Contents: Removal ⤓ Installation ⤓
Removal
1. Disconnect the cable from the negative terminal of the battery.
2. Remove the protective cover.
3. Drain the coolant from the engine cooling system.
4. Remove the air inlet hose.
Fig. 3.21. Cylinder head covers: 1 – engine cover; 2 – connector for combination of control wiring harness and injector wiring harness; 3 – control wiring harness; 4 – bolt, 5.0 Nm; 5 – camshaft position sensor connector; 6 – Engine coolant temperature gauge connector; 7 – Engine coolant temperature sensor connector; 8 – ignition system malfunction sensor connector; 9 – bolt, 11 Nm; 10 – ignition coil connectors; 11 – Front oxygen concentration sensor connector; 12 – crankshaft position sensor connector; 13 – fuel pressure sensor; 14 – Connector for combination of control harness and exhaust gas recirculation (EGR) harness; 15 – connector of the electromagnetic valve of the adsorber purge; 16 – throttle position sensor connector; 17 – bolt, 7.0 Nm; 18 – Throttle control servo connector; 19 – bolt, 10–12 Nm; 20 – connector bracket (injector wiring harness); 21 – forced crankcase ventilation hose; 22 – bolts, 3–4 Nm; 23 – cylinder head cover (from the exhaust valve side); 24 – cylinder head cover gasket; 25 – cylinder head cover gasket; 26 – Positive Crankcase Ventilation (PCV) Hose; 27 – cylinder head cover (intake valve side)
5. Loosen the bolts and remove cover 1 (Fig. 3.21) of the engine.
6. Disconnect connector 12 of the crankshaft position sensor.
7. Disconnect the connectors of the fuel pressure sensor 13, the front oxygen concentration sensor 11, the control harness and exhaust gas recirculation (EGR) harness combination 14, the canister purge solenoid valve 15, the throttle position sensor 16, the throttle control servo 18, the control harness and injector harness combination 2, the ignition coil 10, the ignition system malfunction sensor 8, the camshaft position sensor 5, the engine coolant temperature sensor 7 and the engine coolant temperature gauge 6.
8. Loosen the bolts and remove the 3 control wire harness.
9. Disconnect the crankcase ventilation (PCV) hose 26.
10. Disconnect the forced crankcase ventilation hose 21.
11. Remove the ignition coil.
12. Remove the intake manifold.
13. Remove the timing belt.
14. Loosen the bolt and remove the bracket 20 of the connector (injector wiring harness).
15. Loosen the bolts and remove the cylinder head cover 27 (from the intake valve side) and the gasket.
16. Loosen the bolts and remove the cylinder head cover 23 (from the exhaust valve side) and the gasket.
17. Using a special device, secure the camshaft pulley from turning, unscrew the bolt and remove the camshaft pulley.
Fig. 3.22. Camshafts and camshaft seals: 1 – rear upper timing belt cover; 2 – camshaft bearing cap; 3 – bolt, 10–12 Nm; 4 – bolts, 21–25 Nm; 5 – bolt, 21–25 Nm; 6 – camshaft bearing cover gasket; 7 – bolt, 22 Nm; 8 – camshaft position sensor cylinder; 9 – exhaust camshaft; 10 – plug; 11 – camshaft position sensor support; 12 – Idle (guide) pulley/roller; 13 – bolt, 35 Nm; 14 – camshaft pulley; 15 – camshaft oil seal; 16 – bolt, 88 Nm; 17 – intake camshaft
18. Loosen the bolt and remove the idler (guide) pulley/roller 12 (Fig. 3.22).
19. Loosen the bolts and remove the rear upper timing belt cover 1.
20. Remove the camshaft oil seal 15.
21. Loosen the bolt and remove support 11 of the camshaft position sensor.
22. Remove plug 10.
23. Remove the high pressure fuel pump assembly.
24. Evenly and gradually unscrew the bolts securing the 2 camshaft cover and remove it.
25. Remove gasket 6 of the camshaft bearing cover.
26. Remove the intake camshaft 17.
27. Remove the 9 exhaust camshaft.
28. Loosen the bolt and remove cylinder 8 of the camshaft position sensor.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Fig. 3.23. Places for applying lubricant (engine oil) and sealant when installing camshafts in the cylinder head: A – bottom view of the camshaft bearing cap and the place where sealant ЗМ ATD Part # 8660 or similar is applied; B – support of the camshaft position sensor and places for applying sealant MITSUBISHI GENUINE PART MD970389 or similar; C – front camshaft oil seal and engine oil lubrication points; D – top view of the cylinder head and the place where the sealant ЗМ ATD Part # 8660 or equivalent is applied
1. Before installation, apply engine oil to all moving parts (Fig. 3.23).
2. Lubricate the camshaft cams and journals with engine oil.
3. Install the camshafts onto the cylinder head.
Fig. 3.24. Location of the hole for the bolt (1) in the camshaft (2) on the exhaust valve side: A – camshaft pulley side
Caution! Be careful not to mix up the intake and exhaust camshafts. There is a hole on the exhaust side of the camshaft for the camshaft position sensor cylinder mounting bolt (Fig. 3.24).
Fig. 3.25. Installing the camshaft pins: A - intake valve side; B – exhaust valve side; 1 – pin
4. Install the camshaft pins as shown in Fig. 3.25.
Fig. 3.26. Sequence of tightening the camshaft bearing cover bolts: A - intake valve side; B – exhaust valve side
5. Tighten the camshaft bearing cover mounting bolts to the specified torques in the sequence shown in Fig. 3.26.
Tightening torques:
- bolts marked with a black dot, 10-12 Nm;
- bolts marked with a white dot, 21–25 N·m.
Fig. 3.27. Using a special tool to press in the plug: 1 – special tool MD998762; A – pressing depth 2 mm
6. Use a special tool to press in the plug (Fig. 3.27).
7. Lubricate the inner circumference of the seal lip with engine oil.
8. Press in the oil seal.
9. To secure the camshaft pulley, use the same special tool as for removal and tighten the mounting bolt.
Fig. 3.28. Sequence of tightening the engine cover mounting bolts
10. Install the engine cover and temporarily tighten the mounting bolts in the sequence shown in Fig. 3.28 so that the cover can be easily moved by hand.
11. Tighten the mounting bolts to a torque of 3.0 N·m in the sequence shown in Fig. 3.28.
12. Blow out the high pressure fuel line.
13. Check for fuel leaks.
14. Install the protective cover.
15. Fill the engine cooling system with coolant.
16. Install the air inlet hose.