check engine MITSUBISHI ECLIPSE 1991 Repair Manual

ENGINE <1.8L Ennine> -Rocker Arms, Rocker Arm Shafts and Camshaft&49
MD9984431
6EN245
IFuel pump
3EN287
r
0
Camheight6EN0184
hl,
3EN153, Oil seal
MD998364
DEN632
SERVICE POINTS OF DISASSEMBLYNWLFM.
9. REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLYBefore removing the rocker arm and shaft assembly, use
the special tool to ensure that the lash adjuster doesn’t fall
out.
Caution
Put the rocker arms and lash adjusters in order in
cylinder No. separated places with clear distinction
between the intake and exhaust ones to prevent
confusion.
INSPECTION
CAMSHAFT
NOBLCDDI
(1) Visually check the camshaft journal surfaces and replace if
damage or seizure is evident.
If the journal is seized, check the cylinder head for possibledamage. Check also for clogged oil holes in the cylinder
head.
(2) Check cams for excessive wear and damage and replace if
defects are evident. Measure the cam height and replace ifthe limit is not reached.
Standard value: 35.91 mm (1.4138 in.)
Limit: 35.41 mm (1.3941 in.)SERVICE POINTS OF
INSTALLATIONNOSLQACa
11. INSTALLATION OF OIL SEAL
(1) Apply engine oil to oil seal lip.
(2) Using the special tool, drive the camshaft oil seal into
the cylinder head.

7EN0064
IIENGINE
<1.8L Engine> -Rocker Arms and Rocker Shafts
SERVICE POINTS OF DISASSEMBLY
NOTEBefore disassembly, mark the rocker arm for
indentificahon.
INSPECTIONNoaNGAG
ROCKER ARM(1) Visually check the roller and replace if dent, damage, or
seizure is evident.
(2) Check roller for smooth rotation. Replace if it is binds or
there is an excessive play.
ICuts in rocker shafts(3) Check the inside diameter and replace the rocker arm if
damage or seizure is observed.SERVICE POINTS OF REASSEMBLYNOBNHBC
9./8. INSTALLATION OF ROCKER AeM SHAFTSInsert the rocker shafts into the holes in front bearing cap
and temporarily install the bolts to hold the shafts in place.
When the rocker arm shafts are inserted, make sure that
the shaft front end cuts are facing up as shown.
I3EN021Front mark
Cap No.Rocker cove1attaching
No.2No.3No.43EN0093
7./6./4. INSTALLATION OF BEARING CAPSThe No. 2, No.3 and No.4 caps look alike in shape. Install
correct one at correct position. They can be identified by
the front mark, cap number and rocker cover attaching bolt
hole as illustrated.
3. INSTALLATION OF WAVE WASHERInstall the wave washer in correct direction as shown.
3EN0081

ENGINE <I .8L Engine>- Cylinder Head and Valve9-55
3EN026
w -w===j=Margin , EN034
Squareness
IFree length
INSPECTION
CYLINDER HEADNosocAMl Check the cylinder head for cracks, damage and engine
coolant leakage.l
Remove the scale, sealing compound and carbon deposits
completely. After cleaning oil passages, apply compressedair to make certain that the passages are clear.
l Check the cylinder head gasket surface for flatness by
using a straight edge in the direction of A, B, . . . as shown. Ifthe flatness exceeds the limit in any direction, either
resurface or replace the cylinder head.
Flatness of cylinder head gasket surface:
Standard dimension
Limit
Overall height:
Limit
Caution
Less than 0.05 mm (0020 in.)
0.2 mm (008 in.)
88.5 mm (3.484 in.)
88.3 mm (3.478 in.)
If cylinder block gasket surface has already been
ground, thickness of the removed stock should be
included in the grinding limit of -0.2 mm
(-,008 in.).
VALVESNo9PGMa
(1) Check each valve for wear, damage and deformation of
head and stem at
B. Correct or replace excessively worn,
damaged or deformed valves.
(2) If stem tip A is pitted, correct with an oil stone or other
means. The correction must be limited to a minimum. Also
reface the valve.
(3) Replace the valve if the margin has decreased to less than
the limit.
Margin:
Standard dimension
Intake1.0 mm (.039 in.)
Exhaust0.7 mm (028 in.)
Limit
Intake0.7 mm (.028 in.)
Exhaust0.5 mm LO20 in.)
VALVE SPRINGSNOWGh
(1) Check the valve spring for free length and load. If they
exceed the limits, replace the spring.
(2) Using a square, check the squareness of each spring. If thespring is out of square beyond the limit, replace.
Valve spring:
Standard dimension
Free length
49.2 mm (1.937 in.)
Load274.6 N (62 Ibs.) at installed height
Installed height37.3 mm (1.469 in.)
Out of square
Less than 2”
Limit
Free length48.2 mm (1.888 in.)
Installed height38.3 mm (1.516 in.)
Out of square4”

