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 (Upper) 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, Alternator Drive Belt and Crankshaft Pulley Removal (Refer to ).
  • EGR Cooler Assembly and EGR Cooler Bracket Removal (Refer to GROUP 17 - Emission Control, 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, By-pass Pipe, 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 ).
  • Vacuum Pump Removal (Refer to ).
  • Camshaft Assembly and Rocker Arm Removal (Refer to ).
  • Cylinder Head and Cylinder Head Gasket Removal (Refer to ).
  • Engine Oil Pan Removal (Refer to ).
  • Camshaft Position Sensor and Crank Angle Sensor Removal (Refer to GROUP 13D - Camshaft Position Sensor and Crank Angle Sensor ).
  • Water Pump Removal <4M4> (Refer to GROUP 14 - Water Pump )

 Post-installation Operation
  • Water Pump Installation <4M4> (Refer to GROUP 14 - Water Pump )
  • Camshaft Position Sensor and Crank Angle Sensor Installation (Refer to GROUP 13D - Camshaft Position Sensor and Crank Angle Sensor ).
  • Engine Oil Pan Installation (Refer to ).
  • Cylinder Head and Cylinder Head Gasket Installation (Refer to ).
  • Camshaft Assembly and Rocker Arm Installation (Refer to ).
  • Vacuum Pump 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, By-pass Pipe, 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 - Emission Control, EGR Valve and EGR Cooler ).
  • A/C Compressor Drive Belt, Alternator Drive Belt and Crankshaft Pulley Installation (Refer to ).
  • Cooling Fan and Cooling Fan Clutch Assembly Installation <4M4> (Refer to GROUP 14 - Cooling Fan ).
  • Radiator Shroud Cover (Upper) 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>>
·
 Power steering oil pump assembly


1.
 Harness bracket


2.
 Harness clamp

>>C<<
 3.
 Timing gear case assembly


4.
 Timing gear case stiffener


5.
 Crankshaft sensing blade

>>B<<
 6.
 Chain bracket

>>B<<
 7.
 Idler A washer

>>A<<
 8.
 Oil jet assembly

>>A<<
 9.
 Spring pin

>>A<<
 10.
 Idler washer

>>A<<
 11.
 Camshaft sprocket
<<B>>
 >>A<<
 12.
 Timing chain


13.
 Tension lever assembly


14.
 Tension lever shaft


15.
 Guide plate


16.
 Guide lower plate

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump assembly from the engine assembly. (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
2.After removing the power steering oil pump assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<B>> TIMING CHAIN REMOVAL
Remove special tool camshaft sprocket holder kit (MH063490) that is installed when removing the cylinder head assembly and cylinder head gasket. Then, remove the timing chain.

INSTALLATION SERVICE POINTS

>>A<< TIMING CHAIN/CAMSHAFT SPROCKET/IDLER WASHER/SPRING PIN/OIL JET ASSEMBLY INSTALLATION

1.Using special tool camshaft sprocket holder kit (MH063490), support the camshaft sprocket.

  • A: Nut
  • B: Washer
  • C: Spacer
  • D: Adjust plate
  • E: Bolt
  • F: Bolt
  • G: Nut

2.Check that the mating mark “1” on the idler gear and sprocket assembly is in alignment with that on the crankshaft gear.

3.
caution Note that the timing chain has one mark plate for the idler gear and sprocket assembly side, and two mark plates for each camshaft sprocket.
Align the mating mark on the idler gear and sprocket assembly with the yellow mark ring plate on the timing chain.

4.Align the mark ring plates with the camshaft sprocket mating marks.
5.Tie up the timing chain and the camshaft sprocket with a cord to prevent the mating mark misalignment.

6.Install the idler washer, the spring pin and the oil jet. The idler washer front mark "F" must face toward the front of the engine.

>>B<< IDLER A WASHER/CHAIN BRACKET INSTALLATION

Install the idler A washer and the chain bracket. The idler A washer front mark "F" must face toward the front of the engine.

>>C<< TIMING GEAR CASE ASSEMBLY INSTALLATION
1.Clean the timing gear case and the plate mating surfaces with a scraper or a wire brush.

2.
caution
  • After applying the sealant, install the timing gear case within 15 minutes.
  • When installing the timing gear case, be careful not to disturb the sealant.
  • Whenever the timing gear case mounting bolts are loosened or tightened again after the timing gear case installation, always apply the sealant again.
  • After the timing gear case is installed, wait for at least one hour, and then start the engine.
Apply a continuous bead of the specified sealant to the timing gear case mating surface as shown.
Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

3.Install the mounting nuts and bolts to the timing gear case at the shown positions.
Name
 Symbol
 Size (Nominal diameter × length mm)
Flange bole
 A
 8 × 75
B
 8 × 85
C
8 × 90
D
8 × 55
E
 8 × 60
F
 10 × 60
Cap nut
 G
 -