MITSUBISHI SPYDER 1990 Service Repair Manual

ENGINE Timing
TIMING BELT
REMOVAL AND INSTALLATION
(Engine oil) Nm
Removal steps1. Timing belt (Refer to
2. Crankshaft sprocket 3. Crankshaft sensing blade l Timing belt tension adjustment
4. Timing belt tensioner 5. Timing belt
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REMOVAL SERVICE POINTS
CRANKSHAFT SPROCKET
(1) Use thespecial tool to remove the bolt,
(2) Use the special tool to remove the crankshaft
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ENGINE Timing Belt
CounterbalanceBelt tension side
Timingmarks
Belt tension side tension side
installation bolt
BELT REMOVAL
Caution
If timing belt is ‘to be use chalk to
it with an arrow on its flat side indicating the tu rning
direction (to the right).
INSTALLATION SERVICE POINTS
BELT INSTALLATION
Install’ timing belt “B” by the following procedure .
(1) Ensure that crankshaft sprocket “B” timing mark and the
counterbalance shaft sprocket timing mark are align ed.
(2) Fit timing belt “B” over crankshaft sprocket
and the
silent shaft sprocket. Ensure that there is no slac k in
the belt.
BELT TENSION ADJUSTMENT
Adjust the tension of timing belt by the following procedure.
(1) Temporarily fix the timing belt “B” tensioner s uch that
the center of the tensioner pulley is to the left and above
the center of the installation bolt, and temporarily attach
the tensioner pulley so that the flange the front
of the engine.
Holding the timing belt “B” tensioner your finger
in the direction arrow, place the
belt so that the tension side of the taut. Now tighten
the bolt to fix the tensioner.
Caution
When tightening the bolt, ‘the tensioner
pulley shaft does not rotate
“bolt.
it to rotate with the bolt can cause excessive
on the belt.
(3) Press the belt at the shown point by a finger ‘ to check
belt tension. If not, adjust.
__Standard value: 5-7 mm In.)

ENGINE Timing Belt
CRANKSHAFT SENSING BLADE INSTALLATION
When installing, make sure the direction is correct. See figure.
CRANKSHAFT SPROCKET INSTALLATION
Use the special tool to install the crankshaft spro cket and
bolt.
NOTE
Apply the minimum amount of engine oil to the beari ng surface
and thread of the crankshaft bolt.
Revision

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NOTES

CONTENTS
BRACKET65
CRANKSHAFT, FLYWHEEL ANDDRIVE PLATE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
CYLINDER HEAD AND VALVES . . . . . . . . . . . 36
EXHAUST MANIFOLD AND
WATER PUMP. . . . . . . * . . . . . . . . . . . . . . . . . . . .29
FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN . . . . . . . . . . . . . . . . . . . . . 42
FUEL AND EMISSION CONTROL
PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
GENERAL INFORMATION. . . . . . . . . . . . . . . . . .2
General Specifications . . . . . . . . . . . . . . . . . . , . . . . .2
GENERATOR IGNITION SYSTEM. . . . .11
INTAKE MANIFOLD. . . . . . . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD..
. . . . . . . .51
ROCKER ARMS AND CAMSHAFT. . . . . . . .
SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . . . . . . .8
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . .3
Rework Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . .4
Sealant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ..
Service Specifications. . . . . . . . . . . . . . . . . . . ....3
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TIMING BELT
. . . . . . . . . . . . . . . . . .. . . . . . . . .
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ENGINE OVERHAUL General Information
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions
Number of cylinders
Combustion chamber
Total displacement
. . .Specifications
“in-line DOHC
4
type
1,997 (121.9)
Cylinder bore mm (in.)
Piston stroke mm (in.)
(3.35)
88.0 (3.46)
Compression ratio 8.5
Valve, timingIntake valve
Opens (BTDC)2 1 ”
Exhaust valve Closes (ABDC)
51
Opens (BBDC)
57”
‘Closes (ATDC)
Lubrication system Pressure feed, full-flow filtrationI
Oil pump type
Cooling system
Water pump type EGR type
I
Involute gear type
Water-cooled . .
Centrifugal impeller type
Single type,
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Injector type and number
Injector identification number
Fuel regulated pressure
(psi)
4
,
(42.7) .
Throttle bore mm (in.)
Throttle position sensor Closed throttle position switch 54 (2.13)
Variable resistor type
Contact type

