External Components
GENERATOR AND IGNITION SYSTEM
Removal
Follow removal steps outlined in illustration.
Removal Service Point
[A] Crankshaft Bolt Removal.
1. Lock the flywheel or drive plate in position, then loosen the crankshaft bolt.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Cam Position Sensor Support Installation.
1. Clean the sealant application surfaces of cam position sensor support and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant to the area shown in the illustration. Be sure to install the sensor support with in 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
3. After installation, wait at least one hour. Never start the engine or let engine oil touch the adhesion surface during that time.
]B[ Crankshaft Bolt Installation.
1. Lock the flywheel or drive plate in position using the special tool shown in the illustration, then tighten the crankshaft bolt.
TIMING BELT
Removal
Follow removal steps outlined in illustration.
Removal Service Points
[A] Timing Belt Removal.
1. Mark the belt running direction for reference in reinstallation.
2. Loosen the tensioner mounting bolt.
3. Insert a cross-tip screwdriver into the hole of the tensioner arm as shown illustration.
4. Move the screwdriver all the way in the direction of the arrow, and tighten the tensioner mounting bolt to hold this position.
5. Remove the timing belt.
NOTE:
1. Water oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
2. If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.
[B] Camshaft Sprocket Bolt Loosening.
INSPECTION
Timing Belt
Check the timing belt closely. Replace the belt with a new one if any of the following defects are evident:
1. Hardened backing rubber (the backing rubber is glossy, non-elastic, and so hard that scratching with fingernails leaves no mark.)
2. Surface cracks on the backing rubber.
3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
6. Abnormal wear on the belt sides.
NOTE: The sides of the belt are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth. Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Final stage: Canvas worn, exposing rubber (tooth width reduced)
8. Missing teeth.
Tensioner Puller
1. Check the pulley for smooth rotation, without play and are not noisy.
INSTALLATION
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Sprocket Bolt Tightening.
]B[ Timing Belt Tensioner Installation.
1. Install the timing belt tensioner in the illustrated position, and then tighten the tensioner mounting bolt.
]C[ Tensioner Spring Installation.
1. Install the tensioner spring onto the boss of the front case, and then hook the spring end "A" (shorter one) to the front case rib.
2. Grip the spring end "B" (longer one), and then hook it onto the tensioner arm.
]D[ Timing Belt Installation.
1. Align the crankshaft sprocket timing mark with the timing mark on the front case, and then rotate the crankshaft sprocket three teeth counterclockwise.
CAUTION: Aligning the timing marks positions the piston to the top dead center. Then, if the camshaft turns, the valves might interfere and damage the pistons.
2. Align the camshaft sprocket timing mark with the timing mark on the cylinder head.
3. Rotate the crankshaft sprocket three teeth counterclockwise, and align the crankshaft sprocket timing mark with the timing mark on the front case.
4. Keeping the tension side of the timing belt tight, fit the timing belt onto the crankshaft sprocket, water pump sprocket, camshaft sprocket and tensioner puller in that order.
5. Slightly loosen the timing belt tensioner bolt to tension the belt by a force of the tensioner spring.
6. Turn the crankshaft twice in the clockwise direction.
CAUTION: This procedure utilizes the camshaft's driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft counterclockwise.
7. Check that the timing marks are correctly aligned.
8. Tighten the timing belt tensioner locking bolt to the specified torque.
FUEL AND EMISSION CONTROL SYSTEM
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Injectors Installation.
1. Fit a new O-ring and grommet onto the injector.
2. Apply clean engine oil or gasoline to the injector O-ring.
3. Fit the injector onto the fuel rail, turning it to the left and right as it goes in.
4. Check that the injector rotates smoothly.
5. Check that the clearance between the injector connector and the fuel rail is uniform (A = B).
]B[ Fuel Pressure Regulator Installation.
1. Apply a drop of clean engine oil to the O-ring, then insert the fuel pressure regulator into the fuel rail, being careful not to damage the O-ring.
CAUTION: Do not let engine oil get into the fuel rail.
2. Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be binding. If this occurs, remove the fuel pressure regulator, check the O-ring for damage, then re-insert the regulator into the fuel rail.
]C[ Gasket Installation.
1. Position the projection as shown in the illustration.
INTAKE AND EXHAUST MANIFOLDS
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Point
]A[ Exhaust Manifold/Bracket Installation.
1. Install the exhaust manifold brackets "A" and "B" as shown in the illustration, and finger tighten each bolt.
2. Tighten the all bolts to the specified torque.
WATER PUMP AND WATER HOSE
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[Water Pump Installation.
1. Clean the sealant application surfaces of the water pump case and cylinder block.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant to the area shown in the illustration. Be sure to install the water pump within 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.
]B[ Water Inlet Pipe/d-ring Installation.
1. Replace the water inlet pipe O-ring with new ones, then apply water to the O-rings so that they can be inserted easily into the cylinder block and the thermostat case.
CAUTION:
1. Never apply any oil or grease to the O-ring.
2. Secure the water pipe after the thermostat case has been installed.
]C[ Thermostat Case Installation.
1. Clean the sealant application surfaces of the thermostat case and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant to the area shown in the illustration. Be sure to install the thermostat case within 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No. 970389 or equivalent.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.
]D[ Thermostat Installation.
1. Install the thermostat so that the jiggle valve is at the top.
]E[ Outlet Fitting Installation.
1. Clean the sealant application surfaces of the fittings and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant to the area shown in the illustration. Be sure to install the fitting within 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.
]F[ Engine Coolant Temperature Gauge Unit Installation.
1. When reusing the gauge unit, clean its thread.
2. Apply the specified sealant to the threads.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent.
]G[ Engine Coolant Temperature Sensor Installation.
1. When reusing the sensor, clean its thread.
2. Apply the specified sealant to the threads.
Specified sealant:
3M ATD Part No. 8660 or equivalent.