Removal and Installation

REMOVAL
1. Perform fuel line inner pressure release. Refer to Powertrain Management.
2. Drain engine coolant.
3. Drain engine oil.
4. Follow removal steps outlined in the illustration, noting the following:





5. Place mating marks on the radiator hose and the hose clamp, and then disconnect the radiator hose.





6. Using the cylinder head bolt wrench tool No. MB991654, or equivalent, loosen the bolts in the order shown in the illustration (in 2 or 3 stages), and then remove the cylinder head assembly.

INSTALLATION
1. Follow removal procedure in reverse order noting the following.
2. Wipe off all oil and grease from the gasket mounting surface.





3. Install the gasket to the cylinder block with the identification mark facing upwards.





4. Apply engine oil to the bolt thread and the washer.

NOTE: When installing the cylinder head bolts, the length below the head of the bolts should be within (A): 99.4 mm (3.91 inch). If it is outside (A): 99.4 mm (3.91 inch), replace the bolts.





5. Tighten the bolts by the following procedure.
a. Tighten to 78 Nm (58 ft. lbs.). In the order shown in the illustration.
b. Loosen fully in the reverse order of that shown in the illustration.
c. Tighten to 20 Nm (15 ft. lbs.). In the order shown in the illustration.





d. Mark the head of the cylinder head bolt and cylinder head with paint. Tighten 90° of a turn. In the order shown in the illustration.
e. Tighten 90° of a turn. In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

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 the 1st step, (step a).





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

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





7. Loosen the water inlet pipe bolt shown in the illustration.





8. Apply specified sealant to the thermostat case assembly in the places shown in the illustration. Using specified sealant Mitsubishi Genuine Part No. MD970389, or equivalent.
9. Apply a small amount of water to the O-ring of the water inlet pipe, and then press the thermostat case assembly into the water inlet pipe.
10. Tighten the thermostat case assembly mounting bolts.
11. Tighten the water inlet pipe bolts.





12. Insert each hose as far as the projection of the water outlet fitting or water inlet fitting.
13. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

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

14. 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 O-ring.
15. Refill engine oil.
16. Refill engine coolant.