engine MITSUBISHI SPYDER 1990 Service Repair Manual

11 E N G I N E O V E R H A U L Cylinder Head
Identification mark
RETAINER LOCK . .
The ‘valve spring,if excessively, compressed, causes the
bottom end of retainer to be in contact with, and d amage,:
the stem seal.
H E A D G A S K E T
I d e n t i f i c a t i o n m a r k :
HEAD BOLT INSTALLATION
(1) When installing the cylinder bolts, that
shank length of each bolt meets the limit. If the
exceeded, replace the’ bolt.’
Limit: Max. 99.4 mm (3.91 in.)
(2) Apply engine oil to the threaded portions of bo lts
to the washers.
(3) According to the tightening sequence, tighten’ the bolts
to the specified torque 78 Nm
t o o l
(4) Loosen bolts completely.
(5) Retighten the loosened bolts to
Nm in
the specified tightening sequence.
(6) Make a paint mark across each-‘bolt cylinder
head.
(7) Give a turn to the bolts in the specified’ tightening
sequence.
(8) Give another turn to the bolts and sure that
the paint mark on the head of each, bolt ‘and that
the cylinder head are on the same straight line.
Caution
1.If the bolt is turned less than
may e x p e c t e d .
tightening the bolt, therefore, be
a sufficient turn to
2. If the bolt is t h e b o l t
completely and then retighten It
the
tightening procedure from step
,
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ENGINE OVERHAUL Cylinder Head and
Valve seat
contact
Margin
I
I
Free
height
INSPECTION
CYLINDER HEAD (1) Check the cylinder head gasket surface for flat ness by
using a straightedge and feeler gauge.
Standard value: 0.05 mm
in.)
Limit: 0.2 mm
in.)
(2) If the service limit is exceeded, correct to me et specifica-
tion.
Grinding limit: mm in.)
Includes combined with cylinder grinding.
Cylinder head height (Specification when
1 3 1 . 9 - 1 3 2 . 1 m m in.)
VALVE
(1)Check the valve face for correct contact. I/incorre ct, reface
using valve Valve seat contact should be main-
tained uniform at the center
valve face.
(2) the margin exceeds the service limit, replace the valve.
(3) Measure the valve’s total length. If the measurement is
less than specified, replace the valve.
VALVE
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Standard value: 47.0 mm
in.)
Limit: 46.0 mm (1.811 in.)
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ENGINE OVERHAUL Head and
(2) Measure the squareness of the spring and,
is exceeded, replace.
Standard value: or less
Limit: Max.
Stem O.D.
Valve stem end
Valve stem
projection
Spring seating
surface
GUIDE
(1)Measure the clearance between the valve guide and v alve
stem. If the limit is exceeded, replace the valve guide
or valve, or both.
Item
Intake
Exhaust Standard value mm (in.) Limit mm (in.)0.10
0.15
VALVE
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and th e
spring seating surface. If the measurement
the
specified limit, replace the valve seat.
VALVE SEAT RECONDITIONING PROCEDURE
(1) Before correcting the valve seat, check for cle arance
between the valve guide and valve and, if necessary ,
replace the valve guide.
(2) Using the seat grinder, correct to obtain the s pecified
seat width and angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION) .
VALVE SEAT REPLACEMENT
(1) Cut the valve seat to be replaced inside to thin
the wall thickness. Then, remove the
seat..
I
mm in.)
mm in.)

ENGINE OVERHAUL Cylinder Head and Valves,
Oversize I.D.
RemovalInstallation
PressPress
Push rod
Valve
guide Push rod
Valve
guide
(2) Rebore the valve seat hole in the cylinder to’
selected oversize valve seat diameter.
I n t a k e s e a t r i n g h o l e ’
0.3 O.S. 35.30 35.33 mm (1.3989 1.3909 in.)
0.6 OS. 35.60
35.63 mm (1.4018
Exhaust seat ring hole diameters
0.3 O.S. 33.30
33.33 mm (1.3110 1.3122 in.)
0.6 O.S. 33.60
36.63 mm (1.3228 in.)
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately
or cool the valve seat
in liquid nitrogen, to prevent the cylinder head bo re from
galling.
(4) Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”.
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Using the push rod and a press, remove the valv e guide
toward cylinder head gasket surface.
(2) Rebore valve guide hole to the new oversize valve guide
outside diameter.
Valve guide hole diameters
0.05 O.S. 12.05
12.07 mm in.)
0.25 O.S. 12.25
12.27 mm
0.50 O.S. 12.50 12.52 mm In.)
NOTE
Do not install a valve guide of the same size again .
(3) Using the special tool, press-fit the valve gui de, working
from the cylinder head top surface.
(4) After installing valve guides, insert new valve s in them
to check for sliding condition.
(5) When valve guides have been replaced, check for valve
contact and correct valve seats as necessary.
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ENGINE OVERHAUL.
FRONT CASE, COUNTERBALANCE SHAFT AND OIL
REMOVAL AND INSTALLATION
1 3 1
24 Nm17
10 Nm
I18I I
76
17 Nm
19 Nm 101 4
45 Nm
33. . Nm
17I
10 Nm19 Nm14
40 Nm
5
Removal steps
Oil filter
2. Oil cooler bolt
3. Oil cooler
4. Drain plug
5. Drain plug gasket
6. Oil pan
7.Oil screen
8. Oil screen gasket
9. Baffle plate 10. Plug11. O-ring 12. Flange bolt 13. Oil pressure switch 14. Oil pressure gauge unit15. Relief plug
16. Gasket 17. Relief spring
18. Relief plunger
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20. Oil filter bracket gasket
21. Oil pump cover
22. Oil pump driven gear 23. Oil pump drive gear 24. Crankshaft front oil seal
25. Oil pump oil seal 26. Counterbalance shaft oil seal 27. Front case
28. Front case gasket
29. Counterbalance shaft, left
30. Counterbalance shaft, right
31. Counterbalance shaft, front 32. shaft, rear
33. shaft, rear bearing,

