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1.Loosen (or remove) the
tensioner and relieve the tension of the timing chain before
removing
the cylinder head assembly.
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2.Remove the front packing.
Remove the bolt and separate the camshaft from the cam
sprocket.
| caution |
- When removing the bolt, hold the
camshaft at
the hexagonal section A to prevent it
from turning together. Do not utilize
the timing chain
for this purpose.
- The bolt is inversely threaded. The
arrow marked on its head shows the
tightening
direction. To remove it, turn it in the
reverse direction.
- The cam sprocket and timing chain
require to be positioned relatively to
each other.
Do not separate them unless absolutely
necessary.
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3.Loosen the cylinder head
bolts stepwise in the sequence of the numbers shown, then
remove
them.
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4.Lift up the cylinder head
assembly straight and remove, while keeping the cam sprocket
in engagement with the timing chain.
5.After the
cylinder head assembly is removed, hold the cam sprocket
with the special
tool Cam sprocket holder kit (MH062381) to keep the timing
chain on it.
Component Parts of the Special Tool Cam
sprocket holder kit (MH062381)
C:
Nut
D: Washer
E: Spacer
F:
Adjusting plate
G: Nut
H:
Bolt
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Choose a cylinder head gasket
having an appropriate thickness that meets the piston
protrusion.
The following thickness of gaskets are available. They are
identified by Measure the piston
protrusion and calculate their average, and select an
appropriate gasket thickness from the
following table. If a piston protrudes 0.03 mm lager then
the average, use one-size thicker
gasket.
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|
Piston
protrusion
|
Piston
protrusion
|
Average piston
protrusion
|
Crankcase
identification mark
|
Classification
|
Thickness when
tightened
|
0.475 ± 0.028
mm
|
A
|
A (1 notch)
|
1.35 ± 0.03
mm
|
0.532 ± 0.028
mm
|
B
|
B (2 notch)
|
1.40 ± 0.03
mm
|
0.589 ± 0.028
mm
|
C
|
C (3 notch)
|
1.45 ± 0.03
mm
|
0.646 ± 0.028
mm
|
D
|
D (4 notch)
|
1.50 ± 0.03
mm
|
|
When only the gasket is so be replaced, check the
identification mark stamped on the top
of the crankcase assembly and choose the one with the same
classification mark.
| note |
If no identification mark is
stamped, select classification.
|
| caution |
If a piston, connecting rod,
etc. has been replaced, be sure to
measure the piston protrusion as the replacement
may change the piston protrusion.
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1.Choose a usable cylinder
head gasket.
2.Apply an even coat of sealant to
the upper part of the mating surface of the timing
gear case assembly and crankcase
assembly.
3.Within three minutes after the
application od sealant, install the cylinder head assembly,
with the cylinder head gasket attached, to the crankcase
assembly.
Specified
sealant:
Mitsubishi Genuine part No.970389 or
equivalent
| caution |
- Prior to applying sealant, make sere
that the
surfaces to be coated are clean and free
of slush and other foreign
matters.
- When installing the cylinder head
assembly, be sure that sealant is in
place.
- After the cylinder head assembly is
installed wait foe at least one hour
before
starting the engine.
|
4.If the cylinder head bolts were loosened or
removed after installing the cylinder
head assembly, be sure to replace the existing sealant with
a fresh coat.
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5.Tighten the cylinder head
bolts, M12 bolts of 1 through 18 and M8 bolts of 19 and 20,
in the sequence of the following steps:
Tightening bolts
1 - 18
- Fit the washer on each cylinder head bolt,
with its
shear droop side facing in the direction shown in
the illustration.
- Apply a thin coat of engine oil evenly to
the threaded part of each of the cylinder
head bolts and tighten them to 100 N·m in the
sequence shown in the illustration.
- Loosen the tightened cylinder head bolts in
the reverse sequence, and retighten
them to 50 N·m in the sequence of the numbers
shown.
- Then, tighten the cylinder head bolts
further by giving them an additional 1/4 turn
(90°) in the specified sequence
- Finally, give the cylinder head bolts
another 1/4 turn (90°)
Tightening bolts 19 and 20
After the tightening of
the bolts 1 through 18 is finished tighten the
bolts 19 and 20 to the specified torque.
6.Secure
the cam shaft to the cam sprocket with the bolt.
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Install the gasket onto the
cylinder head assembly with its surfaces facing the correct
directions as indicated in the illustration.
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1.Turning the cam, force the
plunger into the tensioner by hand and lock it with the
hook.
Then, install the tensioner.
2.After the tensioner
is installed, crank the engine in the normal (clockwise)
direction.
| caution |
- When installing the tensioner, be sure
to force
the plunger into it, or the timing chain
will be stressed excessively and may be
damaged.
- The tensioner keeps the timing chain in
tension by means of the internal ratchet
mechanism. Cranking the engine in
reverse direction with the tensioner
installed, therefore,
causes the plunger to be stressed by an
excessive force, which may cause damage
to the cam. Therefore,
never crank the engine in reverse
direction. If the engine is accidentally
cranked in reverse direction,
remove and reinstall the tensioner
according to the correct installation
procedure.
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1.Apply sealant uniformly
without breaks so the front packing and rear packing at the
position
shown in the illustration. [Bead diameter: 2 ± 1
mm]
2.Install the front packing and rear
packing within three minutes after the application
of sealant.
Specified
sealant:
Mitsubishi Genuine part No.MD970389 or
equivalent
| caution |
- When installing the packing, use care
that the surroundings
are not smeared with sealant.
- Make sure that the surfaces to be coated
with sealant are clean and free of slush
and other foreign matters.
- After the front packing and rear packing
are installed, wait for at least one
hour
before starting the engine.
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|
1.Install the rocker cover
gasket in the groove of the rocker cover in the direction
shown
in the illustration.
2.Apply sealant to the rocker
cover gasket at the position shown in the illustration.
The sealant must be so applied that it can seal the front
packing and rear packing on the cylinder
head.
3.Install the rocker cover to the cylinder
head assembly within three minutes after
the application of
sealant.
Spcified
sealant:
Mitsubisi Genuine part No. MD970389 or
eqivalent
| caution |
- Be sure that the surfaces to be coated
with
sealant are clean and free of slush and
other foreign matters.
- When installing the rocker cover, take
care that sealant dose not smear the
surroundings.
- After the rocker cover is installed,
wait for at least one hour before
starting
the engine.
- If the bolt (holding the rocker cover)
was loosened or removed after
installation,
be sure to reinstall the rocker cover
with a fresh coat of sealant.
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