REMOVAL AND INSTALLATION

CAUTION

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

Pre-removal Operation

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

Ignition Coils Removal (Refer to GROUP 16, Ignition System - Ignition Coil ).

Timing Belt Upper Cover Removal (Refer to ).

Post-installation Operation

Timing Belt Upper Cover Installation (Refer to ).

Ignition Coils Installation (Refer to GROUP 16, Ignition System - Ignition Coil ).

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

Drive Belt Tension Check (Refer to ).

Valve Clearance Check and Adjustment (Refer to ).

		Camshaft removal steps
	1.	Rocker cover PCV hose connection
	2.	Rocker cover breather hose connection
	3.	Control wiring harness connection
	4.	Engine hanger
>>J<<	5.	Oil control valve
>>J<<	6.	O-ring
	7.	Rocker cover assembly
	8.	Rocker cover gasket
	9.	Spark plug guide oil seals
	10.	Accumulator assembly
	•	Valve timing belt (Refer to ).

			Camshaft removal steps
		11.	Connector bracket <For Hong Kong spec.>
	>>I<<	12.	Camshaft position sensor support
		13.	Camshaft position sensing cylinder
<<A>>	>>H<<	14.	Camshaft sprocket
	>>G<<	15.	Camshaft oil seal
	>>F<<	16.	Exhaust rocker arm shaft caps
<<B>>	>>F<<	17.	Exhaust rocker arm and shaft assembly
	>>E<<	18.	Inlet rocker arm shaft caps
<<B>>	>>E<<	19.	Inlet rocker arm and shaft assembly
	>>D<<	20.	Camshaft
		•	Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
		21.	Cylinder head plug
		22.	Oil control valve filter
			Valve stem seal removal steps
		1.	Rocker cover PCV hose connection
		2.	Rocker cover breather hose connection
		3.	Control wiring harness connection
		4.	Engine hanger
		7.	Rocker cover assembly
		8.	Rocker cover gasket
		9.	Spark plug guide oil seals
	>>F<<	16.	Exhaust rocker arm shaft caps
<<B>>	>>F<<	17.	Exhaust rocker arm and shaft assembly
	>>E<<	18.	Inlet rocker arm shaft caps
<<B>>	>>E<<	19.	Inlet rocker arm and shaft assembly
		23.	Spark plugs
<<C>>	>>C<<	24.	Valve spring retainer locks
		25.	Valve spring retainers
	>>B<<	26.	Inlet valve springs
	>>B<<	27.	Exhaust valve springs
	>>A<<	28.	Valve stem seals
		29.	Valve spring seats

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

Use the following special tools to hold the camshaft sprocket.

Front hub and flange yoke holder (MB990767)

Pin (MD998719)

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

<<B>> EXHAUST ROCKER ARM AND SHAFT ASSEMBLY/INLET ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

CAUTION

Never disassemble the exhaust rocker arm and shaft assembly, and inlet rocker arm and shaft assembly.

<<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 and then remove the valve spring retainer lock.

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEALS INSTALLATION

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

CAUTION

Do not re-use the valve stem seal.

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

>>B<< EXHAUST VALVE SPRINGS/INLET 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 and then install the valve spring retainer lock in the same manner as removal.

>>D<< CAMSHAFT INSTALLATION

Set the dowel pin of the camshaft in the position shown in the figure.

>>E<< INLET ROCKER ARM AND SHAFT ASSEMBLY/INLET ROCKER ARM SHAFT CAPS INSTALLATION

Place the inlet rocker shaft so that its 5.5 mm hole faces toward the cylinder head.

Install the inlet rocker arm shaft caps.

Tighten the inlet rocker shaft mounting bolts to the specified torque.

Tightening torque: 31 ± 3 N·m

>>F<< EXHAUST ROCKER ARM AND SHAFT ASSEMBLY/EXHAUST ROCKER ARM SHAFT CAPS INSTALLATION

Install the exhaust rocker shaft so that its notch is positioned as shown.

Install the exhaust rocker arm shaft caps.

Tighten the exhaust rocker shaft mounting bolts to the specified torque.

Tightening torque: 13 ± 1 N·m

>>G<< 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 as shown.

>>H<< CAMSHAFT SPROCKET INSTALLATION

Use the following special tool as during removal to hold 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

>>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 the sealant.

Install the camshaft position sensor support to the cylinder head.

CAUTION

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<< O-RING/OIL CONTROL VALVE INSTALLATION

CAUTION

Never re-use the O-ring.

Before installing O-ring, wind the tape with the soft adhesion (sealing tape) around the oil passages cut-out area of engine oil control valve to prevent the damage. If the O-ring is damaged, it can be the cause of oil leak.

Apply a small amount of engine oil to the O-ring and then install it to the oil control valve.

Assemble the oil control valve to the cylinder head.

Tighten the oil control valve mounting bolt to the specified torque.

Tightening torque: 11 ± 1 N·m