Cylinder Head Assembly: Service and Repair

REMOVAL
Pre-removal Operation:
(1) Fuel Line and Hose Reduce the Inner Pressure.
(2) Engine Coolant Draining.
(3) Engine Oil Draining.
(4) Air Intake Hose Removal.

Follow removal steps outlined in illustration.

Removal Service Points





[A] Camshaft Sprocket Removal.
(1) Rotate the crankshaft in the forward (right) direction and align the timing marks.

CAUTION: The crankshaft must always be rotated in the forward direction only.





(2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt.





(3) Use the special tool to remove the camshaft sprocket with the timing belt attached.

CAUTION: After removing the camshaft sprocket, be sure not to rotate the crankshaft.





[B] Cylinder Head Bolt Removal.
Loosen the bolts in the order shown in the illustration (in 2 or 3 cycles), remove them and then remove the cylinder head assembly.

CAUTION: Because the plug guides cannot be replaced by themselves, be careful not to damage or deform the plug guides when removing the cylinder head bolts.

INSTALLATION
Installation in reverse order as removal.

Installation Service Points





]A[ Cylinder Head Gasket Installation.
(1) Wipe off all oil and grease from the gasket mounting surface.
(2) Install the gasket to the cylinder block with the identification mark facing upwards.





]B[ Cylinder Head Bolt Installation.
(1) When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.

Limit (A): Within 99.4 mm (3.913 inch)

(2) Apply engine oil to the bolt thread and the washer.

Torque Sequence:

(3) Tighten the bolts by the following procedure.

CAUTION:
1. Always make a tightening angle of just 90°. If it is less than 90°, the head bolt will loosen.
2. If it is more than 90°, remove the head bolt and repeat the procedure from step 1.





]C[ Thermostat Case Assembly Installation.
(1) Loosen the water inlet pipe bolt shown in the illustration.





(2) Apply specified sealant to the thermostat case assembly in the places shown in the illustration.

Specified sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

(3) Apply a small amount of water to the O-ring of the water inlet pipe, and then press the thermostat case assembly into the water inlet pipe.
(4) Tighten the thermostat case assembly mounting bolts.
(5) Tighten the water inlet pipe bolts.

Post-installation Operation:
(1) Air Intake Hose Installation.
(2) Engine Oil Refilling.
(3) Engine Coolant Refilling.
(4) Accelerator Cable Adjusting.