9-56ENGINE <1.8L Engine> - Cylinder Head and ValveStem O.D.
YEN323
3EN0039
-I
VALVE GUIDESCheck the valve stem-to-guide clearance. If the clearance
exceeds the limit, replace the valve guide with a next higher
7-c.oversize guide.“I
Valve stem-to-guide clearance:
Standard dimension
Intake0.03-0.06 mm (.0012-.0024 in.)
Exhaust0.05-0.08 mm (.0020-.0035 in.)
Limit
Intake0.10 mm (004 in.)
Exhaust0.15 mm (.006 in.)
Valve Guide OversizesSize mm
(in.)0.05
l.002) OS.0.25
LOlO) OS.
0.50
i.020) OS.
Size markValve guide fitting holediameter mm (in.)
513.05-13.068(.5138-.5145)
2513.25-13.268(.5216-.5244)
5015.5-13.518(.5315-.5323)
SERVICE POINTS OF REASSEMBLY
15./ 13. INSTALLATION OF VALVE STE,M SEAL/l6./14.
VALVE SPRING SEAT
Install the spring seat, then using the special tool, install the-stem seal by lightly tapping the tool. Seal is installed in
-dspecified position using the special tool.
Caution
1. Incorrect installation of the seal without using the
special tool will result in poor sealing and cause oil
leakage down valve guide.
2. Do not reuse stem seal.
12.18. INSTALLATION OF EXHAUST, INTAKE VALVEApply engine oil to each valve. Insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.PL

ENGINE <1.8L Engine> - Cylinder Head and Valve9-57
Enamel-
coating
sideSpring
retainerStem seal
Spring- seat
3EN324intake side
3EN315Front of engine
I,Exhaust side
11./7. INSTALLATION OF VALVE SPRINGInstall the valve spring with its enamel coated end toward
the valve spring retainer.
9.15. INSTALLATION OF RETAINER LOCK(1) Using the special tool, compress the spring, and then
install the retainer lock.
Caution
When compressing the spring, check to see that the
valve stem seal is not pressed to the bottom of the
retainer.
(2) Make certain that retainer locks are positively installed.
1. INSTALLATION OF CYLINDER HEAD BOLTSUsing the special tool, tighten in the order shown in two or
three steps, gradually tighten. Finally tighten to the speci-
fied torque.

S-60ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft
3EN040
7LUOOO6
27. REMOVAL OF SILENT SHAFT REAR BEARINGUsing the special tool, remove the rear bearing from
A=cylinder block..i
INSPECTION
SILENT SHAFTNOSRUEl(1) Check oil holes for clogging.
(2) Check journal for seizure, damage, and contact with
bearing. If there is anything wrong with the journal, replace
silent shaft, bearing or front case assembly.
(3) Check the silent shaft oil clearance. If the clearance is
excessively due to wear, replace the silent shaft bearing
silent shaft or front case assembly.
Standard value:
Front
Right
0.030-0.060 mm (.0012-.0024 in.)
LeftO.O20-0.064 mm (.OOOS-.0021 in.)
Rear
Right
Left
0.050-0.091 mm (.0020-.0036 in.) rt
0.050-0.091 mm (.0020-.0036 in.1-4FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check left silent shaft front bearing section for wear,
damage and seizure. If there is anything wrong with the
section, replace the front case.
(3) Check the front case for cracks and other damage. Replacecracked or damaged front case.
OIL SEALNOORCMAO
(1) Check the oil seal lip for wear and damage. Replace oil sealif
necessan/.(2) Check the oil seal lip for deterioration. Replace oil seal if
necessary.
OIL PRESSURE SWITCH
(1) Connect a tester (ohm range) between the terminal and thebody and check for conductivity. If there is no conductivity,
replace the switch.

ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft9-61
Fine
7LUOOO7
3LUOOOl
3LUOOO2
I
1(2) Next insert a very fine wedge through the oil hole, pushing
it slightly. There should be no conductivity (resistance
should be infinite). If there is conductivity even when
wedge is pushed, replace the switch.
(3) Or, if there is no conductivity when a 50
kPa (71 psi)
pressure is placed through the oil hole, the switch is
operating properly. Check at this time to see that there is
no air pressure leakage. If there is air pressure leakage, thediaphragm is broken, and the switch should be replaced.
OIL PUMPNomcGH
(1)Install the oil pump gears in the front case and check the tipclearance of each gear using a thickness gauge.
Standard value:
Drive gear
0.06-0.12 mm (.0024-.0047 in.)
Driven gear0.04-0.12 mm (.0039-.0079 in.)
Limit:
Drive gear0.20 mm (.079 in.)
Driven gear0.18 mm (.071 in.)
NOTECheck the tip clearance of each gear at position indicated
by an arrow.
(2) Check the side clearance of each gear.
Standard value:
Drive gear
0.10-0.16 mm (.0039-.0063 in.)
Driven gear0.02-0.05 mm (.0008-.0020 in.)
Limit:Drive gear0.20 mm (308 in.)
Driven gear0.15 mm (AI66 in.)(3) Check for ridge wear on the surface of the oil pump cover
that are in contact with the pump gear side.

