Part 1

ROCKER ARMS AND CAMSHAFT






Removal
Follow removal steps outlined in illustration.

Installation
Installation in reverse order as removal.

Installation Service Points





]A[ Lash Adjuster Installation.
1. Immerse the lash adjuster in clean diesel fuel.
2. Using a special tool, move the plunger up and down 4 or 5 times while pushing down lightly on the check ball in order to bleed out the air.





]B[ Camshaft Installation.
1. Apply engine oil to journals and cams of the camshafts.
2. Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with the exhaust one. The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.





3. Install the crankshaft sprocket 13 or spacer and flange to an end of the crankshaft, and turn the crankshaft until the turning marks are lined up, setting No.1 cylinder to the TDC.
4. Place the camshafts so that their dowel pins are positioned at top.





]C[ Bearing Caps Installation.
1. According to the identification mark stamped on top of each bearing cap, install the caps to the cylinder head. Only "L" or "R" is stamped on No.1 bearing cap. Cap No. is stamped on No.2 to No.5 bearing caps. Rear bearing cap has no stamping.
1: For intake camshaft side
2: For exhaust camshaft side





2. Tighten the bearing caps in the order shown two to three times by torquing progressively. Tighten to specification in the final sequence.
3. Check to ensure that the rocker arm is held in position on the lash adjuster and valve stem end.





]D[ Camshaft Oil Seal Circular Packing Installation.

Inspection








Camshaft
1. Measure the cam height.





Rocker Arm
1. Check the roller surface. If any dents, damage or seizure is evident, replace the rocker arm.
2. Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace the rocker arm.
3. Check the inside diameter. If damage or seizure is evident, replace the rocker arm.

Lash Adjuster Leak Down Test

CAUTION:
1. The lash adjuster is a precision part. Keep it free from dust and other foreign matter.
2. Do not disassemble lash adjuster.
3. When cleaning lash adjuster, use clean diesel fuel only.





1. Immerse the lash adjuster in clean diesel fuel.
2. While lightly pushing down inner steel ball using the special tool, move the plunger up and down four or five times to bleed air.
Use of the special tool helps facilitate the air bleeding of the rocker arm mounted type lash adjuster.
3. Remove the special tool and press the plunger. If the plunger is hand to push in, the lash adjuster is normal. If the plunger can be readily pushed in all the way, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster.

CAUTION: Upon completion of air bleeding, hold lash adjuster upright to prevent inside diesel fuel from spilling.








4. After air bleeding, place lash adjuster on the special tool (Leak down tester).
5. After plunger has gone down somewhat (0.2 - 0.5 mm), measure time taken for it to go down 1 mm. Replace if measured time is out of specification.

Standard value: 4 - 20 seconds / 1 mm (0.04 inch)
[Diesel fuel at 15 - 20°C (59 - 68°F)]

CYLINDER HEAD AND VALVES






Removal
Follow removal steps outlined in illustration.

Removal Service Points
Precaution For Removed Parts
1. Keep removed parts in order according to the cylinder number and intake/exhaust.





[A] Cylinder Head Bolts Removal.
1. Using the special tool, loosen the cylinder head bolts. Loosen evenly, little by little.





[B] Retainer Lock Removal.
1. Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.





[C] Valve Stem Seal Removal.
1. Do not reuse valve stem seal.

Installation
Installation in reverse order as removal.

Installation Service Points





]A[ Valve Stem Seal Installation.
1. Install the valve spring seat.
2. The special tool must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.

CAUTION: Do not reuse the valve stem seal.





]B[ Valve Springs Installation.
1. Direct the valve spring end with identification color end toward the spring retainer.





]C[ Retainer Lock Installation.
1. The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with, and damage, the stem seal.





]D[ Cylinder Head Gasket Identification.

Identification mark: 4G63K





]E[ Cylinder Head Bolt Installation.
1. When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is exceeded, replace the bolt.

