REMOVAL AND INSTALLATION


Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Cover Removal (Refer to ).
  • Air Cleaner Assembly and Air Intake Duct Removal <4M4> (Refer to GROUP 15 - Air Cleaner ).
  • Radiator Shroud Cover and Radiator Shroud Removal (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Cooling Fan Clutch Assembly Removal <4M4> (Refer to GROUP 14 - Cooling Fan ).
  • A/C Compressor Drive Belt and Alternator Drive Belt Removal (Refer to ).
  • EGR Cooler Assembly and EGR Cooler Bracket Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
  • Turbocharger Assembly and Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold and Turbocharger Assembly ).
  • Thermostat Removal <4M4> (Refer to GROUP 14 - Thermostat ).
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Removal <4M4> (Refer to GROUP 14 - Water Hose and Water Pipe ).
  • Throttle Body Assembly Removal (Refer to GROUP 13D - Throttle Body Assembly ).
  • Air Inlet Pipe and Inlet Manifold Assembly Removal <4M41> (Refer to GROUP 15 - Inlet Manifold ).
  • Fuel Injector Assembly and Common Rail Assembly Removal (Refer to GROUP 13D - Fuel Injector and Common Rail ).
  • Camshaft Assembly and Rocker Arm Removal (Refer to ).
  • Oil Pipe Removal (Refer to ).

 Post-installation Operation
  • Oil Pipe Installation (Refer to ).
  • Camshaft Assembly and Rocker Arm Installation (Refer to ).
  • Fuel Injector Assembly and Common Rail Assembly Installation (Refer to GROUP 13D - Fuel Injector and Common Rail ).
  • Air Inlet Pipe and Inlet Manifold Assembly Installation <4M41> (Refer to GROUP 15 - Inlet Manifold ).
  • Throttle Body Assembly Installation (Refer to GROUP 13D - Throttle Body Assembly ).
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Installation <4M4> (Refer to GROUP 14 - Water Hose and Water Pipe ).
  • Thermostat Installation <4M4> (Refer to GROUP 14 - Thermostat ).
  • Turbocharger Assembly and Exhaust Manifold Installation (Refer to GROUP 15, Exhaust Manifold and Turbocharger Assembly ).
  • EGR Cooler Assembly and EGR Cooler Bracket Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
  • Cooling Fan and Cooling Fan Clutch Assembly Installation <4M4> (Refer to GROUP 14 - Cooling Fan ).
  • A/C Compressor Drive Belt and Alternator Drive Belt Installation (Refer to ).
  • Radiator Shroud Cover and Radiator Shroud Installation (Refer to GROUP 14 - Radiator ).
  • Air Cleaner Assembly and Air Intake Duct Installation <4M4> (Refer to GROUP 15 - Air Cleaner ).
  • Engine Cover Installation (Refer to ).
  • Engine Oil Refilling <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Drive Belt Tension Check and Adjustment (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Fuel line Air-bleeding (Refer to GROUP 13D - On-vehicle Service, Evacuation of Air From Fuel Line ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).




Removal steps
<<A>>
 >>C<<
 1.
 Radiator upper hose connection
<<B>>
 >>B<<
 2.
 Cylinder head assembly
<<B>>
 >>A<<
 3.
 Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

<<B>> CYLINDER HEAD ASSEMBLY/CYLINDER HEAD GASKET REMOVAL

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 (MH063490) 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: Bolt
  • G: Nut

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET INSTALLATION
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 11H - Cylinder Head and Valves ).
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 (0.70 ± 0.04)
 1005B222
B (0.75 ± 0.04)
 1005B223
C (0.80 ± 0.04)
 1005B224
D (0.85 ± 0.04)
 1005B225

>>B<< CYLINDER HEAD ASSEMBLY INSTALLATION
1.Select a cylinder head gasket of correct specification.
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.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 engine oil pan, be careful not to disturb the sealant.
  • Whenever the cylinder head bolts, are loosened after the cylinder head is installed, always apply the sealant again.
  • After the engine oil pan is installed, wait for at least one hour, and then start the engine.
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 ± 10 N·m in the order shown.
Bolt size: Nominal diameter × length mm

  • <Except 3, 6, 11, 14 >: 12 × 118
  • < 3, 6, 11, 14 >: 12 × 133
(2) Loosen the bolts fully in the reverse sequence to that shown.
(3) Tighten the bolts to 49 ± 5 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) Apply a small amount of engine oil to the thread and the flange of bolts A, and tighten them to A to 58 ± 6 N·m.

>>C<< RADIATOR UPPER HOSE CONNECTION


Align the mating marks in the radiator lower hose and the hose clamp, and install the hose.