engine MITSUBISHI ECLIPSE 1991 Service Manual

9-124ENGINE <2.0L DOHC Engine> -Front Case, Oil Pump and Silent ShaftOil hole
6EN075 1
6EN331j(3) Furthermore, make sure that clinch of bearing is in
upper most position.
28. INSTALLATION OF DRIVE
GEAR/27. DRIVEN GEAR
Coat the gear with plenty of engine oil, and align the two
timing marks.
25. INSTALLATION OF CRANKSHAFT FRONT OIL SEAL
Using the special tool, install the crankshaft front oil seal
into front case.
24./23. INSTALLATION OF OIL SEAL
Using a socket wrench, press-in the oil seal into front case.21. INSTALLATION OF FRONT CASE
(1) Set the special tool on the front end of the crankshaft
and apply a thin coat of engine oil to the outer
circumference of the special tool to install the front
case.

ENGINE <2.0L DOHC Engine> -Front Case, Oil Pump and Silent Shaft9-1256E
N026:(2) Install the front case assembly through a new front
case gasket and temporarily tighten the flange bolts
(other than those for tightening the filter bracket).
(3) Mount the oil filter bracket with oil filter bracket gasket.
Then, install the four bolts with washers.
(4) Tighten the bolts to specification.
NOTE
Bolts indicated by the * symbol should be tightened at atorque of 27-34 Nm
(20-25 ft.1b.s.).20. INSTALLATION OF DRIVEN GEAR BOLT
(1) Insert a Phillips screwdriver into a hole in the left side ofthe cylinder block to lock the silent shaft.
(2) Secure the oil pump driven gear onto the left silent
shaft by tightening the driven gear bolt to specified
torque.18. INSTALLATION OF PLUG CAP
(1) Install a new O-ring to the groove of front case.
(2) Using the special tool, install the plug cap and tighten tospecified torque.

9-126ENGINE <2.0L DOHC Engine>- Front Case, Oil Pump and Silent Shaft
6EN0213
w Crank pulley side
Oil pan
from lower side
‘- Apply sealant7LUOOO0
6LUOO49 tBracket side
-----Be
\Apply oil9. INSTALLATION OF OIL PAN
(1) Clean both mating surfaces of oil pan and cylinder
+
block.
(2) Apply a 4 mm (.I 6 in.) wide bead of sealant to the entirecircumference of the oil pan flange.
Specified sealant:
MITSUBISHI GENUINE PART No.
MD9971 10 or
equivalent
(3) The oil pan should be installed in 15 minutes after the
application of sealant.
(4) Note the difference in bolt lengths at the location
shown.8. INSTALLATION OF OIL PRESSURE SWITCH
(1) Coat sealant on the thread area, and using the special
tool, install the pressure switch.
Specified sealant: MOPAR Part No.4318034
orequivalent
Caution
1. Do not let sealant ooze out of the top of the
thread area.
2. Do not overtighten the pressure switch.
(2) Install the oil pressure switch terminals.
5. INSTALLATION OF OIL COOLER
First insert the oil cooler projecting stopper in the oil filter
bracket groove and then tighten the oil cooler bolts.lu3. INSTALLATION OF OIL FILTER
Wipe clean the mounting surface on the filter bracket.
Then, apply a thin coat of engine oil to filter O-ring and
tighten the oil filter by hand.
Caution
-.Never use a wrench to tighten the oil filter.
-i
16LUO26

ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod
PISTON AND CONNECTINGRODNonlE-8
cIISASSEMBLY AND REASSEMBLY
6
disassembly steps1. Nut
+e l +2. Connecting rod cap
3. Connecting rod bearing
e+ 4. Piston and connecting rod assembly5. Connecting rod bearing
6. Bolt+e ~~ 7. Piston ring No. 1+e ++ 8. Piston ring No.2
l * 9. Oil ring10. Piston pin11. Piston12. Connecting rod
f86 50-53 Nm36-36 ftlbs.6EN0216
NOTE(1) Reverse the disassembly procedures to reassemble(2) l e : Refer to “Service Points of Disassembly”.(3) +4 : Refer to “Service Points of Reassembly”.

9-128ENGINE <2.0L DOHC Enaine> - Piston and Connectina Rod
DEN050
6EN185
95EN057
Piston ringring gap6EN037
JSERVICE POINTS OF DISASSEMBLY
NOSTFAC2. REMOVAL OF CONNECTING ROD CAP
Mark the large end of the connecting rod with the cylinder
number for use during reassembly.
7. REMOVAL OF NO. 1 PISTON RING
/8. NO.2 PISTON
RINGRemove the piston rings with a piston expander.
INSPECTION
PISTONNO@lCAFReplace the piston if scratches or seizure is evident on its
surfaces (especially the thrust surface). Replace the piston if it
is cracked.PISTON PIN
(1) Insert the piston pin into the piston pin hole with a thumb.
You should feel a slight resistance. Replace the piston pin ifit can be easily inserted or there is an excessive play.
(2) The piston and piston pin must be replaced as an assembly.PISTON RING
NOSTCBF
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check the clearance between the piston ring and ring
groove. If the limit is exceeded, replace the ring or piston,
or both.
Standard value: 0.03-0.07 mm
(.0012-.0028 in.)
Limit: 0.1 mm
(.004 in.)
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring, to
correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston ring.
Standard value:
No. 10.25-0.40 mm (.0098-.0157 in.)
No.20.20-0.35 mm (.0079-.0138 in.)
Oil0.20-0.70 mm (.0079-.0276 in.)
Limit:
No. 1,
No.20.8 mm (.031 in.)
Oil1.0 mm (.039 in.)

