Mitsubishi Endeavor 2004-06

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



Intake manifold
 
Exhaust manifold
 
Timing belt
 
Thermostat housing
 
Alternator
 
Blow-by hose from the left and right rocker arm covers
 
Positive Crankcase Ventilation (PCV) hose from the left and right rocker arm covers
 
Spark plug wires; tag before disconnecting
 
Ignition coil connectors and ignition coils
 
Engine control wiring harness clamp
 
Rocker covers and gaskets
 
Camshaft Position (CMP) sensor connector
 
Grounding
 
Timing belt rear center cover
 

  1. Loosen the left cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the left cylinder head assembly and remove the head gasket.

    Power steering oil pump bracket
     
    Exhaust Gas Recirculation (EGR) pipe B and gasket
     

  2.  
  3. Loosen the right cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the right cylinder head assembly and remove the head gasket.
  4.  


    Click image to see an enlarged view

    Fig. Loosen the cylinder head bolts in the proper sequence-3.8L engine


To install:

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Right cylinder head on the block. Be sure the head bolt washers are installed with the beveled edge upward. Torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501, then loosen the bolts completely and retighten in sequence to 77-83 ft. lbs. (105-113 Nm).
     


    Click image to see an enlarged view

    Fig. The cylinder head bolts must be installed with the beveled side up and tighten in the proper sequence-3.8L engine

    Exhaust Gas Recirculation (EGR) pipe B and gasket
     
    Power steering oil pump bracket
     
    Left cylinder head on the block. Be sure the head bolt washers are installed with the beveled edge upward. Torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501, then loosen the bolts completely and retighten in sequence to 77-83 ft. lbs. (105-113 Nm).
     
    Timing belt rear center cover
     
    Grounding
     
    CMP sensor connector
     
    Rocker covers with new gaskets
     
    Engine control wiring harness clamp
     
    Ignition coils and their connectors
     
    Spark plug wires
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Blow-by hoses
     
    Alternator
     
    Thermostat housing
     
    Timing belt
     
    Exhaust manifold
     
    Intake manifold
     
    Negative battery cable
     

  6.  
  7. Change the engine oil and oil filter.
  8.  
  9. Refill the system with coolant.
  10.  
  11. Run the vehicle until the thermostat opens.
  12.  
  13. Once the vehicle has cooled, recheck the coolant level.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Intake manifold
     
    Exhaust manifold
     
    Timing belt
     
    Thermostat housing
     
    Alternator
     
    Blow-by hose from the left and right rocker arm covers
     
    Positive Crankcase Ventilation (PCV) hose from the left and right rocker arm covers
     
    Spark plug wires; tag before disconnecting
     
    Ignition coil connectors and ignition coils
     
    Engine control wiring harness clamp
     
    Rocker covers and gaskets
     
    Camshaft Position (CMP) sensor connector
     
    Grounding
     
    Timing belt rear center cover
     

  8.  
  9. Loosen the left cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the left cylinder head assembly and remove the head gasket.

    Power steering oil pump bracket
     
    Exhaust Gas Recirculation (EGR) pipe B and gasket
     

  10.  
  11. Loosen the right cylinder head mounting bolts in 3 steps, in the sequence shown. Lift off the right cylinder head assembly and remove the head gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence

  12.  

To install:

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.0012 in. (0.030mm), normally with 0.008 in. (0.203mm) the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. (0.203mm) maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks in the front top (upward) position. Do not use sealer on the gasket.
  4.  
  5. Install or connect the following:

    Right cylinder head on the block. Be sure the head bolt washers are installed with the beveled edge upward. Torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501, then loosen the bolts completely and retighten in sequence to 77-83 ft. lbs. (105-113 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence

     
    Exhaust Gas Recirculation (EGR) pipe B and gasket
     
    Power steering oil pump bracket
     
    Left cylinder head on the block. Be sure the head bolt washers are installed with the beveled edge upward. Torque the head bolts in sequence, to 77-83 ft. lbs. (105-113 Nm) with a torque wrench and Special Tool No. MD998501, then loosen the bolts completely and retighten in sequence to 77-83 ft. lbs. (105-113 Nm).
     
    Timing belt rear center cover
     
    Grounding
     
    CMP sensor connector
     
    Rocker covers with new gaskets
     
    Engine control wiring harness clamp
     
    Ignition coils and their connectors
     
    Spark plug wires
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Blow-by hoses
     
    Alternator
     
    Thermostat housing
     
    Timing belt
     
    Exhaust manifold
     
    Intake manifold
     

  6.  
  7. Connect the negative battery cable. On 2005-2006 vehicles, turn the ignition ON and then OFF , and keep it off for at least ten seconds.
  8.  
  9. Change the engine oil and oil filter.
  10.  
  11. Refill the system with coolant.
  12.  
  13. Run the vehicle until the thermostat opens.
  14.  
  15. Once the vehicle has cooled, recheck the coolant level.
  16.  

 
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