ENGINE OVERHAUL ‘Specifications
SPECIFICATIONS
SERVICE SPECIFICATIONS
Rocker arms and camshaft
cam height mm (in.)
Camshaft journal O.D. mm (in.)
Cylinder head and valve
Standard valueLimit
Intake 34.91 (1.37) 34.41
Exhaust 34.91 (1.37) 34.41
25.96 (1.02)
Cylinder head flatness of gasket surface mm (in.) Le ss than 0.05 0.2
Cylinder head grinding limit of gasket surface mm (in.)l 9.2
*Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm (in.) 131.9-132.1
Cylinder head bolt shank length mm (in.) Max. (3.91)
Valve thickness of valve head (margin) mm (in.) Intake
16 . 8
Exhaust1.5 0.8
Valve overall height mm (in.)Intake109.50 (4.3110) (4.2913)
Exhaust 199.70 (4.3189)
.
Valve thickness to valve guide clearance mmIntake0.10
(in.)Exhaust0.15
Valve face angle mm (in.),
Valve spring free length mm (in.) 47.0 (1.85) 46.0 (1
.83)
Valve spring load/installed height N/mm
Valve spring out of squarenessMax. 1.5”4”
Valve seat valve contact width mm (in.)
Valve guide I.D. mm (in.) 6.6
Valve guide mm (in.)12.1
Valve guide projection from cylinder head upper sur
face mm (in.)19.5
Valve stem projection mm (in.) Intake 49.20 (1.9370)4 9 . 8 0 .
Exhaust48.40 (1.9055) ‘ 4 8 . 9 0
Front case, oilpump and oilp a n
pump side clearance Drive gear
Driven gear
cooler by-pass valve dimension (L) [Normal tempera
ture]34.5 (1.36)
cooler by-pass hole closing temperature 40 (1.57) or more
97 to (207 to or more]
pressure at curb idle speed (psi)80 (11.4) or more
Oil temperature is 75 to (167 to
and connecting rod ,
O.D. mm (in.)
84.98 (3.334)
ring side clearance mm (in.) 0 . 1
0 . 1
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ENGINE OVERHAUL
Items Standard value
Piston ring end gap mm (in.)
Piston pin O.D. mm (in.)
0 . 8
Oil 9 . 8
21
Piston pin press-in load (Ibs.)
[Room temperature]
Crankshaft pin oil clearance mm (in.) 17,500
Connecting rod big end side clearance mm (in.)
Crankshaft, flywheel and drive plate
Bearing cap bolt shank length mm (in.)
0 . 4
Crankshaft end play mm (in.)
Crankshaft journal O.D. mm (in.) 0 . 2 5
57 (2.24)
pin O.D. mm (in.) 42 (1.77)
Crankshaft journal oil clearance mm (in.)
to cylinder clearance mm (in.)
0 . 1
block flatness of gasket surface mm (in.) 0.05 0.1
block grinding limit of gasket surface mm (in.)l 0.2‘Total resurfacing depth of both cylinder head and cylinder block
block overall height mm (in.)283.9-284.1
(11.177-11.185)
block I.D. mm (in.) 85.0 (3.35)
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REWORK DIMENSIONS
Items
Cylinder head and valve
Oversize rework dimensions of valve guide0.05 O.S.
hole (both intake and exhaust) mm (in.) 0.25 O.S.
0.50
Intake oversize rework 0.3
dimensions of valve seat hole mm (in.)
0.6 O.S.
Exhaust oversize rework dimensions of valve 0.3 O.S.
seat hole
mm (in.)0.6 O.S.
Crankshaft, flywheel and drive plate
Crankshaft out of roundness and taper of journal an d pin mm (in.)
Standard value
12.25-12.27 ,
,
Max. 0.01
NOTE
O.D.: Outer diameter
I.D.: Inner diameter
Oversize diameter

ENGINE OVERHAUL
TORQUE SPECIFICATIONS
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Items
Generator and ignition system
W a t e r p u l l e y b o l tpump
Generator mounting bolt
Generator brace bolt
Generator pivot nut
Crankshaft pulley bolt
Spark plug
Ignition coil bolt
Center cover bolt Ignition power transistor bolt
Plate
Camshaft position sensor
Camshaft position sensor support
Camshaft position sensing cylinder
Timing belt
Crankshaft position sensor bolt
Tensioner pulley bolt
Tensioner arm bolt
Auto tensioner bolt Idler pulley bolt
Oil sprocket nutpump
Crankshaft bolt
Tensioner
bolt
Counterbalance shaft sprocket bolt
Camshaft sprocket bolt
Engine support bracket bolt
Fuel and emission parts
EGR valve bolt
Throttle body stay bolt
Throttle body bolt
Fuel pressure regulator bolt
Intake manifold
manifold bolt
ntake manifold nut ntake manifold stay bolt
ntake manifold plenum bolt and nut
ntake manifold plenum stay bolt
outlet fitting bolt
coolant temperature gauge unit
coolant temperature sensor
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N m
118”
23 17
2417
1410
25 18
25 18
1410
32
1410
107
97
14 10
2216
97
4935
22 16
24
‘17’
3827
5540
12087
1914
4633
9065
45 33
22 16
19 14
1914
97
2014
3626
2820
18
1813
1914
118
30 22

E N G I N E O V E R H A U L ,
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