9-62ENGINE -4.8L Engine> -Front Case, Oil Pump and Silent Shaft
OIL RELIEF PLUNGER(1) Check that the relief plunger slides smoothly.
(2) Check the relief spring for breakage.
3EN044J
MD998280
3EN270
0M D998304
SERVICE POINTS OF REASSEMBLYNOBRHAF
27. INSTALLATION OF SILENT SHAFT REAR BEARING
(1) Apply engine oil to the rear bearing outer circumferenceand bearing hole in cylinder block.
(2) Using the special tool and a hammer, drive the rear
bearing into cylinder block.
26. INSTALLATION OF SILENT SHAFT FRONT BEARING(1) Install two guide pins included in the special tool set to
the threaded holes in cylinder block.
(2) Set the front bearing on the special tool so that the
ratchet ball of special tool fits in the oil hole in bearing.
(3) Apply engine oil to the bearing outer circumference andbearing hole in cylinder block.
(4) Set the special tool on guide pins and drive the bearing
into cylinder block.
22. INSTALLATION OF CRANKSHAFT OIL SEALUsing the special tool, install the crankshaft oil seal into
front case.

ENGINE <1.8L Engine>- Piston and Connecting Rod9-67
Piston ring end gap:
Standard dimension
No. 10.30-0.45 mm (.0118-.0177 in.)
No.20.20-0.35 mm (.0079-.0138 in.)
Limit0.8 mm LO31in.)
Oil ring side rail:
Standard dimension0.2-0.7 mm (.008-.028 in.)
Limit1.0 mm (.039 in.)When replacing the ring only without correcting the
cylinder bore, check the gap with the ring positioned at a
lower part of cylinder that is less worn.
When replacing a ring, be sure to use a ring of the same
size.
Piston ring service size and mark:
STDNone0.25 mm
(.OlO in.) O.S. 25
0.50 mm
(020 in.) O.S. 50
0.75 mm
(030 in.) O.S. 75
1.00 mm (039 in.) B.S.100
CONNECTION RODSNOSTCCA
(1) Replace the connecting rod if it has damage on thrust faces
at either end. Also replace the connecting rod that has ridgewear or severely rough surface on the inside diameter of
the small end.
When using a new connecting rod, the cylinder number
should be stamped in two places, on the cap and on the
rod.(2) Using a connecting rod aligner, check the rod for bend and
twist. If the measured value is close to the limit, correct therod using a press. Any connecting rod that has been
severely bent or distorted should be replaced.
Bend of connecting rod:
0.05/100 mm (.0020/3.937 in.) or less
Twist of connecting rod:
O.l/lOO mm (.004/3.937 in.) or less
SERVICE POINTS OF REASSEMBLYNOSTGEA
9. INSTALLATION OF OIL RING
(1) First, install the oil ring spacer in the piston ring groove.
Next, install the upper side rail and then the lower side
rail. Both upper and lower side rails may be installed
with their either side facing up.
(2) To install the side rail, first place one end in the gap
between the groove and the spacer.
While holding the end firmly, press the portion to be
inserted with finger as illustrated until the side rail is in
position.
Caution
Do not use piston ring expander to install the side
rail.

9-68ENGINE <1.8L Engine> - Piston and Connecting Rod
r-Size and maker marks
No. 1Barrel
faced
1
1 Size and maker marks
L
INo.2
ti2zza
Tapered
Barrelfaced
1 EN064
-1 No. 1 rina aarGap of
upper8. INSTALLATION OF
NO.2 PISTON RING/7. NO. 1
PISTON RINGInstall the No. 2 piston ring and then the No. 1 piston ring
with a piston ring expander.
Caution
1. The No. 1 and No.2 piston rings have a different
cross section. Be sure to install them in correct
positions.
2.Install the No. 1 and No.2 piston rings with the size
mark and maker mark on ring surface toward the
piston top.
4. INSTALLATION OF PISTON AND CONNECTlNG ROD
ASSEMBLY(1) Liberally coat engine oil on the circumference of the
piston, piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of
cylinder bore.
Bearing
bltab notches
DEN057(4) Use suitable thread protectors on connecting rod bolts
before inserting piston and connecting rod assembly
into cylinder block. Care must be taken not to nick crank
pin.(5) Using a suitable piston ring compressor tool, install
piston and connecting rod assembly into cylinder block.
Caution
Insert the front mark (arrow) on the top of the
piston so it faces the engine front (timing belt side).
2. INSTALLATION OF CONNECTING ROD CAPLining up the marks put at the time of disassembly, install
the connecting rod cap on the connecting rod.
If the connecting rod is new without such marks, position
the bearing block tab notches in rod and cap on the same
side as illustrated.
. CHECKING CONNECTING ROD BIG END SIDE CLEAR-
ANCE
Connecting rod big end side clearance:
0.1-0.25 mm (.0039-.0098 in.)
Limit: 0.4 mm (016 in.)