Mitsubishi Outlander 2003-06

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner with all air intake hoses.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Accelerator cable
     

  12.  
  13. Disconnect the following connectors necessary for control wire harness connection removal:

    Air conditioning compressor
     
    Power steering pressure switch
     
    Heated Oxygen (HO2S) sensor
     
    Engine Coolant Temperature (ECT) gauge sender
     
    ECT sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Injector harness
     
    Ignition coil
     
    Camshaft Position(CMP) sensor
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     

  14.  
  15. Remove or disconnect the following:

    Battery wiring harness connection
     
    Radiator lower hose clamp
     
    Evaporative emission vacuum hose connection
     
    Brake booster vacuum hose connection
     
    Engine oil dipstick and dipstick guide
     
    O-ring
     
    Knock sensor connector
     
    Battery wiring harness connection
     
    Inlet manifold stay
     
    Exhaust manifold
     
    Spark plug wires
     
    Coolant hoses and unbolt the thermostat case from the engine, at the thermostat case assembly
     
    Upper timing belt cover
     

  16.  
  17. Align all timing marks.
  18.  
  19. Secure the timing belt to the camshaft sprocket with cord or a wire tie.
  20.  
  21. Remove or disconnect the following:

    Camshaft sprocket
     
    Valve cover and the half-round seal
     
    Intake manifold stay bracket from the intake manifold
     
    High pressure fuel line connection
     
    Valve cover
     

  22.  
  23. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  24.  


    Click image to see an enlarged view

    Fig. Secure the timing belt to the camshaft sprocket and remove the sprocket-2.4L (4G69) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.4L (4G69) engine


To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position on the exhaust side. Do not use sealer on the gasket.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Install the washer onto the bolt so the chamfer on the washer faces towards the head of the bolt.
  6.  
  7. Carefully install the cylinder head on the block and tighten the cylinder head bolts as follows:
    1. Following the proper tightening sequence, tighten the cylinder head bolts to 58 ft. lbs. (78 Nm).
    2.  
    3. Loosen all bolts completely.
    4.  
    5. Torque bolts to 15 ft. lbs. (20 Nm).
    6.  
    7. Tighten bolts an additional14
    8.  
    9. Tighten bolts an additional14
    10.  

  8.  
  9. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
  10.  
  11. Install or connect the following:

    High pressure fuel line
     
    Thermostat case and tighten the mounting bolts to 18 ft. lbs. (24 Nm)
     
    Water and upper radiator hoses to the thermostat case
     
    Camshaft sprocket with the timing belt attached. Remove the cord or wire tie.
     
    Upper timing belt cover
     
    Exhaust manifold
     
    Intake manifold stay and tighten the mounting bolts to 22 ft. lbs. (30 Nm)
     
    Battery wiring harness connector
     
    Knock Sensor connector
     

  12.  
  13. Install or connect the following:

    Spark plug wires and cover
     
    Fuel lines using new O-rings
     
    Engine oil dipstick and guide, using new O-rings
     
    Brake booster vacuum hose
     
    Evaporative emission vacuum hose
     
    Radiator lower hose clamp
     
    Battery wiring harness connector
     

  14.  
  15. Connect the following connectors for the control wiring harness, as necessary:

    Air conditioning compressor
     
    Power steering pressure switch
     
    HO2S sensor
     
    ECT gauge sender
     
    ECT sensor
     
    MAP sensor
     
    IAT sensor
     
    TP sensor
     
    IAC motor
     
    Injector harness
     
    Ignition coil
     
    CMP sensor
     
    EGR solenoid valve
     
    Air cleaner and intake hose
     
    Breather hose
     

  16.  
  17. Install or connect the following:

    Accelerator cable
     
    Air cleaner assembly
     

  18.  
  19. Fill the cooling system.
  20.  
  21. Connect the negative battery cable
  22.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt installation sequence-2.4L (4G69) engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the air cleaner assembly. Disconnect the accelerator cable.
  6.  
  7. Disconnect the control wiring harness. Disconnect the battery wiring harness connector.
  8.  
  9. Remove the radiator hose lower clamp.
  10.  
  11. Disconnect the EVAP hose connection. Disconnect the brake booster vacuum hose, pressure hose clamp and knock sensor connector.
  12.  
  13. Remove the engine oil dipstick and dipstick guide. Remove the knock sensor connector connection. Remove the battery wiring harness connection. Remove the intake manifold stay.
  14.  
  15. Remove the exhaust manifold. Remove the timing belt upper cover.
  16.  
  17. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to position number one piston to TDC of its compression stroke. Never rotate the crankshaft in the counterclockwise direction.
  18.  
  19. Remove the timing belt undercover rubber plug, using tool MD998738. Screw the tool in until it contacts the timing belt tensioner arm.

    Click image to see an enlarged view

    Fig. Timing mark alignment



    Click image to see an enlarged view

    Fig. Tool MD998738 installation



    Click image to see an enlarged view

    Fig. Securing the camshaft sprocket

  20.  
  21. Secure the camshaft and valve timing belt, with wire to prevent slippage between the camshaft sprocket and valve timing belt. Remove the camshaft sprocket. Do not turn the crankshaft after the camshaft sprocket is removed.
  22.  
  23. Remove the upper radiator hose connection and water cooler hose connection. Disconnect the high pressure fuel hose connection.
  24.  
  25. Remove the valve cover.
  26.  
  27. Loosen all cylinder head bolts in two or three steps and in the proper bolt removal sequence. Remove the cylinder head from the engine. Discard the cylinder head gasket.
    NOTE
    If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it with a magnet.



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence

  28.  

To install:

  1. Thoroughly clean the mating surfaces of the head and block.
  2.  
  3. Place a new head gasket on the cylinder block. Position the gasket on the block so that the identification mark -381- is at the top surface and on the exhaust side.
  4.  
  5. Inspect the cylinder head bolt length prior to installation. If the length exceeds 3.91 in. (99.4mm), the bolt must be replaced. Apply a small amount of engine oil to the thread section and washer of the bolt.
  6.  
  7. Position the cylinder head on the engine. Install and torque the retaining bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence

  8.  
  9. Torque the camshaft bolt to 58-72 ft. lbs. (80-98 Nm)
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Fill the engine with the proper grade and type engine oil.
  14.  
  15. Fill the cooling system with the proper grade and type engine coolant.
  16.  
  17. Start the engine and check for leaks.
  18.  
  19. Road test the vehicle.
  20.  

 
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