Mitsubishi L200. Manual — part 38

AK500735

Key top end

Notched area

Slide

True position

Crankshaft

Crankshaft
sprocket

Crankshaft
sprocket "B"

Oil pump

AB

TIMING BELT

ENGINE OVERHAUL

11B-26

NOTE: When the timing belt is installed into the
crankshaft sprocket, install the timing belt after
sliding the crankshaft sprocket to around the key
end. (Pay attention to the notch on the crankshaft
sprocket not to be damaged at the timing belt
installation.) And then, install the crankshaft
sprocket in position.

3. Confirm the timing marks on each sprocket are in

position.

CAUTION

Check that the glow plugs, glow plug mounting
threads and plug seating surfaces of cylinder
head are dry.
4. When installing the glow plug, screw in one thread

or more with fingers and then tighten with a tool.

5. Tighten the glow plugs to 9.0

± 1.0 N⋅m.

AK501273AC

30 to 40˚

MB991614

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

tighten the glow plug to a further 30

° to 40°.

7. Install a glow plug plate to the glow plug, and then

tighten them to the specified torque of 1.8

± 0.2

N

⋅m.

8. Pull out the set pin of an auto tensioner.
9. Turn the crankshaft twice in a clockwise direction

and measure the protrusion height of the auto
tensioner.

Standard value: 2.3

− 7.6 mm

10.Confirm the timing marks on each sprocket are in

position.

>>K<< COVER INSTALLATION

AK500654AB

1. Clean both mating surfaces of cover and cylinder

block.

2. Apply a 2.3

± 1.0 mm wide bead of sealant to the

cylinder block.

Specified sealant:
Three bond 1217G or equivalent

AK500657AB

3. Coat the bolt with sealant, then install and tighten

it.

Specified sealant:
Three bond 2310 or equivalent

INSPECTION

M1113002001428

TIMING BELTS
The timing belts must be checked closely. Should the
following defects be evident, replace the belt with a
new one.

AK202794

1. Hardened back surface rubber.

TIMING BELT

ENGINE OVERHAUL

11B-27

Glossy, non-elastic, and so hard that no mark is
produced even when scratched by fingernails.

AK202793

Cracks

Peeling of canvas

Cracks in tooth roots

Cracks

AB

Cracks in sides

2. Cracked back surface rubber.
3. Cracked or separated canvas.
4. Cracked tooth bottom.
5. Cracked side.

AK202795

Rounded edge

Abnormal wear
(Fluffy strand)

AB

6. Abnormal wear on side.

NOTE: Normal belt should have clear-cut sides as
if cut by a sharp knife.

AK202796

Missing
Tooth

Canvas lost and
rubber exposed

AB

7. Abnormal wear in teeth.
Initial stage:

Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white, and
unclear canvas texture)
Last stage:
Canvas on load side tooth flank worn down and rub-
ber exposed (tooth width reduced)
8. Missing tooth.

AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the

sealed sections.
Replace it if leaky.

2. Check the rod end for wear and other damage.

Replace the auto-tensioner if the rod is badly
worn or damaged.

AK500737AB

14.5 mm

3. Measure the extension length of the rod.

If it is not within the standard value range, replace
the auto-tensioner.

Standard value: 14.5 mm

4. Measure the amount of the retraction when the

rod is pressed with the force of 100

− 200 N. If it

deviates from the standard value, replace the auto
tensioner.

Standard value: within 1.0 mm

AIR BLEEDING PROCEDURE OF AUTO-
TENSIONER
When the auto tensioner is not kept with its rod
upward, or when the set pin having

φ2 mm is pulled

out before the installation to the engine, carry out the
air bleeding as follows.

TIMING BELT

ENGINE OVERHAUL

11B-28

CAUTION

• If the lateral type press is used, the appropri-

ate air bleeding is not carried out. Always use
longitudinal type press.

• To prevent damage to the auto tensioner, do

not apply the load of 5,000 N or more.

•

AK801061AB

100

–

200 N

5 mm

To prevent damage to the auto tensioner, do
not push down the rod from the cylinder end
plane by 0.5 mm or less.

1. Set the auto tensioner to the longitudinal type

press as shown in the illustration.

2. Slowly press down the rod, two or three times, to

the cylinder end plane.

3. When the rod protrusion has approximately 5 mm,

apply the load of 100

− 200 N. Check whether the

auto tensioner has sufficient stiffness.

4. If the auto tensioner does not have sufficient

stiffness, replace the auto tensioner.

5. Slowly pressing down the rod, insert the set pin

having

φ2mm through the hole to fix the auto

tensioner.

CAUTION

To prevent the air from being incorporated, keep
the auto tensioner with its rod upward after the
air bleeding. Do not keep the auto tensioner with
60

° or more tilt.

COMMON RAIL AND SUPPLY PUMP

ENGINE OVERHAUL

11B-29

COMMON RAIL AND SUPPLY PUMP

REMOVAL AND INSTALLATION

M1113029200239

<Except Euro5>

AKB00337

10

11

12

13

7

14

15

1

17 ± 2 N·m

10 ± 2 N·m

24 ± 4 N·m

35 ± 5 N·m

35 ± 5 N·m

AB

24 ± 4 N·m

6

8

2

16

20 ± 2 N·m

10 ± 2 N·m

5

8.9 ± 1.9 N·m

18

9

4

24 ± 3 N·m

3

24 ± 3 N·m

10 ± 2 N·m

17

Removal steps

1.

Fuel return hose

2.

Fuel inlet hose

>>

B

<< 3.

EGR cooler bracket

4.

EGR cooler

>>

B

<< 5.

Suction control valve kit *1

>>

B

<< 6.

Supply pump

7.

Fuel supply pump pipe bracket

>>

B

<< 8.

Fuel supply pump pipe

>>

A

<< 9.

Fuel injection No.1 pipe

>>

A

<< 10. Fuel injection No.2 pipe

>>

A

<< 11. Fuel injection No.3 pipe

>>

A

<< 12. Fuel injection No.4 pipe

>>

A

<< 13. Common rail

>>

A

<< 14. Eye bolt (Cylinder head side)

>>

A

<< 15. Fuel return gasket

>>

A

<< 16. Eye bolt (Common rail side)

>>

A

<< 17. Fuel return gasket

>>

A

<< 18. Fuel return pipe

Removal steps (Continued)