[11A] ENGINE MECHANICAL <4G6-SOHC> - - CYLINDER HEAD GASKET - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
<4G63>
Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) .] Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ). Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ). Exhaust Manifold Removal (Refer to GROUP 15, Exhaust Manifold ). Spark Plug Cables and Ignition Coils Removal (Refer to GROUP 16, Ignition Coil ). | Post-installation Operation Spark Plug Cables and Ignition Coils Installation (Refer to GROUP 16, Ignition Coil ). Exhaust Manifold Installation (Refer to GROUP 15, Exhaust Manifold ). Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ). Fuel Leak Check
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Accelerator cable connection
|  | 2. | A/C compressor connector
|  | 3. | Power steering oil pressure switch connector
<<A>> |  | 4. | Crank angle sensor connector
|  | 5. | Ignition coil connectors
|  | 6. | Throttle position sensor connector
|  | 7. | Manifold absolute pressure sensor connector
|  | 8. | EGR control solenoid valve connector
|  | 9. | Purge control solenoid valve connector
|  | 10. | Detonation sensor connector
|  | 11. | Injector connectors
|  | 12. | Engine coolant temperature gauge unit connector
|  | 13. | Idle speed control servo connector
|  | 14. | Oxygen sensor connector
|  | 15. | Camshaft position sensor connector
|  | 16. | Engine coolant temperature sensor connector
|  | 17. | Capacitor connector
|  | 18. | Earth cable connection
|  | 19. | Brake booster vacuum hose connection
|  | 20. | Engine oil level gauge and guide assembly
|  | 21. | O-ring
|  |  | Removal steps
--- | --- | --- | ---
|  | 22. | Rocker cover PCV hose connection
|  | 23. | Rocker cover breather hose connection
|  | 24. | Vacuum hose connection
|  | 25. | Battery wiring harness connection
|  | 26. | Inlet manifold stay
|  | • | Timing belt upper cover (Refer to ).
<<B>> | >>E<< | 27. | Camshaft sprocket
<<C>> | >>D<< | 28. | Radiator upper hose connection
|  | 29. | Water hose connection
|  | • | Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
|  | 30. | Fuel return line hose connection
| >>C<< | 31. | Fuel high-pressure hose connection
| >>C<< | 32. | O-ring
|  | 33. | Rocker cover
|  | 34. | Rocker cover gasket
<<D>> | >>B<< | 35. | Cylinder head bolts
|  | 36. | Cylinder head assembly
| >>A<< | 37. | Cylinder head gasket
<4G64>
Pre-removal Operation Fuel Line Pressure Reduction [Refer to GROUP 13B, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) .] Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ). Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ). Exhaust Manifold Removal (Refer to GROUP 15, Exhaust Manifold ). Spark Plug Cables and Ignition Coils Removal (Refer to GROUP 16, Ignition Coil ). | Post-installation Operation Spark Plug Cables and Ignition Coils Installation (Refer to GROUP 16, Ignition Coil ). Exhaust Manifold Installation (Refer to GROUP 15, Exhaust Manifold ). Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ). Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ). Fuel Leak Check
|  |  | Removal steps
--- | --- | --- | ---
|  | 1. | Accelerator cable connection
|  | 2. | A/C compressor connector
|  | 3. | Power steering oil pressure switch connector
<<A>> |  | 4. | Crank angle sensor connector
|  | 5. | Ignition coil connectors
|  | 6. | EGR control solenoid valve connector
|  | 7. | Detonation sensor connector
|  | 8. | Throttle position sensor connector
|  | 9. | Injector connectors
|  | 10. | Engine coolant temperature gauge unit connector
|  | 11. | Idle speed control servo connector
|  | 12. | Camshaft position sensor connector
|  | 13. | Engine coolant temperature sensor connector
|  | 14. | Capacitor connector
|  | 15. | Earth cable connection
|  | 16. | Brake booster vacuum hose connection
|  | 17. | Auto-cruise control vacuum hose connection <Vehicles with auto-cruise control>
|  | 18. | Canister vacuum hose connection
|  | 19. | Engine oil level gauge and guide assembly
|  | 20. | O-ring
|  |  | Removal steps
--- | --- | --- | ---
|  | 21. | Rocker cover PCV hose connection
|  | 22. | Rocker cover breather hose connection
|  | 23. | Detonation sensor connector
|  | 24. | Battery wiring harness connection
|  | 25. | Inlet manifold stay
|  | • | Timing belt upper cover (Refer to ).
