Cylinder Head Gasket — Replacement (4G61 DOHC, 16 Valves) (Mitsubishi Colt 4)

Removal

Disconnect the ground cable from the battery.

Remove the left mudguard under the engine.

Drain the coolant into a suitable container.

Remove the radiator.

Disconnect the throttle cable.

On the air filter, remove the plug from the air flow sensor connector.

Remove the breather hose and purge hose. Disconnect the large air ducts that go to the turbocharger and to the intake manifold.

Disconnect the air bypass hose and remove the air intake hose.

Remove the air filter.

Remove the crankcase ventilation hose from the cylinder block cover.

Disconnect the coolant bypass hose and the heater hose.

Disconnect the vacuum hoses from the air intake pressure regulator.

Disconnect the brake booster vacuum hose.

Remove the high pressure fuel hose.

Remove the fuel return hose.

Disconnect the electrical connectors going to the cylinder head and intake manifold.

Place a floor jack and a wide board under the oil pan. Raise the jack enough to support the engine without lifting it.

Remove the engine bracket.

Remove the alternator belt and power steering belt.

Loosen the air conditioner compressor belt. If the belt is loose, remove the tensioner and belt.



Remove the water pump pulley together with the steering pulley and power steering.



Remove the crankshaft pulley.

Remove the upper and lower timing belt covers.

Remove the center cover, remove the crankcase ventilation hose and breather hose from the cylinder head cover.

Disconnect the spark plug wires from the spark plugs.

After unscrewing the mounting bolts, remove the cylinder head cover and its gasket. Remove the semicircular plug from the head cover

Turn the crankshaft clockwise until the timing marks are aligned. (The timing marks on the crankshaft gear should align with the top surface of the head and the timing pins in the center of the gears.).

CAUTION: Once this position has been reached, the camshafts or crankshaft must not be moved.

After removing the automatic tensioner, remove the camshaft drive toothed belt.

Remove the tensioner pulley.

Remove the exhaust manifold heat shield.

Loosen the bolt securing the coolant pipe to the turbocharger.

Disconnect the front exhaust pipe from the lower part of the turbocharger.

Disconnect the oil return line from the turbocharger.

Disconnect the rod bolted to the right rear corner of the head.

Disconnect the intake manifold support bracket.

Loosen the head mounting bolts in the order shown in the figure.



Separate the head from the engine, using a rubber or wooden mallet if necessary.

Installation

Install the new gasket onto the engine with the mark facing up (towards the head) and located at the end of the block where the timing belt is located. Install the new gasket onto the exhaust pipe.

Further installation is carried out in reverse order.