REMOVAL AND INSTALLATION



Removal steps


1.
 Cable retainer


2.
 Rocker arm shaft

>>G<<
 3.
 Seal

>>F<<
 4.
 Bearing frame

>>E<<
 5.
 Bearing shell


6.
 Exhaust camshaft


7.
 Inlet camshaft

>>D<<
 8.
 Sealing plug
<<A>>
 >>D<<
 9.
 Shaft
<<B>>
 >>C<<
 10.
 Shaft


11.
 O-ring


12.
 Exhaust roller rocker fingers


13.
 Inlet roller rocker fingers


14.
 Cotters


15.
 Valve spring plate


16.
 Valve spring


17.
 Inlet valve


18.
 Exhaust valve
<<C>>
 >>B<<
 19.
 Valve stem seal


20.
 Valve guide


21.
 Cylinder head bolt
<<D>>
 >>A<<
 22.
 Washer
<<D>>
 >>A<<
 23.
 Cylinder head

REMOVAL SERVICE POINT

<<A>> SHAFT REMOVAL
1.Remove plug and securing bolt for shaft.

2.Screw special tool Bearing puller (MB995204) into shaft.
3.Pull out shaft by sliding hammer.

<<B>> SHAFT REMOVAL

1.Screw special tool Bearing puller (MB995204) into shaft.
2.Pull out shaft by sliding hammer.

<<C>> VALVE STEM SEAL REMOVAL
1.Remove unit injectors.
2.Set piston of respective cylinder to top dead centre (TDC).
3.Bolt special tool Valve lever support (MB995213) tightly onto cylinder head.

4.Remove valve springs using special tool Valve lever (MB995210) and Attachment (MB995211).
note The valves are supported by the piston crown.
5.Pull out valve stem seals.

<<D>> CYLINDER HEAD REMOVAL

1.Maintain sequence when loosening cylinder head bolts.
2.Lift cylinder head slightly and remove from engine laterally past toothed belt guard.
note
  • Toothed belt tensioning roller remains on engine bracket.
  • The cylinder head must be guided carefully to prevent damage.

INSTALLATION SERVICE POINT

>>A<< CYLINDER HEAD INSTALLATION
note
  • Always renew cylinder head bolts.
  • In cases of repair carefully remove gasket remains from cylinder head and cylinder block. Ensure that no long scores or scratches are created. When using abrasive paper do not use a grade less than 100.
  • Carefully remove emery and abrasive remains.
  • Remove new cylinder head gasket from packaging, just before installation.
  • Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
1.Before fitting cylinder head, remove special tool Crankshaft stopper (MB995209) and turn crankshaft opposite direction of rotation until all pistons are nearly uniformly below TDC.
2.Cylinder head gasket must lie with identification facing upwards.
3.Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.

Tighten cylinder head in four stages in sequence shown as follows:

  1. Tighten initially with torque wrench:
    Stage 1 = 35 N·m
    Stage 2 = 60 N·m
  2. Turn further with rigid spanner:
    Stage 3 = 1/4 turn (90°)
    Stage 4 = 1/4 turn (90°)

>>B<< VALVE STEAM SEAL INSTALLATION

1.Place the plastic sleeve supplied on the respective valve stem. This will prevent the new valve stem seal being damaged.
2.Place new valve stem seal in special tool Valve steam seal installer (MB995212).
3.Oil valve stem seal sealing lip and press carefully onto valve guide to stop.

>>C<< SHAFT INSTALLATION
note Do not interchange used roller rocker fingers.
1.Push shaft into cylinder head, pushing on roller rocker fingers in the process.
2.Shaft must be flush with cylinder head.

>>D<< SHAFT INATALLATION
note Do not interchange used roller rocker fingers.
1.Push shaft into cylinder head, pushing on roller rocker fingers in the process.

2.Install shaft using special tool Bearing puller (MB995204).
3.Tighten shaft securing bolt to the specified torque of 10 N·m.
4.Renew plug and tighten new plug to the specified torque of 10 N·m.

>>E<< BEARING SHELL INSTALLATION
Install bearing shell.
note Ensure proper seating of retaining lugs in bearing caps and cylinder head.

>>F<< BEARING FRAME INSTALLATION
Apply sealant to surface between bearing frame and cylinder head, and then install bearing frame to cylinder head.
Specified sealant: Mitsubishi Genuine Part No.MN980026

>>G<< BEARING FRAME INSTALLATION
Install seal using special tool Oil seal installer (MB995223).