REMOVAL AND INSTALLATION

<4G63>

CAUTION

*Remove and assemble the marked parts in each cylinder unit.

Pre-removal Operation

Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ).

Battery and Battery Tray Removal

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 ).

Battery and Battery Tray Installation

Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ).

Drive Belt Tension Check (Refer to ).

			Camshaft removal steps
		•	Valve timing belt (Refer to ).
		1.	Control wiring harness connection
		2.	Rocker cover PCV hose connection
		3.	Rocker cover breather hose connection
		4.	Rocker cover
		5.	Rocker cover gasket
		6.	Cylinder head spark plug guide seals
		7.	Camshaft position sensor connector
		8.	Control wiring harness connection

			Camshaft removal steps
	>>H<<	9.	Camshaft position sensor support
		10.	Camshaft position sensing cylinder
<<A>>	>>G<<	11.	Camshaft sprocket
	>>F<<	12.	Camshaft oil seal
<<B>>	>>E<<	13.	Rocker arm, shaft and lash adjuster assembly
<<C>>	>>D<<	14.	Rocker arm, shaft, lash adjuster and spring assembly
	>>D<<	15.	Rocker shaft springs
<<C>>	>>D<<	16.	Rocker arm, shaft and lash adjuster assembly
		17.	Camshaft
			Valve stem seal removal steps
		•	Timing belt upper cover (Refer to ).
		1.	Control wiring harness connection
		2.	Rocker cover PCV hose connection
		3.	Rocker cover breather hose connection
		4.	Rocker cover
		5.	Rocker cover gasket
		6.	Cylinder head spark plug guide seals
<<B>>	>>E<<	13.	Rocker arm, shaft and lash adjuster assembly
<<C>>	>>D<<	14.	Rocker arm, shaft, lash adjuster and spring assembly
	>>D<<	15.	Rocker shaft springs
<<C>>	>>D<<	16.	Rocker arm, shaft and lash adjuster assembly
		18.	Spark plugs
<<D>>	>>C<<	19.	Valve spring retainer locks
		20.	Valve spring retainers
	>>B<<	21.	Valve springs
	>>A<<	22.	Valve stem seals
		23.	Valve spring seats

<4G64>

CAUTION

*Remove and assemble the marked parts in each cylinder unit.

Pre-removal Operation

Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ).

Battery and Battery Tray Removal

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 ).

Battery and Battery Tray Installation

Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ).

Drive Belt Tension Check (Refer to ).

			Camshaft removal steps
		•	Valve timing belt (Refer to ).
		1.	Accelerator cable connection <LH drive vehicles>
		2.	Control wiring harness connection
		3.	Rocker cover PCV hose connection
		4.	Rocker cover breather hose connection
		5.	Rocker cover
		6.	Rocker cover gasket
		7.	Cylinder head spark plug guide seals
		8.	Camshaft position sensor connector
		9.	Battery wiring harness connection

			Camshaft removal steps
		10.	Engine wiring bracket
	>>H<<	11.	Camshaft position sensor support
		12.	Camshaft position sensing cylinder
<<A>>	>>G<<	13.	Camshaft sprocket
	>>F<<	14.	Camshaft oil seal
<<B>>	>>E<<	15.	Rocker arm, shaft and lash adjuster assembly
<<C>>	>>D<<	16.	Rocker arm, shaft, lash adjuster and spring assembly
	>>D<<	17.	Rocker shaft springs
<<C>>	>>D<<	18.	Rocker arm, shaft and lash adjuster assembly
		19.	Camshaft
			Valve stem seal removal steps
		•	Timing belt upper cover (Refer to ).
		1.	Accelerator cable connection <LH drive vehicles>
		2.	Control wiring harness connection
		3.	Rocker cover PCV hose connection
		4.	Rocker cover breather hose connection
		5.	Rocker cover
		6.	Rocker cover gasket
		7.	Cylinder head spark plug guide seals
<<B>>	>>E<<	15.	Rocker arm, shaft and lash adjuster assembly
<<C>>	>>D<<	16.	Rocker arm, shaft, lash adjuster and spring assembly
	>>D<<	17.	Rocker shaft springs
<<C>>	>>D<<	18.	Rocker arm, shaft and lash adjuster assembly
		20.	Spark plugs
<<D>>	>>C<<	21.	Valve spring retainer locks
		22.	Valve spring retainers
	>>B<<	23.	Valve springs
	>>A<<	24.	Valve stem seals
		25.	Valve spring seats

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

Use the following special tools to support the camshaft sprocket.

Front hub and flange yoke holder (MB990767)

Pin (MD998719)

Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.

<<B>> ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY REMOVAL

CAUTION

Never disassemble the rocker arm, shaft and lash adjuster assembly.

Before rocker arm, shaft and lash adjuster assembly removal, install special tool lash adjuster holder (MD998443) as shown in the illustration so that the lash adjusters will not fall out.

<<C>> ROCKER ARM, SHAFT, LASH ADJUSTER AND SPRING ASSEMBLY/ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY REMOVAL

CAUTION

Never disassemble the rocker arm, shaft and lash adjuster assembly.

Before rocker arm, shaft, lash adjuster and spring assembly removal, install special tool lash adjuster holder (MD998443) as shown in the illustration so that the lash adjusters will not fall out.

<<D>> VALVE SPRING RETAINER LOCKS REMOVAL

CAUTION

When removing valve spring retainer locks, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer locks.

NOTE: Installation position of special tool is different between exhaust side and inlet side.

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEALS INSTALLATION

Apply a small amount of engine oil to the valve stem seals.

CAUTION

Valve stem seals cannot be reused.

The special tool valve stem seal installer (MB991999) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.

Use special tool to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

>>B<< VALVE SPRINGS INSTALLATION

Install the valve springs with its identification colour painted end facing the locker arm.

>>C<< VALVE SPRING RETAINER LOCKS INSTALLATION

Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal.

>>D<< ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY/ROCKER SHAFT SPRINGS/ROCKER ARM, SHAFT, LASH ADJUSTER AND SPRING ASSEMBLY INSTALLATION

Ensure that all rocker arms do not press against the valve, then pre-tighten the rocker arm, shaft and lash adjuster assembly with the assembling bolt.

Install the rocker shaft spring so that it is at a right angle against the spark plug guide.

Tighten the mounting bolts to the specified torque.

Tightening torque: 31 ± 3 N·m

Remove special tool lash adjuster holder (MD998443).

>>E<< ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY INSTALLATION

Install the rocker arm, shaft and lash adjuster assembly.

Tighten the mounting bolts to the specified torque.

Tightening torque: 31 ± 3 N·m

Remove special tool lash adjuster holder (MD998443).

Check that notches in the each rocker shaft are facing the direction shown in the illustration.

>>F<< CAMSHAFT OIL SEAL INSTALLATION

Apply engine oil to the entire inner diameter of the oil seal lip.

Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seal.

>>G<< 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 bolt to the specified torque.

Tightening torque: 89 ± 9 N·m

>>H<< CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

Remove sealant from the camshaft position sensor support and cylinder head surfaces.

Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

NOTE: Install the camshaft position sensor support within 15 minutes after applying liquid gasket.

Install the camshaft position sensor support to the cylinder head.

CAUTION

Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.

Tighten the camshaft position sensor support mounting bolts to the specified torque.

Tightening torque: 14 ± 1 N·m