Mitsubishi L200. Manual - part 43

 

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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˚

 

 

 

 

 

 

 

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