Replacing the cylinder head gasket (Mitsubishi Lancer 9)

Removal

Before you begin removing parts, perform the following operations.

a) Release residual pressure from the high-pressure fuel line (see chapter "Fuel injection system (MPI)").

b) Remove the engine crankcase protective cover.

c) Drain the coolant and engine oil.

d) Remove the air filter.

d) (Engine 4G93) Remove the thermostat housing assembly.

e) (Engine 4G15) Remove the battery and battery tray.

The parts are removed in the order of numbers shown in the figure "Replacing the cylinder head gasket".

When removing parts, pay attention to the following operations:

1. (Engine 4G93) Removing the upper radiator hose.

Before disconnecting the upper radiator hose, place relative position marks on the hose and hose clamp.

Replacing the cylinder head gasket (engine 4G15). 1 - Air conditioning compressor electromagnetic clutch connector, 2 - Power steering hydraulic system fluid pressure switch connector, 3 - Crankshaft position sensor connector, 4 - Knock sensor connector, 5 - EGR electromagnetic valve connector, 6 - Manifold absolute pressure sensor (with integrated manifold air temperature sensor), 7 Ignition coil connector, 8 - Injector connector, 9 - Throttle position sensor connector, 10 - Idle speed control servo connector, 11 - Canister purge electromagnetic valve connector, 12 Coolant temperature gauge sensor connector, 13 Oxygen sensor connector, 14 Coolant temperature sensor connector, 15 - Camshaft position sensor connector, 16 - Brake booster vacuum hose connection, 17 - Evaporative emission system vacuum hose connection fuel vapors (remove the cylinder head cover and gasket, exhaust manifold and intake pipe of the cooling system).

Replacing the cylinder head gasket (engine 4G15, continued). 18 - Fuel return hose connection, 19 - High pressure fuel hose flange connection, 20 - O-ring, 21 - Heater hose connection, 22 - Knock sensor connector retainer, 23 - Front upper timing belt cover, 24 - Camshaft pulley and timing belt assembly, 25 - Cylinder head mounting bolt, 26 - Cylinder head assembly, 27 - Cylinder head gasket.

2. Removing the camshaft pulley and timing belt assembly.

a) Turn the camshaft clockwise until the timing mark on the camshaft pulley aligns with the corresponding timing mark and set the piston of cylinder No.1 to TDC of the compression stroke.

Caution: Always turn the crankshaft clockwise only.

Engine 4G15.

Engine 4G93.

b) Using a strap or wire, secure the timing belt to the camshaft pulley in the position shown in the figure.

c) Secure the camshaft pulley from turning using a special fork holder and special bolts.

Caution: Be careful not to allow the camshaft to turn after removing the pulley.

3. Removing the cylinder head.

Using a special tool, loosen the mounting bolts in two or three steps (in the sequence shown in the figure), and then unscrew them, after which remove the cylinder head assembly.

Replacing the cylinder head gasket (engine 4G93). 1 - Accelerator pedal cable connection, 2 - Air conditioning compressor electromagnetic clutch connector, 3 - Power steering hydraulic fluid pressure switch connector, 4 - Crankshaft position sensor connector, 5 - Evaporative canister purge electromagnetic valve connector, 6 - Ignition coil connector, 7 - Injector connector, 8 - Throttle position sensor connector, 9 - Idle speed control servo connector, 10 - EGR valve servo connector, 11 - Coolant temperature sensor connector, 12 - Camshaft position sensor connector, 13 - Ground wire connection, 14 - Knock sensor connector, 15 - Coolant temperature gauge sensor connector, 16 - Oxygen sensor connector, 17 - Brake booster vacuum hose connection (remove the cylinder head cover and gasket, remove the exhaust manifold).

Replacing the cylinder head gasket (engine 4G93, continued).18 - Upper radiator hose connection, 19 - Heater hose connection, 20 - Positive crankcase ventilation hose connection, 21 - Ground wire connection, 22 - Fuel return hose connection, 23 - High pressure fuel hose flange connection, 24 - O-ring gasket, 25 - Front upper timing belt cover, 26 - Camshaft pulley and timing belt assembly, 27 - Rear upper timing belt cover, 28 - Coolant inlet pipe retainer mounting bolt, 29 - Cylinder head mounting bolt, 30 - Cylinder head assembly, 31 - Cylinder head gasket.

Stop

Installation of parts is carried out in the reverse order of removal.

When installing the parts, please pay attention to the following operations.

