REMOVAL AND INSTALLATION

CAUTION

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

Pre-removal Operation

Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Intercooler Removal (Refer to GROUP 15, Intercooler ).

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

Battery Removal

Valve Timing Belt Removal (Refer to ).

Post-installation Operation

Valve Timing Belt Installation (Refer to ).

Battery Installation

Air Cleaner Installation (Refer to GROUP 15, Air Cleaner ).

Intercooler Installation (Refer to GROUP 15, Intercooler ).

Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Drive Belt Tension Check (Refer to ).

			Removal steps
		1.	Rocker cover centre cover
		•	Spark plug cables and ignition coils (Refer to GROUP 16, Ignition Coil ).
		2.	Control wiring harness connection
		3.	Camshaft position sensor connector
		4.	Capacitor connector
		5.	Rocker cover breather hose
		6.	Rocker cover PCV hose
		7.	Vacuum hose and pipe assembly
	>>N<<	8.	Rocker cover
	>>M<<	9.	Camshaft end seal
		10.	Spark plug hole gaskets
	>>L<<	11.	Rocker cover gasket
<<A>>	>>K<<	12.	Radiator upper hose connection

			Removal steps
		13.	Camshaft position sensor support cover
		14.	Camshaft position sensor support cover gasket
	>>J<<	15.	Camshaft position sensing cylinder
	>>I<<	16.	Camshaft position sensor support
<<B>>	>>H<<	17.	Camshaft sprockets
	>>G<<	18.	Camshaft oil seals
	>>F<<	19.	Camshaft bearing caps, front
	>>F<<	20.	Camshaft bearing caps, rear
	>>F<<	21.	Camshaft bearing caps, No.2
	>>F<<	22.	Camshaft bearing caps, No.5
	>>F<<	23.	Camshaft bearing caps, No.3
	>>F<<	24.	Camshaft bearing caps, No.4
	>>E<<	25.	Inlet camshaft
	>>E<<	26.	Exhaust camshaft
		27.	Rocker arms
	>>D<<	28.	Rocker arm lash adjusters
		29.	Oil delivery body
		30.	Spark plugs
<<C>>	>>C<<	31.	Valve spring retainer locks
		32.	Valve spring retainers
	>>B<<	33.	Valve springs
	>>A<<	34.	Inlet valve stem seals
	>>A<<	35.	Exhaust valve stem seals
		36.	Valve spring seats

LUBRICATION AND SEALING POINTS

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

<<B>> CAMSHAFT SPROCKETS REMOVAL

Hold the hexagon part of the camshaft with a wrench.

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

<<C>> 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.

INSTALLATION SERVICE POINTS

>>A<< EXHAUST VALVE STEM SEALS/INLET VALVE STEM SEALS INSTALLATION

Check the valve stem seal colour to identify the inlet side or exhaust side.

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 (MD998737) 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 LASH ADJUSTERS INSTALLATION

CAUTION

If the rocker arm lash adjuster is reused, always clean and check it before installation. (Refer to GROUP 11D, Rocker Arms and Camshaft - Inspection

>>E<< EXHAUST CAMSHAFT/INLET CAMSHAFT INSTALLATION

Remove sealant remained on the cylinder head.

Apply engine oil to the cam and the journal of the camshaft.

CAUTION

Do not install wrong camshaft at the side of inlet or exhaust. The exhaust camshaft has a slit at the rear surface.

Install the camshaft to the cylinder head.

>>F<< CAMSHAFT BEARING CAPS, NO. 4/CAMSHAFT BEARING CAPS, NO. 3/CAMSHAFT BEARING CAPS, NO. 5/CAMSHAFT BEARING CAPS, NO. 2/CAMSHAFT BEARING CAPS, REAR/CAMSHAFT BEARING CAPS, FRONT INSTALLATION

Set the dowel pin of the camshaft to the position as shown in the illustration.

Since the shape of camshaft bearing caps No. 2 - 5 is identical, check the identification marks so that the bearing cap No., inlet side, or exhaust side cannot be mistaken to install to the direction as shown in the illustration.

Identification mark (engraved on the front and bearing caps No. 2 - 5)

I: Inlet side

E: Exhaust side

Apply sealant to the positions (6 areas) of the upper side of the cylinder head as shown in the illustration.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

NOTE: Install the camshaft bearing caps, rear and camshaft bearing caps, front within 15 minutes after applying liquid gasket.

Position the camshaft bearing caps, rear in the direction as shown in the illustration for installation.

Check the identification marks on the camshaft bearing caps, front so that inlet side and exhaust side cannot be mistaken in the same way as that of bearing caps No. 2 - 5.

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 bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque.

Tightening torque: 20 ± 1 N·m

Ensure that the rocker arms are installed properly.

NOTE: Remove an excess of sealant completely.

>>G<< CAMSHAFT OIL SEALS 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 seals.

>>H<< CAMSHAFT SPROCKETS INSTALLATION

Hold the hexagon part of the camshaft with a wrench in the same manner as removal.

Tighten the camshaft sprocket mounting bolts to the specified torque.

Tightening torque: 89 ± 9 N·m

>>I<< 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

>>J<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION

Set the dowel pin of the exhaust camshaft to the position (No. 1 cylinder at compression TDC) as shown in the illustration.

NOTE: Use the force of the exhaust valve spring to rotate anti-clockwise.

Install the vane (small) of the camshaft position sensing cylinder at an angle of approximately 45 degrees to the position of the dowel pin of the exhaust camshaft.

Tighten the camshaft position sensing cylinder mounting bolts to the specified torque.

Tightening torque: 22 ± 4 N·m

>>K<< 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.

>>L<< ROCKER COVER GASKET INSTALLATION

Remove sealant remained on the rocker cover.

Apply sealant to the positions (4 areas) of the lower side of the rocker cover as shown in the illustration.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

NOTE: Install the rocker cover gasket within 15 minutes after applying liquid gasket.

Install the rocker cover gasket to the rocker cover.

>>M<< CAMSHAFT END SEAL INSTALLATION

Apply sealant to the positions of the camshaft end seal as shown in the illustration and install to the cylinder head.

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

NOTE: Install the camshaft end seal within 15 minutes after applying liquid gasket.

>>N<< ROCKER COVER INSTALLATION

Apply sealant to the positions of the rocker cover gasket (6 areas) as shown in the illustration.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

NOTE: Install the rocker cover within 15 minutes after applying liquid gasket.

Install the rocker cover 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 rocker cover mounting bolts to the specified torque.

Tightening torque: 3.5 ± 0.5 N·m