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Colt Lancer Galant L200 Outlander Pajero Others

Outlander 1 (2003-2008)

Removal and installation of a head of the block of cylinders

(4G64, 4G69)
Home Outlander 1 (2003-2008) Power unit Engine repair

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Removing

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 Relieve residual pressure from the high pressure fuel line.

Drain the coolant.

Drain the engine oil.

Remove the air filter assembly.

Disconnect the accelerator pedal cable.

Remove the exhaust manifold.

Remove the top timing belt cover.

Remove the coolant inlet pipe and thermostat housing assembly.

Remove the cylinder head cover.

Removing the camshaft sprocket

Turn the crankshaft clockwise until the timing marks on the camshaft
sprocket and crankshaft sprocket are aligned with the corresponding timing
marks, and set the No. 1 cylinder piston to TDC on the compression stroke.

Attention! Turn the crankshaft only clockwise.

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 Remove the plug and screw the special rod into the hole of the attachment
mounting bracket so that it rests against the groove on the tensioner arm.

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Slowly screw in the special rod, aligning the hole «IN» on the body of the
automatic tensioner with a hole «A» on the tensioner rod.

Attention! Screw in the special rod in increments of no more than 30°per

second. If the rod is turned at full speed immediately, it may be deformed due
to the difficult movement of the tensioner rod.

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 Fix the timing belt to the camshaft sprocket in the position shown in the
illustration using a band or wire.

Secure the camshaft sprocket against rotation with a special holder and
bolts.

Loosen the camshaft sprocket bolt.

Attention! Do not rotate the crankshaft after removing the camshaft sprocket.

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 Before removal, apply installation marks of the original position of the
radiator hose and clamp. Disconnect the upper radiator hose.

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On 4G69 series engines, before disconnecting the high pressure fuel hose,
remove its bracket.

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 Remove the fuel hose clamp and pull it in the direction of the arrow in the
figure.

Note. If the high pressure hose retainer has been released, reinstall it after
disconnecting the hose.
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Removing the power steering pump assembly with bracket

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Remove the power steering pump assembly with bracket along with hoses
connected to it.

Note. Tie the removed power steering pump assembly with bracket and hoses
with wire and place it in a place where it will not interfere with the removal
and installation of the cylinder head assembly.

Removing the cylinder head

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 Loosen the bolts in 2 or 3 steps in the sequence shown in the figure, and
then remove the cylinder head assembly.

Attention! When loosening the cylinder head bolts, be careful not to damage
or deform the spark plug guide tubes as they are not supplied separately.

Installing the cylinder head gasket

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 Using a special scraper, remove the remnants of the old cylinder head gasket
from the cylinder block.

Attention! When carrying out this operation, do not allow gasket material or
other foreign particles to enter the channels of the cooling system and
lubrication system.

Degrease adjacent gasket surfaces.

At installation check up coincidence of all openings on a lining and a head of

cylinders.

Verify that the correct engine identification mark is on the new cylinder head
gasket.

Lay the cylinder head gasket on the cylinder block with the identification
mark facing up, so that it is located on the side of the exhaust valves.

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When installing the cylinder head bolts, make sure the length «A» of each
bolt is within the allowable value. If length «A» exceeds the limit value, the
bolts must be replaced.

Limit value «A»: 99.4 mm.

Lubricate the threads and washers of the cylinder head bolts with a thin layer
of engine oil.

Note. If the cylinder head bolt washer has been replaced, install it with the
chamfered side up as shown.

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 Tighten the bolts according to the procedure below.

Note. Always turn the bolt to a strict 90°angle. Otherwise, the cylinder head
bolt may be loosened (the reliability of the gas joint will not be ensured).

Note. If the bolt is turned more than 90°, loosen it completely and repeat all
operations starting from point 1.

High pressure fuel hose installation

Lubricate the O-ring with a little fresh engine oil.

Attention! Do not allow oil to enter the fuel manifold.

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 Slightly turning the fuel hose flange to the right or left, carefully insert it into
the fuel manifold to prevent damage to the gasket. After installation, check
that the hose turns smoothly in the fuel manifold.

If the hose flange sticks when turning, the cause may be a damaged O-ring.
Detach the flange (complete with hose) from the fuel rail and check the
gasket for damage, then reinsert it and check for smooth rotation.

Connecting the Upper Radiator Hose

When connecting the upper radiator hose, put it on the protrusion of the
branch pipe until it stops, then tighten the clamp.

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 The hose clamp should always be installed in the position in which the clamp
was installed when removed. Therefore, before installing the clamp, align the
alignment marks on the hose clamp and the radiator hose, then connect it.

Camshaft sprocket installation

Secure the camshaft sprocket against rotation with a special fork holder and
special bolts.

Wrap a bolt of fastening of an asterisk of a camshaft the nominal moment.

Tightening torque: 89±9 Nm.

After completing the installation of the parts, perform the following

operations:

On 4G69 series engines, install the cylinder head cover.

Install the coolant inlet pipe and thermostat housing assembly.

Install the timing belt top cover.

Install the exhaust manifold.

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 Install the exhaust manifold.

On 4G69 series engines, connect the accelerator pedal cable.

Install the air filter assembly.

Fill with coolant and engine oil.

Adjust the tension of the accessory drive belt.

Adjust the accelerator pedal cable.

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PREVIOUS

Removal and installation of front and rear crankshaft oil seals (4G63)
Removal and installation of camshaft seals (4G63)
Replacing the timing belt and balancer drive belt (4G63)
Replacing the timing belt and balancer drive belt (4G64, 4G69)

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 Removal, check and installation of the oil pallet (4WD models)
Removal, check and installation of the oil pallet (2WD models)
Removal and installation of the engine assembly
Specifications and engine specifications
Warm engine operation
Periodic maintenance (operations in the engine compartment with a cold engine)
NEXT

Removal and installation of a head of the block of cylinders (4G63)

Removal, check and installation of the distributive mechanism
Removal and disassembly of the connecting rod and piston group
Assembly and installation of the connecting rod and piston group
Cylinder block, crankshaft and flywheel
Cylinder block — condition check
Assembly of cylinder block components

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