1. Installing the cylinder head gasket.

a) Using a special scraper, remove the remains of the old cylinder head gasket from the cylinder block.

Caution: Be careful not to allow gasket material or other foreign parts to enter the cylinders, cooling system passages and lubrication system passages.

b) Degrease the working surface under the gasket on the cylinder block.

c) Ensure that the new cylinder head gasket has the correct identification mark for the engine in question,

d) Place the cylinder head gasket on the cylinder block.

Caution: Since there is a possibility of incorrect installation of the cylinder head gasket, check the correct installation of the gasket before installing the cylinder head (matching of all holes on the gasket and the cylinder head). If the gasket is incorrectly installed, malfunctions may occur, such as lack of oil access to the cylinder head.

2. Installing the cylinder head assembly.

a) Using a scraper, remove any remaining old cylinder head gasket from the cylinder head.

Caution: Be careful not to allow gasket material or other foreign particles to enter the cooling system passages and lubrication system passages.

b) When installing the cylinder head mounting bolts, the length of the bolts must be within the permissible value. If the length of the bolts exceeds the maximum permissible value, the bolts must be replaced.

Maximum permissible value:

Engine 4G15 - no more than 103.2 mm

Engine 4G93 - no more than 96.4 mm

c) Lubricate the threads and washers of the cylinder head bolts with a small amount of clean engine oil.

d) Install the cylinder head bolt washers with the chamfered side facing up as shown in the illustration.

d) Before installation, lubricate the top surface of the washer and the bolt threads with a small amount of engine oil.

e) Tighten the cylinder head mounting bolts using the angular tightening method in the following order (tightening is performed in the sequence of numbers shown in the figure):

Engine 4G 15:

(1) Tighten all bolts to a torque of 49±2 N·m in the order shown in the figure;
(2) Completely loosen all bolts in the reverse order of the illustration.
(3) Tighten all bolts to a torque of 20±2 N·m in the order shown in the figure;
(4) Tighten all bolts 90° (1/4 turn, from position "A" to position "B") in the order shown in the figure;
(5) Tighten all bolts a final 90° (1/4 turn, from position "B" to position "C") in the order shown in the illustration.

Engine 4G93:

(1) Tighten all bolts to a torque of 74±2 N·m in the order shown in the figure;
(2) Completely loosen all bolts in the reverse order of the illustration.
(3) Tighten all bolts to a torque of 20±2 N·m in the order shown in the figure;
(4) Tighten all bolts 90° (1/4 turn, from position "A" to position "B") in the order shown in the figure;
(5) Tighten all bolts a final 90° (1/4 turn, from position "B" to position "C") in the order shown in the illustration.

Note:

After tightening, the marks on the bolts and cylinder head should be in line ("C").

If the cylinder head mounting bolt is turned at an angle less than 90° (1/4 turn), the bolt will not be tightened sufficiently (the reliability of the gas joint will not be ensured).

If the cylinder head mounting bolt is tightened to a torque exceeding the nominal value, then completely unscrew the mounting bolts and perform the bolt tightening procedure, starting with subparagraph "b".

3. Installing the camshaft pulley with the timing belt assembly.

a) Install the camshaft pulley, aligning the timing marks, and secure it from turning using a special fork holder and special bolts. Then tighten the mounting bolt to the rated torque.

Tightening torque: 88 ±10 Nm

b) Remove the band clamp or wire securing the timing belt to the camshaft pulley.

4. Installing the O-ring and flange of the high pressure fuel hose.

a) Apply a small amount of engine oil to the working edge of the O-ring around its entire circumference.

b) Rotate the flange of the high-pressure fuel hose to the right and left, carefully install the hose without damaging the O-ring. After connecting, check that the hose rotates smoothly.

c) If the hose flange does not rotate smoothly, the O-ring may be jammed. Disconnect the high-pressure fuel hose flange and check the O-ring for damage, then repeat the installation from step b.

d) Tighten the high pressure fuel hose flange mounting bolts to the specified torque.

Tightening torque: 5 ±1 Nm

5. (Engine 4G93) Installing the upper radiator hose.

a) When connecting the upper radiator hose, push the hose onto the branch pipe until it stops against the lug pat-nvbKa, then tighten the clamp.

b) The hose clamp should always be installed in the position in which the clamp was previously installed. Therefore, before installing the clamp, align the installation marks on the hose clamp and the radiator hose, then connect the hose.

After completing the installation of the parts, perform the following operations: