belt MITSUBISHI ECLIPSE 1991 Repair Manual

9-106ENGINE <2.0L DOHC Engine> - Timing Belt. ADJUSTMENT OF TIMING BELT TENSION
(1) After turning the crankshaft
l/4 turn counterclockwise,.5;;turn it clockwise to move the No. 1 cylinder to top dead
center.(2) Loosen the center bolt, and then, as shown in the
illustration, attach the special tool and a torque wrench
and apply a torque of 2.6-2.8 Nm
(1.88-2.03 ft.lbs.).If the body interferes with the special tool and the
torque wrench, use a jack to slightly raise the engine
assembly.
NOTEUse a torque wrench that is capable of measurement
within a range of
O-3 Nm (O-2.2 ft.lbs.).(3) Holding the tensioner pulley with the special tool and
torque wrench, tighten the center bolt to specification.
(4) Screw the special tool into the engine left support
bracket until its end makes contact with the tensioner
arm. At that point, screw the special tool in some more
and then remove the set wire attached to the auto
tensioner.(5) Remove the special tool.
(6) Rotate the crankshaft two complete turns clockwise
and leave it as is for about 15 minutes. Then, measure
the auto tensioner protrusion “A” (distance between
the tensioner arm and auto tensioner body) to ensure,.+
that it is up to specification.
Standard value:
3.8-4.5 mm (.15-.18 in.)
If it is out of specification, repeat steps (6) through (1)
until the specified value is obtained.
(7) If the clearance between the tensioner arm and the
auto tensioner body cannot be measured (when the
engine is being mounted, etc.), the following proce-
dures can be used to substitute for the ordinan/ methodof measurement.
@ Screw in the special tool until it contacts the
tensioner arm.
@ From that point of contact, further screw in the
special tool, screwing it in until the push rod of the
auto tensioner body is caused to move backward
and the tensioner arm contacts the auto tensioner
body.Check to be sure that the amount that the special
tool has been screwed in (when the push rod
moves backward) is the standard value.
Standard value: 2.5-3 turns

ENGINE <2.0L DOHC Engine> - Timing Belt9-107Apply sealant
Cylinder head
3EN004410 mm10 mm
(.4 in.)(.4 in.)
(8) Install the rubber plug to the timing belt rear cover.
19. APPLICATION OF SEALANT ON SEMI-CIRCULAR
PACKING
Apply sealant on the periphery of the semi-circular packing.Specified sealant: MOPAR Part No.4318034 or equiva-
lent
18. APPLICATION OF SEALANT ON ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Specified sealant: MOPAR Part No.4318034 or equiva-
lent
APPLYsealant
6EN0286

9-l 08ENGINE <2.0L DOHC Engine> - Timing Belt
.hread diameter
\: 6 x 16(24 x .63)OlAOO45I: 6 x 18 (.24x .70)‘. 6 x 25 (.24 x .98);. 6x28 (.24~1.10) mm (in,)13. INSTALLATION OF TIMING BELT LOWER COVER/
12. TIMING BELT UPPER COVER
F-sThe dimensions of the installation bolts for the timing
covers differ according to the installation location, so be
sure not to install the bolts in the incorrect locations.
8. TENSION ADJUSTMENT OF THE AIR CONDITIONER
COMPRESSOR DRIVE BELT
Refer to GROUP
24-Service Adjustment Procedures.
6. DEFLECTION ADJUSTMENT OF POWER
STEERING OIL .++PUMP DRIVE BELT
Refer to GROUP 1
g-Service Adjustment Procedures.
5.TENSION ADJUSTMENT OF THE ALTERNATOR DRIVE
BELTRefer to GROUP
7-Maintenance Service.

9-110ENGINE <2.0L DOHC Engine> - Camshaft and Rocker Arm
I
I6EN0183
I6EN0184
I
I6EN0185
,I
+Front of engine (Timing belt side)
WIB’ S’it
’ Intake side
camshaft
6E NO289Cap number
Symbolidentifying
intake or
exhaust6EN6464
I
INSPECTIONCAMSHAFT
h(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:
Intake

35493mm (1.3974 in.)
35.200mm (1.3858 in.)
Exhaust 35.200mm (1.3858 in.)
35.493mm (1.3974 in.)
Limit:
Intake
34.993mm (1.3777 in.)
34.700mm (1.3661 in.)
Exhaust 34.700mm (1.3661 in.)
/“435.993mm (1.3777 in.)
ROCKER ARM
(1) Visually check the roller and replace if dent, damage, or
seizure is evident.
(2) Check the roller for smooth rotation. Replace if it binds or
there is an excessive play.
(3) Check the valve contact surface for possible damage or
seizure and replace as necessary.
SERVICE POINTS OF REASSEMBLYNOSLGAB10. INSTALLATION OF CAMSHAFT
(1) Apply engine oil to journals and cams of the camshafts.
(2) Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crank angle sensor.
(3) Make also sure that the dowel pins on the camshaft
sprocket end are located on the top.
9./8./7./6./4./3. INSTALLATION OF BEARING CAPS
(1) Bearing cap Nos.2 to 5 are of the same shape. At
installation, check with the markings on the caps of capnumber and intake/exhaust identification symbol. Only
“I” or “E” is stamped on No. 1 bearing cap.4I
: For Intake camshaft side
E: For Exhaust camshaft side,