ENGINE <2.0L DOHC Engine> - Piston and Connecting Rodgi’1.29
L
6EN377Side rail gap
I
1 EN062ICONNECTING ROD BEARING
NWTCDD(1) Visually check the bearing surface for uneven contact,
streaks, scratches, and seizure. Replace if defects are
evident. If streaks and seizure are excessive, check also the
crankshaft. If damage is present on the crankshaft, replacecrankshaft or regrind to undersize for reuse.
(2) Measure the connecting rod bearing I.D. and crankshaft pin
O.D. if the oil clearance exceeds the limit, replace bearing,
and crankshaft if necessary. Or, regrind the crankshaft to anundersize and replace bearing with an undersize one.
Standard value:
0.02-0.05 mm (.0008-JO20 in.)
Limit: 0.1 mm
(.004 in.)
NOTEFor oil clearance measuring method using the plastic
gauge, refer to the section CRANKSHAFT.
SERVICE POINTS OF REASSEMBLYNO9TGACa9. INSTALLATION OF OIL RING
(1) Fit the oil ring spacer
into’the piston ring groove.
NOTEThe side rails and spacer may be installed in either
direction.(2) Install the upper side rail.
To install the side rail, first fit one end of the rail into thepiston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to expand the side rail end gap canbreak the side rail, unlike other piston rings.
NOTEDo not use piston ring expander when installing side
rail.(3) Install the lower side rail in the same procedure as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.

9-130ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod
8. INSTALLATION OF PISTON RING
NO.217. PISTON
RING
NO.1
\ ’7EN250
Non-TurboTurbo
Upper
LCsiae rail
6
3wer’ ‘I
EN041
No.2 ring gap
and spacer gap
der
No.
Notch
DEN057Using a piston ring expander, fit the
No.2 and then No. 1 n*tpiston ring into position.
NOTE
1.Note the difference in shape between No. 1 and No. 2
piston rings.
2.Install piston rings No. 1 and No. 2 with their side havingmarks facing up (on the piston crown side).
4. INSTALLATION OF PISTON AND CONNECTING ROD(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
Aspacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of
cylinder bore.
(4) Use suitable thread protectors on connecting rod boltstiefore 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
(aryow) on the top of the
piston so it faces the erigine front (timing belt side).
2. INSTALLATION OF CONNECTING ROD CAP(1) Mate the correct bearing cap with the correct connect-
ing rod by checking with the alignment marks marked
during disassembly. If a new connecting rod is used
which has no alignment mark, position the notches for
locking the bearing on the same side.
I;r.

ENGINE <2.0L DOHC Engine> - Piston and Connecting Rod9-131(2) Check if the thrust clearance in the connecting rod big
end is correct.
Standard value:
0.10-0.25 mm (.0040-.0098 in.)
Limit: 0.4 mm
(.0157in.)

g-132 ENGINE <2.0L DOHC ‘Engine>- Crankshaft, Flywheel and Drive Plate
CRANKSHAFT, FLYWHEEL AND DRIVE PLATEDISASSEMBLY AND REASSEMBLY
NOBUE-B
1
lo-12 Nm5
7-9 ft.lbs.I
FORWARDIO-12
N/m7-9 ft.lbs.
130-140 Nm94-101 ft.lbs.
I47-51
ftlbs.
130-140 Nm‘94-101 ft.lbs.
6ENO227
Disassembly steps
1. Flywheel (Manual transaxle)
2. Adapter plate3. Drive plateAutomatic
4. Crankshaft bushingtransaxle
5. Rear plate6. Bell housing cover
7. Oil seal case8. Gasket
l + 9. Oil separatorl a 10. Oil seall + 11. Bearing cap
l + 12. Lower bearing
13. Crankshaftl + 14. Upper bearing
NOTE(1) Reverse the disassembly procedures to reassemble.(2) e+ : Refer to “Service Points of Reassembly”.(3) 0 : Non-reusable parts

ENGINE <2.0L DOHC Engine>- Crankshaft, Flywheel and Drive Plate,91133
INSPECTIONNOSUHAD
CRANKSHAFT(1) Check the crankshaft journals and pins for streaks and
seizure. Replace if necessary.
6EN0’228
\3EN056
Plastic
6EN043
. .
I1 EN067-(2) Measure the journal O.D. and main bearing I.D. to obtain
the clearance between the two (oil clearance). If the
clearance exceeds the limit, replace the main bearing and,if necessary, the crankshaft.
Standard value:
0.02-0.05 mm (.OOOS-.0020 in.)
Limit: 0.1 mm
(.0040 in.)
Caution
A special
surface treatment has been applied to
crankshaft. Do not machine it to undersize.
CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The crankshaft oil clearance can be measured easily by using aplastic gauge, as follows:
(1) Remove oil and grease and any other foreign matters from
crankshaft journal and bearing inner surface.
(2) Install the crankshaft.
(3) Cut the plastic gauge to the same length as the width of
bearing and place it on journal in parallel with its axis.
(4) Gently place the crankshaft bearing cap over it and tighten
the bolts to the specified torque.
(5) Remove the bolts and gently remove the crankshaft
bearing cap.(6) Measure the width of the smashed plastic gauge at its
widest section by using a scale printed on the plastic gauge
bag.