REMOVAL AND INSTALLATION

Removal steps 1. Control wiring harness connection <<A>> >>H<< 2. Radiator upper hose connection <<A>> >>H<< 3. Radiator lower hose connection 4. Heater hose connection 5. Boost hose connection 6. Vacuum hose connection 7. Freewheel clutch vacuum hose connection 8. Brake booster vacuum hose connection <R.H. drive vehicles without ABS> 9. Earth cable connection 10. Fuel injection pump vacuum pipe, Vacuum pump vacuum pipe and hose · Alternator assembly <4M4> (Refer to GROUP 16 - Alternator Assembly ). · Turbocharger assembly, exhaust manifold and inlet manifold (Refer to GROUP 15 - Inlet, Exhaust Manifold and Turbocharger ). 11. By-pass pipe, thermostat case and thermostat cover assembly >>G<< 12. O-ring

Removal steps <<B>> >>F<< 13. Engine oil pressure switch 14. Connector 15. Vacuum pump oil pipe 16. Vacuum pump oil pipe gasket 17. Fuel hose connection 18. Battery cable connection 19. Harness bracket assembly <<C>> >>E<< 20. Fuel injection pipe assembly 21. Engine hanger >>D<< 22. Timing chain tensioner >>C<< 23. Timing chain tensioner gasket <<D>> >>B<< 24. Camshaft sprocket <<E>> >>A<< 25. Cylinder head assembly <<E>> >>A<< 26. Cylinder head gasket

1.Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose. 2.Disconnect the radiator hose.

Using special tool oil pressure switch socket wrench (MB992118), removal the engine oil pressure switch.

When loosening the nuts at both ends of fuel injection pipe, hold the delivery holder (for fuel injection pump side) and the fuel injection nozzle (for fuel injection nozzle side) with a wrench and loosen the nuts.

1. caution Never turn the crankshaft anti-clockwise. Turn the crankshaft clockwise, align the mating marks on the camshaft sprocket with the brilliant white mark ring plates on the timing chain to set No. 1 cylinder to TDC (Top Dead Centre) of its compression stroke.

2. caution Do not lock the camshaft using the timing chain. The camshaft sprocket bolt is left threaded, so the arrow indicating its tightening direction is marked on the bolt head. To loosen this bolt, turn the bolt to the opposite direction of the arrow. The timing chain must be attached to the camshaft sprocket. Hold the hexagonal part of the camshaft with an open end wrench, loosen the camshaft sprocket bolt, and then remove the camshaft sprocket with the timing chain still attached. 3.Tie up the timing chain and the camshaft sprocket with a cord to prevent the mating mark misalignment.

1.Loosen the cylinder head bolts in the shown sequence progressively, and then remove the cylinder head bolts. 2.Lift the cylinder head assembly and cylinder head gasket straight without removing the timing chain from the camshaft sprocket.

3.After the cylinder head assembly and cylinder head gasket has been removed, use special tool camshaft sprocket holder kit (MH062381) to hold the camshaft sprocket to prevent the timing chain from sliding off. A: Nut B: Washer C: Spacer D: Adjust plate E: Bolt F: Nut

1. caution The thickness of the original cylinder head gasket is selected according to the protrusion amount of the piston. Therefore, if the cylinder block, piston, connecting rod or crankshaft is replaced, the protrusion amount may be changed. Always select a correct gasket by measuring the protrusion amount. (Refer to GROUP 11F - Rocker Cover and Cylinder Head Assembly ). To replace the cylinder head gasket only, select a gasket of correct specification according to the table below. Notch specification (fitted thickness mm) Part number A (1.35 ± 0.03 mm) ME200751 B (1.40 ± 0.03 mm) ME200752 C (1.45 ± 0.03 mm) ME200753 D (1.50 ± 0.03 mm) ME200754 2. caution Do not allow foreign material to enter the engine coolant or oil passages and the cylinder. Clean the cylinder head assembly, the timing gear case assembly, and the crankcase assembly mating surfaces with a scraper or a wire brush.

3. caution After the engine oil pan is installed, wait for at least one hour, and then start the engine. Apply the specified sealant to the upper side of the mating surface between the timing gear case and the crankcase assembly. Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 4. caution When installing the cylinder head gasket, be careful not to disturb the sealant. Immediately after applying the sealant, use the cylinder head gasket to install the cylinder head assembly to the crankcase.

5. caution The cylinder head bolts can be reused up to 3 times. Therefore, the cylinder head bolts with 3 punch marks already applied must be replaced with new cylinder head bolts. Apply punch marks to the bolt heads of the cylinder head bolts.

6.Install the cylinder head bolt washer to the cylinder head bolt so that the washer chamfered side faces as shown. 7.Apply a small amount of engine oil to the cylinder head bolt thread and the washer.

8.Tighten the cylinder head bolts according to the following procedure (angle-tightening procedure). (1) Tighten the bolts to 98 N·m in the order shown. Bolt size: Nominal diameter × length mm <Except 3, 6, 11, 14 >: 12 × 105 < 3, 6, 11, 14 >: 12 × 125 (2) Loosen the bolts fully in the reverse sequence to that shown. (3) Tighten the bolts to 49 N·m in the order shown. (4) caution The bolt is not tightening sufficiently if the tightening angle is less than a 90 degree angle. If the tightening angle exceeds the standard specification, remove the bolt and start over from step 2. Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown. (5) Tighten in a 90 degree angle as shown in the instructions of the figure, then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head is on a linear line. (6) caution Whenever the cylinder head bolts, are loosened after the cylinder head is installed, always apply the sealant again. Apply a small amount of engine oil to the thread and the flange of bolts A, and tighten them to A to 23 N·m.

2.Hold the hexagonal part of the camshaft with an open end wrench in the same manner as removal. 3.Apply a small amount of engine oil to the camshaft sprocket bolt thread and the flange, and then tighten to the specified torque. Tightening torque: 88 N·m

Place the timing chain tensioner gasket with its silicone print facing toward the timing chain tensioner side.

1.Raise the cam, and then push in the plunger, and lock the plunger using a hook. 2. caution To install the timing chain tensioner, always push in the plunger. If you fail to do this, the timing chain will be excessively tensioned, causing damage. Install the timing chain tensioner to the cylinder head. 3. caution If the crankshaft is turned anti-clockwise after the timing chain tensioner is installed, the plunger will be excessively tensioned, causing the plunger to go beyond the cam inside the timing chain tensioner. Turn the crankshaft clockwise. note If the crankshaft is turned clockwise after the timing chain tensioner is installed, the plunger is automatically unhooked. Then its internal ratchet mechanism adjusts the timing chain tension.

When tightening the nuts at both ends of fuel injection pipe, hold the delivery holder (for fuel injection pump side) and the fuel injection nozzle (for fuel injection nozzle side) with a wrench in the same manner as removal, and tighten the nuts to the specified torque. Tightening torque: 23 N·m

1. caution Be careful not to block the oil passage with sealant. When reusing the sensor, apply the specified sealant to the threads. Specified sealant: 3M ATD Part No. 8660 or equivalent

2.Tighten the engine oil pressure switch together with the oil filter bracket to the specified torque, using special tool Oil pressure switch socket wrench (MB992118). Tightening torque: 19 ± 3 N·m

1.Insert the radiator hose as far as the projection of the thermostat case or water outlet pipe. 2.Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.