REMOVAL AND INSTALLATION

Pre-removal Operation

Post-installation Operation

Battery and Battery Tray Removal (Refer to

Water Pump Installation <4M4> (Refer to

GROUP 54A - Battery

).
Under Skid Plate and Engine Room Under
Cover (Front) Removal (Refer to GROUP 51 -

GROUP 14 - Water Pump

)
Camshaft Position Sensor and Crank Angle
Sensor Installation (Refer to GROUP 13D Camshaft Position Sensor and Crank Angle

Under Cover
).
Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service, Engine Coolant
Replacement ).
Engine Oil Draining <4M4> (Refer to GROUP
12 - On-vehicle Service, Engine Oil
Replacement

).

Sensor

Engine Oil Pan Installation (Refer to

).
Cylinder Head and Cylinder Head Gasket
Installation (Refer to
).
Camshaft Assembly and Rocker Arm Installation
(Refer to

Engine Cover Removal (Refer to

).
Air Cleaner Assembly and Air Intake Duct
Removal <4M4> (Refer to GROUP 15 - Air
Cleaner
).
Radiator Shroud Cover (Upper) Removal
(Refer to GROUP 14 - Radiator
).
Cooling Fan and Cooling Fan Clutch Assembly
Removal <4M4> (Refer to GROUP 14 - Cooling
Fan
).
A/C Compressor Drive Belt, Alternator Drive
Belt and Crankshaft Pulley Removal (Refer to
).
EGR Cooler Assembly and EGR Cooler
Bracket Removal (Refer to GROUP 17 Emission Control, EGR Valve and EGR Cooler
).
Turbocharger Assembly and Exhaust Manifold
Removal (Refer to GROUP 15 - Exhaust

).

).

Vacuum Pump Installation (Refer to

).
Fuel Injector Assembly and Common Rail
Assembly Installation (Refer to GROUP 13D Fuel Injector and Common Rail ).
Air Inlet Pipe and Inlet Manifold Assembly
Installation <4M41> (Refer to GROUP 15 - Inlet
Manifold ).
Throttle Body Assembly Installation (Refer to
GROUP 13D - Throttle Body Assembly
).
Vacuum Pipe Assembly, By-pass Pipe, Heater
Return Pipe and Thermostat Case Installation
<4M4> (Refer to GROUP 14 - Water Hose and
Water Pipe
).
Thermostat Installation <4M4> (Refer to GROUP
14 - Thermostat
).
Turbocharger Assembly and Exhaust Manifold
Installation (Refer to GROUP 15 - Exhaust

Manifold and Turbocharger Assembly

).
Thermostat Removal <4M4> (Refer to GROUP

Manifold and Turbocharger Assembly

).
EGR Cooler Assembly and EGR Cooler Bracket
Installation (Refer to GROUP 17 - Emission

14 - Thermostat
).
Vacuum Pipe Assembly, By-pass Pipe, Heater
Return Pipe and Thermostat Case Removal
<4M4> (Refer to GROUP 14 - Water Hose and

Control, EGR Valve and EGR Cooler

).
A/C Compressor Drive Belt, Alternator Drive
Belt and Crankshaft Pulley Installation (Refer to

Water Pipe
).
Throttle Body Assembly Removal (Refer to

).
Cooling Fan and Cooling Fan Clutch Assembly
Installation <4M4> (Refer to GROUP 14 -

GROUP 13D - Throttle Body Assembly

).
Air Inlet Pipe and Inlet Manifold Assembly
Removal <4M41> (Refer to GROUP 15 - Inlet

Cooling Fan
).
Radiator Shroud Cover (Upper) Installation

Manifold ).
Fuel Injector Assembly and Common Rail
Assembly Removal (Refer to GROUP 13D Fuel Injector and Common Rail

).

Vacuum Pump Removal (Refer to

).
Camshaft Assembly and Rocker Arm Removal
(Refer to
).
Cylinder Head and Cylinder Head Gasket
Removal (Refer to

).

(Refer to GROUP 14 - Radiator

).
Air Cleaner Assembly and Air Intake Duct
Installation <4M4> (Refer to GROUP 15 - Air
Cleaner

).

