MITSUBISHI SPYDER 1990 Service Repair Manual

ENGINE OVERHAUL Manifold
EGR tube
INTAKE MANIFOLD
(1) Remove intake air temperature sensor.
(2) Remove manifold absolute pressure (MAP) sensor mount-
ing screws.
(3) Remove manifold absolute pressure (MAP) sensor.
(4) Remove intake manifold stay.
(5) Remove EGR tube fasteners from the
and valve. Remove tube from engine.
Remove vacuum hose and electrical connection from in-
take manifold.
(7) Remove attaching
engine and remove intake
manifold from engine.
I .
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ENGINE OVERHAUL
EGR tubeINSTALLATION11661966616
(1) Install new manifold gasket. DO NOT APPLY SEALER.
(2) Set manifold in place. Tighten retaining fasteners, starting
at center and progressing outward in both direction s to
23 Nm (17 Repeat this procedure until all fasteners
are at specified torque.
(3) Install vacuum hose and electrical’ connection from
manifold. .
(4) Install new EGR tube gaskets at
valve.
(5)Install EGR tube and tighten fasteners to 8 (6
(6) Install intake manifold stay. .
(7) Insert sensor into manifold making
to damage O-ring seals.
(8) Tighten mounting screws to 2 Nm torque.
(9) Install manifold air temperature sensor. Tighte
n sensor
to 7 Nm (5
torque.
CLEANING AND INSPECTION
(1) Discard gasket and clean gasket surfaces of man ifold.
(2) Test manifold gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300 m m
of manifold length.
(3)Inspect manifold for cracks or distortion. Replace manifold
if necessary.
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ENGINE OVERHAUL Exhaust
EXHAUST MANIFOLD
REMOVAL
(1) Remove oil level gauge.
(2) Remove exhaust manifold. heat shield,
(3) Remove 8 exhaust manifold retaining and
move exhaust manifold.
(1) Install new manifold gasket. DO NOT APPLY-SEALER.
(2) Set exhaust manifold in
Tighten nuts
and bolt, starting at center and
in
both directions to 23
procedure until all fasteners are specified
(3) Install exhaust manifold heat shield, ,
(4) Install oil level gauge.
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of manifolds
and cylinder head.
(2) Test manifold gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300 m m
in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion. Rep lace man-
ifold if necessary.
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OVERHAUL Camshaft and Cam
askets
CAMSHAFT AND CAM FOLLOWER
11301990010
REMOVAL
(1) Remove the cylinder head cover fasteners.
(2) Remove cylinder head cover from cylinder head.
, ,
(3) Bearing caps are identified for the
outside bearing caps first.
.
(4) Loosen the camshaft bearing cap attaching faste ners
in sequence shown in one camshaft at a time.
Caution
Camshafts are not interchangeable. The exhaust
cam
number 6 bearing journal ,
,
(5) Identify the
before removing
The cams are not
(6) Remove cam follower assemblies cylinder head.
Keep the cam followers in the order they have been
removed from the head for
(7)Mark hydraulic lash adjusters for reassembly in the ir
positions.
Lash adjusters are serviced as an assembly.
CLEANING
Before installation, clean cylinder head and cover mating sur-
faces. Make certain the rails are flat.
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ENGINE OVERHAUL Camshaft Cam
INSTALLATION
I
Front bearing cap (No. cap)
diameter bead of Loctite 51817
Left rear bearing cap cap)
(1) Install hydraulic lash adjuster
adjusters are at least of
making. that
is
by little or no plunger travel the lash adjuster is
depressed.. .
(2)Lubricate with clean oil and install cam follower a ssemblies
in their original position on the hydraulic adjuster and
valve stem.
Caution
Piston should NOT be at top dead center when
lingthecamshaft.
(3) Lubricate bearing journals and cams with clean oil and
install the camshafts. Install right and left camshaft bearing
caps No. 2 thru No. 5 and right Tighten fasteners
to 12 Nm (9 in sequence shown in the figure.
(4) Apply Loctite 51817 to No. 1 and No. 6 bearing caps.