Limit: Maximum 99.4 mm (3.91 inches)

2. Apply engine oil to the threaded portions of bolts and to the washers.
3. According to the tightening sequence, tighten the bolts to the specified torque 78 Nm (58 ft. lbs.) using special tool (MB991654).
4. Loosen bolts completely.





5. Retighten the loosened bolts to 20 Nm (14.5 ft. lbs.) in the specified tightening sequence.
6. Make a paint mark across each bolt head and cylinder head.
7. Give a 90° turn to the bolts in the specified tightening sequence.
8. Give another 90° turn to the bolts and make sure that the paint mark on the head of each bolt and that on the cylinder head are on the same straight line.

CAUTION:
1. If the bolt is turned less than 90°, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it.
2. If the bolt is over tightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step (1).

Inspection





Cylinder head
1. Check the cylinder head gasket surface for flatness by using a straightedge and feeler gauge.

Standard value: 0.05 mm (0.0020 inch)
Limit: 0.2 mm (0.008 inch)

2. If the service limit is exceeded, correct to meet specification.

Grinding limit: *0.2 mm (0.008 inch)

*Includes combined with cylinder block grinding.

Cylinder head height (Specification when new):
131.9 - 132.1 mm (5.193 - 5.201 inch)





Valve
1. Check the valve face for correct contact. If incorrect, reface using valve refacer. Valve seat contact should be maintained uniform at the center of valve face.





2. If the margin exceeds the service limit, replace the valve.





3. Measure the valve's total length. If the measurement is less than specified, replace the valve.





Valve Spring
1. Measure the free height of spring and, if it is smaller than the limit, replace.

Standard value: 47.0 mm (1.850 inch)
Limit: 46.0 mm (1.811 inch)

2. Measure the squareness of the spring and, if the limp is exceeded, replace.

Standard value: 1.5° or less
Limit: Max. 4°








Valve Guide
1. Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.








Valve Seat
1. Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat.





Valve Seat Reconditioning Procedure
1. Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide.
2. Using the seat grinder, correct to obtain the specified seat width and angle.
3. After correcting the valve seat, lap the valve and valve seat using lapping compound.
Then, check the valve stem projection.





Valve Seat Replacement Procedure
1. Cut the valve seat to be replaced form the inside to thin the wall thickness. Then, remove the valve seat.





2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.

Intake seat ring hole diameters
0.3 O.S. 35.30 - 35.33 mm (1.3989 - 1.3909 inch)
0.6 O.S. 35.60 - 35.63 mm (1.4016 - 1.4028 inch)

Exhaust seat ring hole diameters
0.3 O.S. 33.30 - 33.33 mm (1.3110 - 1.3122 inch)
0.6 O.S. 33.60 - 36.63 mm (1.3228 - 1.3240 inch)

3. Before fitting the valve seat, either heat the cylinder head up to approximately 250°C (482°F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the specified width and angle.





Valve Guide Replacement Procedure
1. Using the press, remove the valve guide toward the cylinder block.
2. Re-bore the valve guide hole of the cylinder head so that it may fit to the press-fitted oversize valve guide.

CAUTION: Do not install a valve guide of the same size again.

Valve guide hole diameters
0.05 O.S. 12.05- 12.07 mm (0.4744 - 0.4752 inch)
0.25 O.S. 12.25 - 12.27 mm (0.4823 - 0.4831 inch)
0.50 O.S. 12.50 - 12.52 mm (0.4921 - 0.4929 inch)





3. Press-fit the valve guide until it protrude 19.5 mm (0.77 inch) from the cylinder head top surface as shown in the illustration.

NOTE:
1. When press-fitting the valve guide, work from the cylinder head top surface.
2. Pay attention to the difference in length of the valve guides. [intake side: 45.5 mm (1.79 inch); exhaust side: 50.5 mm (1.99 inch)]
3. After installing the valve guides, insert new valves in them to check for sliding condition.

FRONT CASE, COUNTERBALANCE SHAFT AND OIL PAN






Removal
Follow removal steps outlined in illustration.

