remove the 4 injectors from the cylinder head.
   

   HINT:

   1. Each injector assembly has its own fuel injection part number. When replacing the injectors, store them in the correct order so that they can be returned to their original locations when reassembled.
      
   2. Arrange the injectors, clamps, washers, bolts and clamp seats in the correct order.
      

1. Remove the 4 injection nozzle seats from the injector or cylinder head.
   

   HINT:

   When removing the injector, check that the injector nozzle seat is either attached to the injector, or remains in the cylinder head.

1. Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), separate the union nut from the supply pump first.
   

2. Then remove the union nut from the common rail, and remove the fuel inlet pipe.
   

3. After removing the fuel inlet pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.
   

1. Remove the No. 2 fuel hose.
   

1. Remove the 3 bolts and supply pump.
   

2. Remove the O-ring.
   

1. Remove the supply pump driving coupling.
   

   NOTICE:

   When removing the supply pump, make sure that the drive coupling does not fall off, as it can be easily removed. If the drive coupling falls off, replace it with a new one.

1. Remove the 2 bolts and common rail.
   

   NOTICE:

   Do not remove the fuel pressure sensor or fuel pressure regulator.

1. Remove the No. 1 intake manifold insulator.
   

1. Remove the 2 bolts and the 2 harness brackets.
   

2. Remove the No. 2 cylinder head cover.
   

1. Remove the hose clamp.
   

2. Disconnect the 2 clamps and remove the No. 2 oil cooler hose.
   

1. Remove the No. 4 water by-pass hose.
   

1. Disconnect the oil cooler hose.
   

2. Disconnect the water by-pass hose.
   

3. Remove the 2 bolts and the water by-pass pipe.
   

4. Remove the O-ring from the water by-pass pipe.
   

1. Remove the 2 bolts and the oil level dipstick guide.
   

2. Remove the O-ring from the oil level dipstick guide.
   

1. Remove the bolt and harness bracket.
   

2. Remove the bolt and camshaft position sensor.
   

1. Remove the 2 bolts and vacuum pump.
   

2. Remove the 2 O-rings from the vacuum pump.
   

1. Remove the bolt and idler pulley.
   

1. Remove the 2 bolts and the V-ribbed belt tensioner.
   

1. Remove the bolt and harness bracket.
   

1. Remove the 12 bolts and the cylinder head cover.
   

2. Remove the cylinder head cover gasket from the cylinder head cover.
   

1. Remove the 4 bolts and the engine mounting bracket.
   

1. Remove the clip and the No. 2 timing chain cover.
   

1. Using SST, hold the crankshaft damper and loosen the crankshaft bolt.
   

   SST

   09213-58014  
   09330-00021  
   

2. Using SST, remove the crankshaft pulley bolt and the crankshaft pulley.
   

   SST

   09950-30012   (09951-03010, 09953-03010, 09956-03020)
   

1. Disconnect the water inlet hose LH.
   

1. Remove the 20 bolts and the 2 nuts.
   

2. Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover by prying between the cylinder head and cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Do not damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

NOTICE:

Do not rotate the crankshaft with the chain tensioner removed.

1. Push in the plunger until the groove is aligned with the tensioner hole, and then insert a 1.1 mm (0.043 in.) diameter bar.
   

   Text in Illustration 

   *1	Plunger
   *2	Groove
   *3	Hole

2. Remove the 2 bolts and the No. 1 chain tensioner.
   

1. Remove the chain tensioner.
   

1. Remove the 2 bolts and the No. 1 chain vibration damper.
   

1. Using SST, hold the camshaft timing sprocket.
   

   SST

   09960-10010   (09962-01000, 09963-01000)
   

2. Remove the 3 bolts and the camshaft timing sprocket.
   

3. Remove the camshaft timing sprocket, crankshaft timing sprocket and chain together.
   

1. Remove the 10 bolts from the camshaft bearing caps by loosening them in the sequence shown in the illustration, and then remove the 5 camshaft bearing caps.
   

2. Remove the camshaft.
   

   NOTICE:

   1. Using several steps, uniformly loosen the bolts while keeping the camshaft level.
      
   2. Do not remove the No. 3 camshaft bearing cap.
      

1. Remove the No. 1 valve rocker arm from the cylinder head.
   

1. Disconnect the water inlet hose RH.
   

1. Using several steps, loosen the 10 bolts in the sequence shown in the illustration, and then remove the bolts and washers.
   

   NOTICE:

   1. When removing the bolts, do not drop the washers into the engine.
      
   2. Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head.
      

2. Remove the cylinder head.
   

1. Remove the cylinder head gasket.