Part 1
ROCKER ARMS AND CAMSHAFT
Removal
Follow removal steps outlined in illustration.
Removal Service Point
[A] Rocker Arm, Rocker Arm Shaft Removal.
1. Install the special tools to the rocker arm to hold the lash adjuster.
2. Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap.
3. Remove the rocker arm, shaft and bearing cap as an assembly.
Inspection
Rocker Arm Shaft
1. Check the rocker arm mounting portions of the rocker arm shafts for wear or damage. Replace as necessary.
Rocker Arm
1. Check the roller surface and replace the rocker arm if recesses, damage or heat seizure is observed.
2. Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is observed.
3. Check the inside diameter and replace the rocker arm if damage or seizure is observed.
Camshaft
1. Inspect the camshaft bearing journals for damage and binding. If the journals are binding, also check the cylinder head for damage. Also check the cylinder head oil holes for clogging.
Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height and replace if out of limit.
Intake:
Standard Value 37.58 mm (1.48 inch)
Limit: 37.08 mm (1.46 inch)
Exhaust:
Standard Value 36.95 mm (1.45 inch)
Limit 36.45 mm (1.44 inch)
Lash Adjuster Leak Down Test
CAUTION:
1. The lash adjuster is a precision part. Keep it free from dust and other foreign matters.
2. Do not disassemble the lash adjusters.
3. When cleaning the lash adjusters, use clean diesel fuel only.
1. Immerse the lash adjuster in clean diesel fuel.
2. While lightly pushing down the inner steel ball using the special tool, move the plunger up and down four or five times to bleed air.
Use of the retainer facilitates the air bleeding of the rocker arm mounted type lash adjuster.
3. Remove the special tool and press the plunger. If the plunger is hard to push in, the lash adjuster is normal. If the plunger can be pushed in all the way easily, bleed the lash adjuster again and test again. If the plunger is still loose, replace the lash adjuster.
CAUTION: After air bleeding is completed, hold the lash adjuster upright to prevent the diesel fuel from spilling.
4. After air bleeding, set the lash adjuster on the special tool (Leak down tester MD998440).
5. After the plunger has gone down slightly 0.2 - 0.5 mm (0.008 - 0.020 inch), measure the time taken for it to go down a further 1 mm (0.04 inch). Replace if the measured time is out of specification.
Standard value:
4 - 20 seconds /1 mm (0.04 inch)
[Diesel fuel at 15 - 20° C (50 - 68° F)]
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Installation.
1. Apply engine oil to the camshaft journals and cams and then install the camshafts.
Use care to prevent confusion of the right and left bank camshafts.
NOTE: The right bank camshaft is identified by a slit 4 mm wide at the rear end of the camshaft.
2. Check to see that the dowel pin of the camshaft is located at the position shown.
]B[ Lash Adjuster Installation.
1. Immerse the lash adjuster in clean diesel fuel.
2. Using the special tool (air bleed wire), 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.
3. Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the special tool to prevent the adjuster from falling out while installing it.
]C[ Rocker Arm Shaft.
The end with the larger chamfer is at the right on the left bank and at the left on the right bank.
NOTE: Before installing the exhaust rocker arms and rocker arm shaft, mount the rocker shaft spring.
The side with the oil holes is on the lower side (cylinder head side).
]D[ Rocker Shaft Spring.
1. Insert the rocker shaft spring at a slant with respect to the spark plug guide and install it normal to the guide.
]E[ Camshaft Oil Seal Installation.
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 Bolt Removal.
[B] Retainer Lock Removal.
1. Using the special tool, compress the spring.
2. Remove the retainer locks.
[C] Valve Stem Seal Removal.
1. Do not reuse removed valve stem seals.
Inspection
Cylinder Head
1. Check the cylinder head gasket surface for flatness by using a straightedge in the directions of A through G shown in the illustration.
Standard value: 0.03 mm (0.0012 inch)
Limit: 0.2 mm (0.008 inch)
2. If the service limit is exceeded, correct to meet the specification.
Grinding limit: *0.2 mm (0.008 inch)
* Total resurfacing depth of both cylinder head and cylinder block.
Overall height: 120 mm (4.72 inch)
Valve
1. If the valve stem is worn (ridge wear) or otherwise damaged, replace. Also replace the valve if the stem end (that contacts the rocker arm lash adjuster) has a dent.
2. Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve should make a uniform contact with the seat at the center of valve face.
3. If the margin exceeds the service limit, replace the valve.
Standard value:
[Intake]
1.0 mm (0.039 inch)
[Exhaust]
1.2 mm (0.047 inch)
Limit:
[Intake]
0.5 mm (0.019 inch)
[Exhaust]
1.2 mm (0.047 inch)
Valve Springs
1. Measure the free height of the spring and, if it is smaller than the limit, replace.
Standard value: 51.0 mm (2.01 inch)
Limit: 50.0 mm (1.97 inch)
2. Measure the squareness of the spring and, if the limit is exceeded, replace.
Standard value: 2°
Limit: Maximum 4°
Valve Guides
Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide or valve, or both.