Removal Service Points





[A] Oil Pan Removal.
1. Remove all oil pan bolts.
2. Drive in the special tool between the cylinder block and oil pan.

NOTE: Never use a screwdriver or chisel, instead of the service tool, as a deformed oil pan flange will result in oil leakage.





[B] Plug Removal.
1. If the plug is too tight, hit the plug head with a hammer two to three times, and the plug will be easily loosened.








[C] Flange Bolt Removal.
1. Remove the plug on the side of cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.32 inch)] into the plug hole to lock the counterbalance shaft.





3. Loosen the flange bolt.





[D] Counterbalance Shaft Front Bearing Removal.
Using the special tool, remove the counterbalance shaft front bearing from the cylinder block.

NOTE: Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot be used.





[E] Counter Balance Shaft Rear Bearing Removal.
Using the special tool, remove the counterbalance shaft rear bearing from the cylinder block.

NOTE: When removing the left counterbalance shaft, install the special tool (A/IB991603) to the front of the cylinder block.

Installation
Installation in reverse order as removal.

Installation Service Points.





]A[ Right Counterbalance Shaft Rear Bearing Installation.
1. Apply engine oil to the outer surface of bearing.
2. Using special tools, install right rear bearing. Make sure that oil hole of bearing is aligned with oil hole of cylinder block.





]B[ Left Counterbalance Shaft Rear Bearing Installation.
1. Install the special tool (GUIDE PLATE) to the cylinder block.
2. Apply engine oil to the rear bearing outer inside diameter and bearing hole in cylinder block.





3. Using the special tool, install the rear bearing.

NOTE: The left rear bearing has no oil holes.





]C[ Counterbalance Shaft Front Bearing Installation.
1. Using special tools, install front bearing.





]D[ Front Case Installation.
1. Place the special tool on the front end of crankshaft and apply a thin coat of engine oil to the outer inside diameter of the special tool to install the front case.





2. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).





]E[ Counterbalance Shaft Oil Seal.





]F[ Oil Pump Oil Seal Installation.





]G[ Crankshaft Front Oil Seal Installation.
1. Using the special tool, install the crankshaft front oil seal into the front case.





]H[ Oil Pump Driven Gear/Oil Pump Drive Gear Installation.
1. Apply engine oil amply to the gears and line up the alignment marks.





]I[ Sealant Application To Oil Pressure Gauge Unit.
1. Coat the threads of switch with sealant and install the switch using the special tool.

Specified sealant:
3M ATD Part No. 8660 or equivalent

CAUTION:
1. Keep the end of threaded portion clear of sealant.
2. Avoid an over tightening.





]J[ Sealant Application To Oil Pressure Switch.
1. Coat the threads of switch with sealant and install the switch using the special tool.

Specified sealant:
3M ATD Part No.8660 or equivalent

CAUTION:
1. Keep the end of threaded portion clear of sealant
2. Avoid an over tightening.





]K[ Flange Bolt Installation.
1. Insert a Phillips screwdriver into a hole in the left side of the cylinder block to lock the counterbalance shaft.





2. Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to specified torque.





]L[ Plug Installation.
1. Install a new O-ring to the groove of front case.
2. Using the special tool, install the plug and tighten to specified torque.





]M[ Oil Pan Installation.
1. Clean both mating surfaces of oil pan and cylinder block.
2. Apply a 4 mm (0.16 inch) wide bead of sealant to the entire circumference of the oil pan flange.

Specified sealant:
MITSUBISHI GENUINE PART No. MD970389 or equivalent

NOTE:
1. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
2. After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.





3. Note the difference in bolt lengths at the location shown





]N[ Drain Plug Gasket Installation.
Install the drain plug gasket in the direction shown in the illustration.





]O[ Oil Cooler Installation.
First insert the oil cooler projecting stopper in the oil filter bracket groove and then tighten the oil cooler bolts.