Page 129 of 2103
ENGINE OVERHAUL
FUEL AND CONTROL PARTS
REMOVAL AND INSTALLATION
9 Nm7
Removal steps
1. Air fitting
2. Air fitting gasket
3. Throttle body
4. Throttle body gasket
5. EGR valve
6. EGR valve gasket
7. Injectors and fuel rail
12Nm9
19 Nm14
8.Insulator9. Fuel pressure
10.O-ring11.Insulator
Grommet15.Fuel rail
T S B R e v i s i o n
Page 130 of 2103
ENGINE OVERHAUL Fuel and
INJECTOR
(1) Before installing an injector the rubber O-ring must be
lubricated with a drop of clean engine oil to aid i n
installation.
(2) Install injector top end into fuel rail.
Be careful not to damage the O-ring during installa tion.
FUEL PRESSURE REGULATOR INSTALLATION
(1) Before installing’ regulator the O-ring must be
lubricated with a drop of
engine O-ring to aid in
installation.
TSB Revision
Page 131 of 2103
ENGINE OVERHAUL Intake Manifold
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
2
(To oil cooler)
13 Nm
9
11 N m 8
20 Nm
14
31 N m
22
Removal steps
1.Water hose2. Water hose
3. Engine coolant temperature gaugeunit
4. Engine coolant temperature sensor5.Water inlet fitting6.Thermostat case
7. Water outlet fitting 8. Thermostat housing
9. Intake manifold stay
10. Engine hanger11.Intake manifold12.Gasket
TSB Revision
Page 132 of 2103
11ENGINE OVERHAUL
in.)diameterbead
diameter
bead sealant
SEALANT APPLICATION TO THERMOSTAT
HOUSING
Specified sealant:
Mitsubishi Genuine Part No. or equiva-
lent
NOTE
(1) Be sure to install the housing quickly while th e
sealant is wet (within 15 minutes).
(2) After installation, keep the sealed area away f rom
the oil and coolant for hour.
SEALANT APPLICATION TO WATER OUTLET
Specified sealant:
Mitsubishi Genuine Part No. or equiva-
lent
NOTE
(1) Be sure to install the housing quickly while the
is wet (within 15 minutes).
(2) After installation, keep the sealed area away f rom
the oil and coolant for approx. 1 hour.
SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
Specified sealant:
Nut Locking ‘Part No. 4171 or equivalent
SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
Specified sealant: ATD Part No. 8660 or equivalent
TSB Revision
Page 133 of 2103
ENGINE OVERHAUL Exhaust Manifold
EXHAUST MANIFOLD AND WATER PUMP
REMOVAL AND INSTALLATION
11300490108
. .
10
Nm
120
2I
27
14 29
21
14 Nmin
Nm
I 7
I - Nm
13 Nm
‘ - 2 3
Nm
10
Nm32
Removal steps
1.Oil dipstick17.Water pipe 2.Oil dipstick guide18.Turbocharger3.O-ring19.Engine hanger4.Heat protector “A”20.Exhaust manifold5.Heat protector 21.Gasket6.Heated oxygen sensor22.Water hose7.Exhaust fitting23.Water pipe 8.Gasket24.Water pipe9.Oil pipe “A”25. Water hose10.Oil pipe 26.Water hose11.Oil return pipe27. Water hose12.Gasket28.Water hose13.Turbocharger assembly29. O-ring14.Gasket30.Water inlet pipe15.Ring31.Water pump16.Water pipe “A”32.Gasket
TSB Revision
Page 134 of 2103
ENGINE OVERHAUL Exhaust Manifold and
O-ring
Identificationhole
Exhaust
manifold
INSTALLATION SERVICE
WATER PIPE/O-RING
Wet the O-ring (with water) to facilitate assembly .
C a u t i o n
Keep the O-ring free of oil or grease.
TURBOCHARGER
(1) the cone disc spring in shown direction.
(2) Tighten the turbocharger mounting bolts and
to
27
31 Nm 22
(3) Use the special tool orsimilar tighten more.
TSB Revision
Page 135 of 2103
ENGINE OVERHAUL Rocker Arms and
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
2014
8,I!
Removal steps
1. Bearing cap rear 2. Bearing cap front 3. Camshaft oil seal4. BearingcapNo. 55.Bearingcap No. 26.BearingcapNo.4
7. cap No. 3 8. Camshaft9. Rocker arm 10. Lash adjuster
11. Oil delivery body
.
TSB Revision
Page 136 of 2103

ENGINE OVERHAUL Rocker, Arms
Camshaft sprocket side
sidecamshaft
Dowel pin
n0
Cap number
Symbol identifying
intake or exhaust
0
Camshaft sprocket side1197 810 12
2 6
I N S T A L L A T I O N S E R V I C E
L A S H A D J U S T E R
(1) the lash adjuster in clean diesel fuel.
(2) Using a special tool, move the plunger up and down
4 or 5 times while pushing down lightly on the chec k
ball in order to bleed out the air.
,
CAMSHAFT INSTALLATION
(1) Apply engine oil to journals and cams of the
(2) Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with th e
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
(3) Install the crankshaft sprocket
or spacer and flange
to an end of the crankshaft, and turn the until
the timing marks are lined up, setting No. cylinder to
the TDC.
(4)Place the camshafts so that their dowel pins are po sitioned
at top.
BEARING CAPS INSTALLATION
(1) According to the identification mark stamped on top of
each bearing cap,
the caps to the cylinder head.
Only
or is stamped on No. 1 bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing
No.
6 bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(2) Tighten the bearing caps in the order shown two . to three
times by torquing progressively.
Tighten to specification in the final sequence.
(3) Check to ensure that the rocker arm is held in position
on the lash adjuster and valve. stem end.
.
Revision