Removal and Installation

REMOVAL
1. Relieve the fuel line pressure.
2. Drain the engine coolant.
3. Drain the engine oil.
4. Refer to the illustrations for the remaining removal procedures, noting the following:





5. When removing the camshaft sprocket, rotate the crankshaft in the forward (right) direction and align the timing marks. (No.1 cylinder is the compression stroke at top dead center position.)

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





6. 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.





7. Use the crankshaft pulley and end yolk holders tool Nos. MD998719, MD998754 and MB990767, or equivalents, to remove the camshaft sprocket with the timing belt attached.

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





8. Place mating marks on the radiator hose and the hose clamp, and then disconnect the radiator hose.
9. 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.

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
Reverse the installation procedure, noting the following:
1. When installing the cylinder head gasket, 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.





3. 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. The limit (A) is 99.4 mm (3.91 inch).





4. Apply engine oil to the bolt thread and the washer. Tighten the bolts in the order shown, using the following procedure:
1. Torque bolts to 78 Nm (58 ft. lbs.).
2. Completely loosen all bolts in reverse order.
3. Torque all bolts to 20 Nm (15 ft. lbs.).





4. Torque all the bolts 90° in the order shown.
5. Torque all bolts an additional 90°.

NOTE:
- Always make a tightening angle just 90°. If it is less than 90°, the head bolt will be loosened.
- If it is more than 90°, remove the head bolt and repeat the procedure.





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

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





6. For the thermostat case assembly, loosen the water inlet pipe bolt shown.





7. Apply Mitsubishi Genuine Sealant Part No. MD970389, or equivalent, to the thermostat case assembly in the places shown.
8. 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.
9. Tighten the thermostat case assembly mounting bolts and the water inlet pipe bolts.





10. Insert the radiator lower and upper hose as far as the projection of the water outlet fitting or water inlet fitting.





11. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
12. 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.

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