Standard value:
[Intake]
0.02 - 0.05 mm (0.0008 - 0.0020 inch)
[Exhaust]
0.04 - 0.07 mm (0.0016 - 0.0028 inch)
Limit:
[Intake]
0.10 mm (0.004 inch)
[Exhaust]
0.15 mm (0.006 inch)
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 special tool or seat grinder, correct to obtain the specified seat width and angle.
3. After correction, valve and valve seat should be lapped with a lapping compound.
Valve Seat Replacement Procedure
1. Cut the valve seat to be replaced from 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.
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. Remove the snap ring from the exhaust valve guide.
2. Using the press, remove the valve guide toward the cylinder block.
3. Rebore 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.
4. Press-fit the valve guide until it protrudes 14 mm (0.55 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
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Valve Stem Seal Installation.
1. Install the valve spring seat.
2. Using the special tool, install a new stem seal to the valve guide.
CAUTION:
1. Valve stem seals for intake valve and for exhaust valve are different. Be sure to install the correct ones. Valve stem seal identification color
Intake: Silver or White
Exhaust: Black
2. Do not reuse removed valve stem seal.
3. Always use the special tool to install the valve stem seal. Improperly installed valve stem seal may cause oil leak.
]B[ Valve Spring Installation.
1. Direct the valve spring end with identification color toward the spring retainer.
]C[ Retainer Lock Installation.
1. Using the special tool, compress the valve spring and insert the retainer lock into position.
]D[ Cylinder Head Bolt Installation.
1. Tighten the cylinder head bolts using the special tool in the sequence shown. Each bolt should be tightened in two to three steps, torquing progressively. Tighten to the specified torque in the final sequence.
OIL PUMP AND OIL PAN
Removal
Follow removal steps outlined in illustration.
Removal Service Point
[A] Oil Pan, Lower Removal.
1 Apply wood to the oil pan side and remove the oil pan lower with a plastic hammer.
CAUTION: Do not use a scraper or special tool to remove the oil pan.
[B] Oil Pan, Upper Removal.
1. Remove the bolts 1 shown in the illustration.
2. Remove all other bolts.
3. Thread the bolt into the illustrated bolt hole A (at each end) to float and remove the oil pan.
CAUTION: Do not use a scraper or special tool to remove the oil pan.
[C] Accouter Rotor /Inner Rotor Removal.
Make alignment dots on the outer and inner rotors for reference in reassembly.
Inspection
Oil Pump
1. Check the tip clearance.
Standard value: 0.06 - 0.18 mm (0.0024 - 0.0071 inch)
2. Check the side clearance.
Standard value: 0.04 - 0.10 mm (0.0016 - 0.0039 inch)
3. Check the body clearance.
Standard value: 0.10 - 0.18 mm (0.0040 - 0.0070 inch)
Limit: 0.35 mm (0.0138 inch)
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Inner Rotor /Outer Rotor Installation.
1. Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned.
]B[ Oil Pump Case Installation.
1. Remove the sealant from the cylinder block (oil pump mounting plane) and oil pump.
2. Apply a 3 mm (0.118 inch) diameter bead of sealant to the oil pump case. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 or equivalent
]C[ Crankshaft Front Oil Seal Installation.
1. Using the special tool, knock the oil seal into the oil pump case.
NOTE: Knock the seal in until it is fully based.
]D[ Oil Pan, Upper Installation.
1. Clean the gasket surfaces of the cylinder block and upper oil pan.
2. Apply a 4 mm (0.157 inch) diameter bead of sealant to the oil pump case. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.
CAUTION: When installing the upper oil pan, be sure not to expel the sealant front the oil pan flange at portion A in the illustration.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 or equivalent
]E[ Oil Pan, Lower Installation.
1. Clean the gasket surfaces of the upper and lower oil pans.
2. Apply a 4 mm (0.157 inch) diameter bead of sealant to the oil pump case. Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
3. After installation, keep the sealed area away from the oil and coolant for approximately 1 hour.
Specified sealant:
MITSUBISHI GENUINE Part No. MD970389 or equivalent
]F[ Drain Plug Gasket Installation.
1. Install the drain plug gasket as illustrated.
]G[ Oil Filter Installation.
1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the O-ring of the oil filter.
3. Screw the oil filter on until the O-ring contacts the bracket. Then tighten approximately one turn [14 Nm (10 ft lbs)].
]H[ Sealant Application To Oil Pressure Switch.
1. Coat the threads of the 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 overtightening.