Mitsubishi L200. Manual — part 43

CYLINDER HEAD AND VALVES

ENGINE OVERHAUL

11B-46

REMOVAL SERVICE POINTS

<<A>> CYLINDER HEAD BOLTS REMOVAL

AK404126

Using a 14 mm

− 12 points socket wrench, loosen

the cylinder head bolt. Loosen each bolt evenly, little
by little, by two or three steps.

AK500581AB

Punch mark

CAUTION

provide one punch mark on the head of the cylin-
der head bolt each time the bolt is tightened.
replace the bolt that already has five punch
marks (the evidence of having been tightened
five times)

<<B>> VALVE SPRING RETAINER LOCK
REMOVAL

AK404133

AB

MD998772

1. Set special tool Valve spring compressor

(MD998772) as illustrated to compress the valve
spring. Remove the retainer lock.

2. Relieve the spring tension and remove the valve,

retainer, spring, etc. Store removed valves,
springs, and other parts, tagged to indicate their
cylinder no. and location for assembly.

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

CAUTION

Do not reuse removed valve stem seals.

AK404135

AB

MD998775

1. Install the valve spring seat.
2. The special tool Valve stem seal installer

(MD998775) must be used to install the valve
stem seal. Improper installation could result in oil
consumption through valve guide.

>>B<< VALVE SPRING RETAINER LOCK
INSTALLATION

AK404133

AB

MD998772

CAUTION

The valve spring, if excessively compressed,
causes the bottom end of the retainer to be in
contact with, and damage, the stem seal.
Compress the valve spring using the special tool
Valve spring compressor (MD998772), them install
the retainer lock.

>>C<< CYLINDER HEAD GASKET
INSTALLATION

AK801812 AB

Identification tab

Timing belt side

Rank A

Rank B Rank C

CYLINDER HEAD AND VALVES

ENGINE OVERHAUL

11B-47

1. In case any of the cylinder block, piston,

connecting rod and crankshaft has not been
replaced, install the gasket of the same rank as
before which can be identified by the identification
tab shown in the illustration at left.

AK402939

Reference for measurement

Protrusion measuring locations
(with each piston at top dead center)

1

2 3

4 5

6 7

8

AB

2. In case any of the cylinder block, piston,

connecting rod and crankshaft have been
replaced, reselect and install the gasket in
accordance with the following procedure.
(1) With each piston held at the top dead center,

measure its protrusion from the upper block
surface at the locations shown in the
illustration at left (total of eight locations). Be
sure to take measurements on the crankshaft
center line.

AK402940 AB

Protrusion

(2) Using the average of the eight measurements,

select the gasket rank (A, B or C) in
accordance with the table given below. If,
however, the maximum protrusion at any one
location exceeds the protrusion tolerance
shown for any rank in the following table, use
the gasket one rank higher that rank.

<Except Euro5>

Rank

Average value of
piston protrusions
mm

Protrusion tolerance
for each rank mm

Thickness of selected
gasket (when
tightened) mm

Identification tab

A

0.06

− 0.12

0.17

0.95

± 0.04

Non-equipped

B

0.12

− 0.18

0.23

1.00

± 0.04

C

0.18

− 0.24

−

1.05

± 0.04

<Euro5>

Rank

Average value of
piston protrusions
mm

Protrusion tolerance
for each rank mm

Thickness of selected
gasket (when
tightened) mm

Identification tab

A

0.16

− 0.22

0.17

1.07

± 0.04

Equipped

B

0.22

− 0.28

0.23

1.12

± 0.04

C

0.28

− 0.34

−

1.17

± 0.04

NOTE: If the piston projection exceeds the tolerance,
replace the piston, connecting rod, crankshaft or cyl-
inder block and check again.

CYLINDER HEAD AND VALVES

ENGINE OVERHAUL

11B-48

>>D<< CYLINDER HEAD BOLT INSTALLATION

CAUTION

Before installing the cylinder head bolt, check
the number of punch marks on its head. (the bolt
is reusable if it is four or less.) the number of
punch marks corresponds to that to times the
bolt has been tightened to the plastic area. if the
bolt has five punch marks, replace it.
1. Set the cylinder head bolt washer with its shear

droop toward the bolt head.

2. Apply engine oil to the bolt threads and washers.

AK404127

NOTE: Using a 14 mm

−

12 points socket wrench.

AK500584AB

Timing belt side

17

18

3

5

13

15

12

14

16

8

4

2

10

9

1

7

11

6

3. Tighten the bolts to 78

± 2 N⋅m in the indicated

sequence.

4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 29

± 2 N⋅m

in the indicated sequence. After that, confirm all
bolts are reached to the specified torque, and then
go to the next process.

AK500582 AB

Paint mark

90˚

90˚

Paint mark

6. Make paint marks on each bolt’s head and on the

cylinder head.

CAUTION

• When the tightening angle is smaller than the

specified tightening angle, the appropriate
tightening capacity cannot be secured.

• When the tightening angle is larger than the

specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure.

7. Turn the bolts 90

° in the tightening direction and in

the indicated sequence.

8. Give another 90

° turn in the tightening direction to

each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.

INSPECTION

M1113007002987

CYLINDER HEAD

AK404142

Check the cylinder head gasket surface for flatness
by using a straightedge in the directions of illustra-
tion.

Standard value: 0.03 mm
Limit: 0.2 mm

VALVE

AK300593AB

Margin

Contact
(Should be at
centre of face)

1. Check the valve face for correct contact. If

incorrect, reface using valve refacer. Valve seat
contact should be maintained uniform at the
center of valve face.

CYLINDER HEAD AND VALVES

ENGINE OVERHAUL

11B-49

2. If the margin is smaller than the service limit,

replace the valve.

Standard value:

Intake: 1.3 mm
Exhaust: 1.5 mm

Limit:

Intake: 0.8 mm
Exhaust: 1.0 mm

AK304590AB

Total length

3. Measure the valves total length. If the

measurement is less than the limit, replace the
valve.

Standard value:

Intake: 107.58 mm
Exhaust: 107.98 mm

Limit:

Intake: 107.08 mm
Exhaust: 107.48 mm

VALVE SPRING

AK300594

Out of square

Free height

AB

1. Measure the free height of spring and if it is

smaller than the limit, replace.

Standard value: 54.3 mm
Limit: 53.3 mm

2. Measure the squareness of the spring and, if the

limit is exceeded, replace.

Standard value: 2

° or less

Limit: Max. 4

°

VALVE GUIDE

AK300168

Guide inside diameter

Stem diameter

Valve
guide

AE

Measure the clearance between the valve guide and
valve stem. If the limit is exceeded, replace the valve
guide or valve, or both.

Standard value:

Intake: 0.020

− 0.047 mm

Exhaust: 0.035

− 0.062 mm

Limit:

Intake: 0.10 mm
Exhaust: 0.15 mm

VALVE SEAT

AK600918AB

Contact width

Valve seat

Assemble the valve, then measure the contact width.
If the measurement exceeds the specified limit,
replace the valve seat.

Standard value: 1.1

− 1.5 mm

VALVE SEAT RECONDITIONING PROCEDURE

AK500585AB

1.1

-

1.5 mm

30˚

75˚

43.5˚

-

44˚