Engine Cover Installation (Refer to

).
Engine Oil Refilling <4M4> (Refer to GROUP 12
- On-vehicle Service, Engine Oil Replacement
).
Engine Coolant Refilling (Refer to GROUP 14,
On-vehicle Service - Engine Coolant

Engine Oil Pan Removal (Refer to

).
Camshaft Position Sensor and Crank Angle
Sensor Removal (Refer to GROUP 13D Camshaft Position Sensor and Crank Angle
Sensor
).
Water Pump Removal <4M4> (Refer to
GROUP 14 - Water Pump

Replacement ).
Drive Belt Tension Check and Adjustment
(Refer to
).
Battery and Battery Tray Installation (Refer to
GROUP 54A - Battery
).
Fuel line Air-bleeding (Refer to GROUP 13D On-vehicle Service, Evacuation of Air From
Fuel Line
).
Under Skid Plate and Engine Room Under
Cover (Front) Installation (Refer to GROUP 51 Under Cover

).

Removal
steps
<<A>>

Power
steering oil
pump
assembly

1. Harness
bracket
2. Harness
clamp
>>C<<

3. Timing
gear case
assembly
4. Timing
gear case
stiffener
5. Crankshaft
sensing
blade

<<B>>

>>B<<

6. Chain
bracket

>>B<<

7. Idler A
washer

>>A<<

8. Oil jet
assembly

>>A<<

9. Spring pin

>>A<<

10. Idler
washer

>>A<<

11. Camshaft
sprocket

>>A<<

12. Timing
chain
13. Tension
lever
assembly
14. Tension
lever shaft
15. Guide
plate
16. Guide
lower plate

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP

ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump
assembly from the engine assembly. (Refer to GROUP 37 Power Steering Oil Pump Assembly
).
2.After removing the power steering oil pump assembly,
secure it with a cord in the location where the removal and
installation of the engine assembly cannot be hindered.

<<B>> TIMING CHAIN REMOVAL

Remove special tool camshaft sprocket holder kit (MH063490)
that is installed when removing the cylinder head assembly and
cylinder head gasket. Then, remove the timing chain.

INSTALLATION SERVICE POINTS

>>A<< TIMING CHAIN/CAMSHAFT

SPROCKET/IDLER WASHER/SPRING
PIN/OIL JET ASSEMBLY
INSTALLATION
1.Using special tool camshaft sprocket holder kit (MH063490),
support the camshaft sprocket.
A: Nut
B: Washer
C: Spacer
D: Adjust plate
E: Bolt
F: Bolt
G: Nut
2.Check that the mating mark 1 on the idler gear and
sprocket assembly is in alignment with that on the crankshaft
gear.

3.
Note that the timing chain has one mark
plate for the idler gear and sprocket
caution
assembly side, and two mark plates for
each camshaft sprocket.
Align the mating mark on the idler gear and sprocket
assembly with the yellow mark ring plate on the timing chain.
4.Align the mark ring plates with the camshaft sprocket mating
marks.

5.Tie up the timing chain and the camshaft sprocket with a

cord to prevent the mating mark misalignment.

6.Install the idler washer, the spring pin and the oil jet. The
idler washer front mark "F" must face toward the front of the
engine.

>>B<< IDLER A WASHER/CHAIN

BRACKET INSTALLATION
Install the idler A washer and the chain bracket. The idler A
washer front mark "F" must face toward the front of the
engine.

>>C<< TIMING GEAR CASE ASSEMBLY

INSTALLATION
1.Clean the timing gear case and the plate mating surfaces
with a scraper or a wire brush.
2.

caution

After applying the sealant, install the

timing gear case within 15 minutes.
When installing the timing gear
case, be careful not to disturb the
sealant.
Whenever the timing gear case
mounting bolts are loosened or
tightened again after the timing gear
case installation, always apply the
sealant again.
After the timing gear case is
installed, wait for at least one hour,
and then start the engine.

Apply a continuous bead of the specified sealant to the timing

gear case mating surface as shown.
Specified sealant: MITSUBISHI GENUINE PART MD970389
or equivalent
3.Install the mounting nuts and bolts to the timing gear case at
the shown positions.
Name Symbol Size (Nominal
diameter
length mm)

Flange A
bole B

8 75

8 90

8 55

8 60

10 60

Cap
nut

8 85