<<B>> | >>E<< | 26. | Camshaft sprocket
<<C>> | >>D<< | 27. | Radiator upper hose connection
|  | 28. | Water hose connection
|  | • | Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
|  | 29. | Fuel return line hose connection
| >>C<< | 30. | Fuel high-pressure hose connection
| >>C<< | 31. | O-ring
|  | 32. | Rocker cover
|  | 33. | Rocker cover gasket
<<D>> | >>B<< | 34. | Cylinder head bolts
|  | 35. | Cylinder head assembly
| >>A<< | 36. | Cylinder head gasket
| REMOVAL SERVICE POINTS
| <<A>> CRANK ANGLE SENSOR CONNECTOR REMOVAL
| CAUTION Do not remove the tape securing the crank angle sensor connector and control wiring harness, since the control wiring harness may contact the power steering oil pump pulley.
| <<B>> CAMSHAFT SPROCKET REMOVAL CAUTION Never turn the crankshaft anti-clockwise.
| Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to set No.1 cylinder to TDC of its compression stroke.
| Remove the timing belt under cover rubber plug and then set the special tool adjusting bolt (MD998738). CAUTION The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend.
| Screw in the special tool until it comes in contact with the timing belt tensioner arm.
| Secure the camshaft sprocket and valve timing belt with wiring bands to prevent slippage between the camshaft sprocket and valve timing belt. CAUTION Do not rotate the crankshaft after camshaft sprocket removal.
| Use the special tool below to remove the camshaft sprocket and the valve timing belt as an assembly. Front hub and flange yoke holder (MB990767) Pin (MD998719) Place the camshaft sprocket above the timing belt lower cover.
| <<C>> RADIATOR UPPER HOSE DISCONNECTION
| Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.
| <<D>> CYLINDER HEAD BOLTS REMOVAL
| Using special tool cylinder head bolt wrench (MB991654), loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration.
| INSTALLATION SERVICE POINTS
| >>A<< CYLINDER HEAD GASKET INSTALLATION CAUTION Do not allow any foreign materials to get into the coolant passages, oil passages and cylinder. Remove the gasket from the cylinder head and cylinder block.
| Assemble to the cylinder block so the cylinder head gasket identification mark "63" or "64" is at the top surface and on the exhaust side.
| >>B<< CYLINDER HEAD BOLTS INSTALLATION
| Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm Apply a small amount of engine oil to the thread of the bolts and to the washers.
| Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows: Tighten the cylinder head bolts to 78 ± 2 N·m in the order shown. Loosen the bolts fully in the reverse order of that shown. Tighten the cylinder head bolts to 20 ± 2 N·m in the order shown.
| Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown. CAUTION The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle. Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned. If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.
| >>C<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION CAUTION Do not let any engine oil get into the delivery pipe. Apply a small amount of new engine oil to the O-ring. Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 ± 1.0 N·m
| >>D<< RADIATOR UPPER HOSE CONNECTION
| Insert each hose as far as the projection of the water outlet fitting. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
| >>E<< CAMSHAFT SPROCKET INSTALLATION
| Use the following special tool as during removal to support the camshaft sprocket. Front hub and flange yoke holder (MB990767) Pin (MD998719) Tighten the camshaft sprocket mounting bolts to the specified torque. Tightening torque: 89 ± 9 N·m
| Remove special tool adjusting bolt (MD998738), then assemble the timing belt under cover rubber plug.

[11A] ENGINE MECHANICAL <4G6-SOHC> - - CYLINDER HEAD GASKET - REMOVAL AND INSTALLATION | PRINT PAGE / INDEX / PRIOR / NEXT

©2004 Mitsubishi Motors Corporation