ENGINE <2.0L DOHC Engine> - Camshaft and Rocker Arm9-111_ Front of engine (Timing belt side)
0 Co@
6EN0192
MD998306Oil seal
-
Y-II6ENI01946EN030’
1(2) Tighten the bearing caps in the order shown two to
three times by torquing progressively.
Tighten to specification in the final sequence.
(3) Check to be sure that the rocker arm is correctly placedon the lash adjuster and valve stem end.
5. INSTALLATION OF CAMSHAFT OIL SEAL
(1) Install the special tool, Guide, on the camshaft.
(2) Apply oil to the oil seal and insert the seal along the
Guide until it contacts the cylinder head.
(3) Using the special tool, Installer, press-fit the oil seal intothe cylinder head.
2. INSTALLATION OF CAMSHAFT SPROCKET
Using a wrench hold the camshaft at its hexagon (betweenthe
No.2 and No.3 journals) and tighten the bolt to
specification.Caution
Locking the camshaft sprocket with a tool damages the
sprocket.1. INSTALLATION OF CRANK ANGLE SENSOR
(1) Locate the dowel pin on the sprocket side of the intake
camshaft at top.
(2) Align the punch mark on the crank angle sensor housingwith the notch in plate.
NOTE
The crank angle sensor can be installed even when thepunch mark is positioned opposite the notch; however,
the position results in incorrect fuel injection and
ignition timings.
(3) Install the crank angle sensor on the cylinder head.

ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve9-l 13
.
.
a Front of engine (Timing belt side)
6EN0211
SERVICE POINTS OF DISASSEMBLYNOBPFAti1. REMOVAL OF CYLINDER HEAD BOLTS
(1)Using the special tool, remove the cylinder head bolts insequence shown in figure.
(2) Loosen the cylinder head bolts in the order shown.
Loosen bolts evenly little by little, taking several steps.
8. REMOVAL OF INTAKE
VALVE/12. EXHAUST VALVE
(1) Using the valve spring compressor, compress the
spring and remove the retainer lock.
(2) Remove the spring retainer, valve spring, spring seat,
and valve.
(3) Keep removed parts in order according to the cylinder
number and intake/exhaust.13./15. REMOVAL OF VALVE STEM SEALS
To remove the valve stem seal, use pliers.
Caution
Do not reuse the stem seals.
INSPECTIONCYLINDER HEAD
(1) Before cleaning the cylinder head, be sure to check for
possible coolant or gas leak, damage, and cracks.
(2) Completely remove oil, scale, sealant, and carbon deposits.After the oil passages have been flushed, blow air into the
passages to ensure that they are not plugged.

9416
I
ENGINE <2.0L DOHC Engine> - Cylinder Head and Valve
I1. INSTALLATION OF CYLINDER HEAD BOLTS
(1) Using the special tool, tighten the cylinder head bolts.
G Front of engine (Timing belt side)(2) Tighten the cylinder head bolts in the sequence shown.
Each bolt should be tightened in two to three steps,
torquing progressively. Tighten to specified torque in
the final sequence.

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> -Crankshaft, Flywheel and Drive Plate g-135
‘I. _
Front ofengine
(Timing
belt side)
BEN02
DEN063
6ENO48-
11. INSTALLATION OF BEARING CAP
(1) Verify the correct identification mark and the directionof the arrow for installation.
(2) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct. Ifthe end play exceeds the limit, replace crankshaft
bearings.Standard value:
0.05-0.18 mm (.0020-.0071 in.)
Limit: 0.25 mm
(.0098 in.)
10. INSTALLATION OF OIL SEALUsing the special tool, press-fit the oil seal into the
crankshaft rear oil case. Use a new oil seal.9. INSTALLATION OF OIL SEPARATOR
Force the oil separator into the oil seal case so that the oilhole in the separator is directed downward (arrow in
illustration).

STEERING
CONTENTSNISAA-
MANUAL STEERINGGEAR BOX.................21
POWER STEERINGGEAR BOX...................
28
POWER STEERING
HOSES........................
46
POWER STEERING OIL PUMP....................39
SERVICE ADJUSTMENT PROCEDURES >...........................7
Steering Angle Check..............................7
Steering Wheel Centering.........................8
Steering Wheel Free Play Check.............:..7Tie Rod End Ball Joint Starting Torque
Check..................................................8Tie Rod End Ball Joint Variation Check
(Shaft direction).....................................7
SERVICE ADJUSTMENT PROCEDURES
< POWER STEERING >.............................
10
Bleeding...............................................13Fluid Level Check...................................
12
Fluid Replacement..................................12
i;,
Oil Pressure Switch Check........................15
Oil Pump Pressure Test...........................14
Stationary Steering Effort Check.................11Steering Angle Check..............................
10
Steering Wheel Centering.........................1 1
Steering Wheel Free Play Check................10Steering Wheel Return to Center Check.......
11Tie Rod End Ball Joint Starting Torque
Check..................................................10Tie Rod End Bail Joint Variation Check
(Shaft direction).....................................10
V-Belt Tension Check..............................12
SPECIAL TOOLS......................................6
SPECIFICATIONS.....................................2;
General Specifications..............................2
Lubricants.............................................5
Sealants and Adhesives............................5
Service Specifications.............‘................2
Torque Specifications,. . . . . . . . . . . . . . . . . ..*..........3
STEERING WHEEL AND SHAFT.................. 16