Mitsubishi L200. Manual — part 40

ROCKER COVER AND INJECTOR

ENGINE OVERHAUL

11B-34

ROCKER COVER AND INJECTOR

REMOVAL AND INSTALLATION

M1113028500282

AK801108AB

10 ± 1 N·m

+120˚ to 125˚

3.0 ± 1.0 N·m

10 ± 2 N·m

15 ± 2 N·m

15 ± 2 N·m

1

2

7

8

3

9

4

6

5

11

15

12

16

17

19

20

88 ± 10 N·m

10 ± 2 N·m

10

13

14

14

13

18

Removal steps

1.

Breather hose

2.

Oil filler cap

>>

F

<< 3.

Rocker cover

4.

Gasket "A"

5.

Gasket "B"

6.

Gasket "C"

>>

E

<< 7.

Oil seal

>>

D

<< 8.

Oil seal

>>

C

<< 9.

Semi-circular packing

>>

B

<< 10. Injector holder bolt

>>

B

<< 11. Injector holder

>>

B

<< 12. Fuel leakage pipe

>>

B

<< 13. Eye bolt

>>

B

<< 14. Fuel leak-off gasket

15. Pivot boss
16. Injector
17. Nozzle gasket

>>

A

<< 18. Camshaft sprocket bolt

<<

A

>> >>

A

<< 19. Camshaft sprocket

20. Timing belt rear cover

Removal steps (Continued)

ROCKER COVER AND INJECTOR

ENGINE OVERHAUL

11B-35

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

AK500708

Remove the camshaft sprocket holding the hexago-
nal area of the camshaft with a wrench.

INSTALLATION SERVICE POINTS

>>A<< CAMSHAFT SPROCKET INSTALLATION

AK500708

Tighten the camshaft sprocket to the specified torque
of 88

± 10 N⋅m holding the hexagonal area of the

camshaft with a wrench.

>>B<< INJECTOR / PIVOT BOSS / FUEL LEAK-
OFF GASKET / EYE BOLT / FUEL LEAKAGE PIPE
/ INJECTOR HOLDER / INJECTOR HOLDER BOLT
INSTALLATION
1. Clean the fuel injector assembly (nozzle) and the

cylinder head (fuel injector insertion hole) by
following the procedure below.

CAUTION

Do not clean the injection part of the nozzle with
a resin spatula.

AC900270 AB

Fuel injector

A: Nozzle side face

Injection part of the nozzle

(1) Using a resin spatula, scrape off the carbon

deposit on the fuel injector nozzle side face
("A" shown in the figure).

AC900203

Fuel injector

AB

(2) Spray the carburetor cleaner (MZ100139) or

equivalent to the nozzle side face ("A" shown
in the figure).

CAUTION

Do not touch the injection part of the nozzle with
hand or wipe it with a rag.

(3) Leave the injection part for a while until the

carbon deposit melts down, and then blow air
to the injection part.

AC900204

MB990784

Cylinder head

AB

(4) Insert the special tool ornament remover

(MB990784) to the cylinder head (fuel injector
insertion hole) with turning the special tool as
shown, and scrape off the carbon deposit.

ROCKER COVER AND INJECTOR

ENGINE OVERHAUL

11B-36

CAUTION

In order to prevent carbon from adhering to the
inner surface of the cylinder, blow air with the
piston in the TDC position.

(5) Remove the special tool MB990784, and blow

off the carbon deposit on the cylinder head
(fuel injector insertion hole) by air.

(6) Check that there is no carbon deposit

remaining on the contact surface of the fuel
injector nozzle gasket.

NOTE: Repeat step 4 to step 6 several times
until the carbon deposit is completely removed.

AC502872 AB

Injector holder bolt

Injector supporter

Pivot boss

Fuel injector

Nozzle
gasket

2. Install the nozzle gasket, fuel injector, pivot boss,

and injector supporter to the cylinder head as
shown in the figure.

3. Apply a small amount of engine oil to the seat

surface and thread of injector holder bolt, and
then temporarily tighten the bolt to the cylinder
head.

4. Set the fuel leak-off gasket to the fuel leakage

pipe, and temporarily tighten to the fuel injector
and to the cylinder head using the eye bolt.

5. Tighten the eye bolt of the fuel injector side to the

specified torque.

Tightening torque: 15

± 2 N⋅m

6. Tighten the eye bolt of the cylinder head side to

the specified torque.

Tightening torque: 15

± 2 N⋅m

7. Tighten the injector holder bolt to the specified

torque.

Tightening torque: 10

± 1 N⋅m

CAUTION

• When the tightening angle is smaller than the

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

•

AK500711

MB991614

AB

When the tightening angle is larger than the
specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure.

8. Using the special tool Angle gauge (MB991614),

tighten the injector holder bolt in the illustrated
sequence by a further 120 to 125

°.

>>C<< SEMI-CIRCULAR PACKING
INSTALLATION

AK202860AB

Apply specified sealant to portions indicated in illus-
tration.

Specified sealant:
Three bond 1217G or equivalent

>>D<< OIL SEAL INSTALLATION

AK500713AB

Oil seal

Socket wrench

Rocker cover

ROCKER COVER AND INJECTOR

ENGINE OVERHAUL

11B-37

Using a proper socket wrench, the oil seal is pressed
and fit into the rocker cover.

>>E<< OIL SEAL INSTALLATION

AK500712AB

Oil seal

Socket wrench

Rocker cover

Using a proper socket wrench, the oil seal is pressed
and fit into the rocker cover.

>>F<< ROCKER COVER INSTALLATION

AK304411AB

10 mm

10 mm

Semicircular
packing

Cylinder head

AK800029AB

10 mm

10 mm

10 mm

Rocker cover

Gasket "A"

1. Apply specified sealant to portions indicated in

illustration.

Specified sealant:
Three bond 1217G or equivalent

AK603148AB

Rocker cover

Oil seal lip

Injector

Connector

AK603149AB

CAUTION

Pay attention that the connector does not dam-
age the seal lip when inserting the rocker cover.
2. Slightly press the oil seal lip to the place in the

opposite direction of the connector, shown in the
illustration.

3. Leave enough clearance for the connector to

avoid touching the seal lip.

AK603150AB

4. Slowly get the seal lip through not making contact

with the connector.

5. Put the rocker cover down to the installation

location.