Front Case,
ENGINE OVERHAUL and Pan
Phillips screwdriver
F r o n tbearing
REMOVAL SERVICE POINTS
PAN REMOVAL
(1) Remove all oil pan bolts.
(2) Drive in the special tool between the
and.
oil pan.
NOTE
Never use a screwdriver or chisel, instead of
tool, as a deformed oil pan flange result in oil leakage.
PLUG REMOVAL
(1) If the plug is too tight, hit the plug head wit h a hammer
two to three times, and theplug will be easily loosened.
FLANGE BOLT REMOVAL
(1) Remove the plug on the side of cylinder block.
(2) Insert a Phillips screwdriver [shank diameter 8 mm
in.)] into the plug hole to lock the counterbalance shaft.
(3) Loosen the flange bolt.
COUNTERBALANCE FRONT
REMOVAL ,
Using the special tool, remove the counterbalance s haft
front bearing from the cylinder block.
NOTE
Be sure to remove the front bearing
If it has not been removed, the Rear Bearing Puller cannot
b e u s e d .
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11Front Case, ENGINE OVERHAUL Shaft and
Rear bearing
COUNTERBALANCE SHAFT REAR BEARING
REMOVAL
Using the special tool, remove the counterbalance shaft
. rear bearing from the cylinder block.
NOTE
When removing the left counterbalance shaft, install the
special tool
to the front of the cylinder block.
INSTALLATION SERVICE POINTS
RIGHT COUNTERBALANCE REAR
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearin g.
(2) Using special tools, install right rear bearing .
that oil hole of bearing is aligned oil hole of
block.
,
LEFT COUNTERBALANCE SHAFT
BEARING INSTALLATION
(1) Install the special tool (GUIDE to
block.
(2) Apply engine oil to the rear bearing outer
and bearing hole in cylinder block.
(3) Using the special tool, install’ the rear
NOTE
The left rear bearing has no oil holes.
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Front Case, Counterbalance
ENGINE OVERHAUL Shaft and
C y l i n d e rblock
COUNTERBALANCE
INSTALLATION
(1) Using special tools, install front bearing., ,
FRONT CASE
(1) Place the special tool on the front end of crankshaft and
apply a thin coat of engine oil to the outer
of the special tool to install the front
(2) Install the front case assembly through a new f ront case
gasket and temporarily tighten the flange bolts (ot her
than those for tightening the filter bracket).
COUNTERBALANCE SHAFT OIL SEAL
INSTALLATION

11Front Case, ENGINE OVERHAUL Shaft and
Socket
Oil seal
case
OIL PUMP OIL SEAL INSTALLATION
FRONT OIL SEAL INSTALLATION
(1) Using the special tool, install the crankshaft front seal
into the front case.
PUMP DRIVEN GEAR OIL PUMP DRIVE
GEAR INSTALLATION
Apply engine oil amply to the gears’ and line up align-
ment marks.
SEALANT APPLICATION TO OIL
GAUGE UNIT
(1) Coat the threads of switch with sealant and
the
switch using the special
Specified sealant: ATD Part No. 8660 or equivalent
Caution
1.Keep the end of threaded portion clear of sealant.
2. Avoid an
SEALANT APPLICATION TO OIL PRESSURE
SWITCH
(1) Coat the threads of switch with sealant and ins tall the
switch using the special tool.
Specified sealant: ATD Part or equivalent
Caution
1.Keep the end of threaded portion clear of
2. Avoid an overtightening.
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Front Case,, ENGINE OVERHAUL Shaft and ‘Pan
Phillips screwdriver
B O L T ,
(1) Phillips screwdriver hole in the left side
of the cylinder block to lock the counterbalance sh aft.
(2) Secure the oil pump driven gear onto the left c ounterbal-
ance shaft by tightening the flange bolt to specified torque.
PLUG INSTALLATION
(1) Install a new O-ring to the front case.
(2)Using the special tool, install the plug and tighten to speci-
fied torque.
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