Install bearing caps and tighten
fasteners to 28 Nm
(21
(5) Bearing end caps must be installed before seals can
be installed.
(6) Install timing belt, sprockets and timing cover s. Refer
to “Timing belt”.
Caution
Do not allow oil or solvents to contact the timing
belt as they can deteriorate the rubber and cause
tooth skipping.
(7) Install new cylinder head cover gaskets.
(8) Apply Loctite 18718 at the camshaft cap corners and
at the top edge of the
round seal.
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11 ENGINE OVERHAUL
(9) Install head cover assembly to head and tighten
fasteners in sequence shown in the figure. Using th e
3 step torque method:
Step 1 Tighten all fasteners to 4.5 Nm (3.3
Step 2 Tighten all fasteners to 9.0 Nm (6.5
Step 3 Tighten all fasteners to 12 Nm (9
Spark plug well gaskets
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(1) Inspect camshaft bearing journals for damage and bind-
ing.
If journals are binding, also check the cylinder head bear-
ing surface for damage, and check the camshaft bearing
oil feed holes in the cylinder head for clogging.
(2) Check the cam surface for abnormal wear and damage.
Replace if defective. Also measure the cam height and
replace if out of limit.
Standard value: 0.0254 mm
in.)
Limit: 0.254 mm in.)
To measure cam lobe lobe in
two places at the largest diameter Take
first reading with micrometer area ‘at edge
of the lobe. Take second reading in
where
cam follower contacts the
from the first. The is ‘wear.
ENGINE OVERHAUL Camshaft and Cam Follower
INSPECTION
CAMSHAFT
adjusterket
Roller
CAM
(1) Inspect the cam follower assembly for wear damage.
Replace as necessary.
CAMSHAFT END PLAY
(1) Oil. camshaft journals and install camshaft wit hout cam
follower assemblies. Install rear cam caps and tigh ten
screws to specified torque.
(2) Using a suitable tool, move camshaft as far rea rward
a s i t w i l l g o .
(3) Zero dial indicator.
(4) Move camshaft as far forward as it will go.
End play standard value: 0.15 mm
in.)
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ENGINE OVERHAUL
C Y L I N D E R A N D
REMOVAL
(1) Remove cylinder head bolts.
(2) With cylinder head removed, compress valve springs using
Special Tool or equivalent.
retaining locks, valve retainers and
valve- spring. ,
(4) Remove valve stem seal/valve spring seat Spe-
cial Tool or
(5) Before removing valves, remove from valve
stem lock grooves to prevent damage to the valve guides.
Identify valves to’ insure original location.
CLEANING
CYLINDER HEAD
Caution
Be careful not to gouge or scratch the aluminum hea d
sealing surface.
(1) Remove all gasket material from cylinder head a nd block.
VALVE ASSEMBLY,
(1)Clean all valve guides, valves and valve assemblies
thoroughly with suitable
reassem-
bling.,
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ENGINE OVERHAUL Cylinder and Valve
Valve retaining locks
INSTALLATION
(1) Coat valve stems with clean engine oil and
in cylinder head:
(2) If valves or seats have been reground,!
valve tip
height (A).
Make sure of measurements from cylinder head
(3) Install valve seal/spring seat assembly over va lve guides
to the top of valve stem.
on all valve stems. Ensure garter intact
around the top of the rubber seal. Install valve springs,
valve retainers.
(4) Compress valve springs with a valve spring comp ressor.
Install locks and release tool.
(5) Before installing the bolts, the threads should be oiled
with clean engine oil.
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11ENGINE OVERHAUL Cylinder
l
(6) Tighten the cylinder head bolts in the sequence shown
in the figure.
Using the 4 step torque turn method, tighten accord ing
to the following values:
Step
Tighten center fasteners 1 thru 6 to 33 Nm (24
then outer fasteners 7 thru 10 to 26
(20
2
Tighten center fasteners
to 67. Nm (46
then outer fasteners’ 7 to 28 Nm
(20,
Step 3 Tighten center fasteners 1
6 to (46
then outer fasteners 7 thru to
(20
Step 4
Turn all fasteners 1 thru 10 turn (90 degrees).
Do not use a torque wrench for step.
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