Mitsubishi GS16R Engine

⚠ Do not make any sudden large adjustments while the engine is running.

Tools: Timing light, PC monitoring tool

1. Check the adjustment of the magnet disk installed on the front end of the left camshaft.
2. Connect CD200D output unit and fasten timing light clip to No. 1 cylinder spark plug cord.
3. Start the engine and operate at rated speed.
4. Illuminate the pointer and damper using the timing light; the aligned angle is the ignition timing.
5. If not to standard, adjust by turning the timing switch on the CD200D unit.
6. After adjusting at No. 1 cylinder, check again at No. 9 cylinder at rated speed.

⚠ Secure the standard clearance between the valve bridge and the valve rotator.

1. Loosen the adjusting screw so its top protrudes from the nut top face by 6 to 7 mm.
2. Press the top of the bridge by hand so the solid side contacts the valve stem top face.
3. Turn the adjusting screw slowly until it contacts the valve stem top face.
4. Turn the screw further by 10 degrees, and tighten the lock nut to the specified torque.

⚠ Adjust the gas valve clearance after adjusting the inlet valve clearance.

Tools: Feeler gauge

1. Adjust the valve clearance when the engine is cold.
2. According to the firing order, adjust at TDC of compression stroke by turning the crankshaft in the normal direction.
3. Insert a feeler gauge between the rocker arm and the bridge cap to measure.
4. Tighten or loosen the screw to adjust until feeler gauge movement is slightly restricted.
5. After adjustment, tighten the lock nut firmly, then check the clearance again.

⚠ Ensure the battery is fully charged to crank the engine with the starter.

Tools: Compression gauge P/N 35A91-03300, Gauge hose P/N 35A91-03400, Gauge adapter P/N 35A91-03500

1. Remove the spark plug from the cylinder head where the compression pressure is to be measured.
2. Install the gauge adapter into the spark plug hole with the gauge hose inserted.
3. Shut off the fuel gas supply, and crank the engine with the starter.
4. Read the engine speed and compression pressure while running at a stable speed.
5. If the measured value exceeds the limit, overhaul should be done.

⚠ [Wet] 2-time tightening method.

Tools: Connecting rod gauge P/N 37791-01500 (0.5 mm), Connecting rod gauge P/N 37791-01600 (0.6 mm)

1. Install the lower connecting rod bearing, aligning its lug with the lug slot of the cap.
2. Apply engine oil on bolt threads, seating surfaces, and sliding surface.
3. Make sure matching numbers are on the same side, then install the cap.
4. Hand tighten the connecting rod bolts.
5. Measure connecting rod end play and adjust within standard.
6. Tighten connecting rod bolts to specified torque, loosen completely, and tighten again.

⚠ [Wet] apply engine oil to thread and bolt bearing face.

Tools: Head bolt plate P/N 37598-08900

1. Tighten cylinder head bolts to the specified snug torque in the sequence shown.
2. Place the head bolt plate on the top of the cylinder head.
3. Put a mark on the cylinder head bolt.
4. Tighten bolts by turning 60 ± 3° in the specified sequence.
5. Loosen all bolts, and then tighten them again with the angle method.

⚠ DO NOT apply engine oil on O-ring grooves on cylinder liner.

Tools: Cylinder liner installer

1. Install the O-rings on the cylinder liner.
2. Insert the shim into the cylinder needing flange protrusion adjustment.
3. Apply engine oil on O-ring sliding surface in the crankcase and on the cylinder liner O-rings.
4. Slowly insert the cylinder liner into the bore in the crankcase.
5. Lightly tap with a cylinder liner installer until the flange contacts snugly.

⚠ Be sure to tighten the main bearing cap bolts and side bolts in the specified tightening sequence.

1. Ensure main bearings and thrust plates are coated with clean engine oil.
2. Install main bearing caps with stamp numbers in order from engine front to rear.
3. Apply engine oil on the main bearing cap bolts and washers, and hand tighten.
4. Install main bearing cap evenly with a soft-head hammer.
5. Apply oil on the side bolts and O-rings, and hand tighten.
6. Temporarily tighten bolts except rearmost to half of specified torque in sequence.
7. Then tighten to specified torque in sequence.

⚠ If tightened with excessively high torque, the thread may be damaged.

Tools: Plug wrench, Extension bar

1. Lubricate the spark plug threads with high temperature stainless steel grade anti-seize compound.
2. Using a plug wrench and extension bar, install the spark plug into the cylinder head.
3. Tighten it to the specified torque.

⚠ Be prepared to activate the emergency stop for an unforeseeable trouble.

1. Stop the gas supply and crank the engine approx. 10 seconds with starter; repeat 2 or 3 times with one minute intervals.
2. Start the engine in the normal procedure and confirm low idle speed.
3. Make sure oil pressure increases immediately and coolant circulates.
4. Confirm no oil, coolant or fuel gas leaks, and no abnormal noise or vibration.
5. Increase load progressively per the break-in table.