Cylinder Head Assembly: Service and Repair

CYLINDER HEAD GASKET








REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS

A. CAMSHAFT SPROCKET REMOVAL





(1) Rotate the crankshaft in the forward (right) direction and align the timing marks. (No.1 cylinder is the compression stroke top dead center position.)

CAUTION: The crankshaft must always be rotated in the forward direction only.





(2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt.





(3) Use the special tool to remove the camshaft sprocket with the timing belt attached.

CAUTION: After removing the camshaft sprocket, be sure not to rotate the crankshaft.





B. RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION
Place mating marks on the radiator hose and the hose clamp, and then disconnect the radiator hose.





C. CYLINDER HEAD BOLT REMOVAL
Loosen the bolts in the order shown in the illustration (in 2 or 3 stages), and then remove the cylinder head assembly.

CAUTION: Because the plug guides cannot be replaced by themselves, be careful not to damage or deform the plug guides when removing the cylinder head bolts.





INSTALLATION SERVICE POINTS

A. CYLINDER HEAD GASKET INSTALLATION





(1) Wipe off all oil and grease from the gasket mounting surface.
(2) Install the gasket to the cylinder block with the identification mark facing upwards.

B. CYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.

Limit (A): 99.4 mm (3.91 in.)

(2) Apply engine oil to the bolt thread and the washer.











(3) Tighten the bolts by the following procedure.

CAUTION:
1. Always make a tightening angle just 90°. If it is less than 90°, the head bolt will be loosened.
2. If it is more than 90°, remove the head bolt and repeat the procedure from step 1.





C. O-RING INSTALLATION
Insert the O-ring to the water inlet pipe, and coat the outer inside diameter of the 0-ring with water or engine coolant.

CAUTION: Do not let engine oil or other greases contact with the O-ring.

D. THERMOSTAT CASE ASSEMBLY INSTALLATION





(1) Loosen the water inlet pipe bolt shown in the illustration.





(2) Apply specified sealant to the thermostat case assembly in the places shown in the illustration.

Specified sealant:
MITSUBISHI GENUINE PART MD970389 or equivalent

(3) Apply a small amount of water to the 0-ring of the water inlet pipe, and then press the thermostat case assembly into the water inlet pipe.
(4) Tighten the thermostat case assembly mounting bolts.
(5) Tighten the water inlet pipe bolts.

E. RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION





(1) Insert each hose as far as the projection of the water outlet fitting or water inlet fitting.





(2) Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

HIGH-PRESSURE FUEL HOSE CONNECTION
When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of clean engine oil to the hose union and then insert, being careful not to damage the 0-ring.

CAUTION: Do not let engine oil get into the fuel rail.