MITSUBISHI SPYDER 1990 Service Repair Manual

ENGINE OVERHAUL Intake Manifold
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
2
(To oil cooler)
13 Nm
9
11 N m 8
20 Nm
14
31 N m
22
Removal steps
1.Water hose2. Water hose
3. Engine coolant temperature gaugeunit
4. Engine coolant temperature sensor5.Water inlet fitting6.Thermostat case
7. Water outlet fitting 8. Thermostat housing
9. Intake manifold stay
10. Engine hanger11.Intake manifold12.Gasket
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11ENGINE OVERHAUL
in.)diameterbead
diameter
bead sealant
SEALANT APPLICATION TO THERMOSTAT
HOUSING
Specified sealant:
Mitsubishi Genuine Part No. or equiva-
lent
NOTE
(1) Be sure to install the housing quickly while th e
sealant is wet (within 15 minutes).
(2) After installation, keep the sealed area away f rom
the oil and coolant for hour.
SEALANT APPLICATION TO WATER OUTLET
Specified sealant:
Mitsubishi Genuine Part No. or equiva-
lent
NOTE
(1) Be sure to install the housing quickly while the
is wet (within 15 minutes).
(2) After installation, keep the sealed area away f rom
the oil and coolant for approx. 1 hour.
SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
Specified sealant:
Nut Locking ‘Part No. 4171 or equivalent
SEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
Specified sealant: ATD Part No. 8660 or equivalent
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ENGINE OVERHAUL Exhaust Manifold
EXHAUST MANIFOLD AND WATER PUMP
REMOVAL AND INSTALLATION
11300490108
. .
10
Nm
120
2I
27
14 29
21
14 Nmin
Nm
I 7
I - Nm
13 Nm
‘ - 2 3
Nm
10
Nm32
Removal steps
1.Oil dipstick17.Water pipe 2.Oil dipstick guide18.Turbocharger3.O-ring19.Engine hanger4.Heat protector “A”20.Exhaust manifold5.Heat protector 21.Gasket6.Heated oxygen sensor22.Water hose7.Exhaust fitting23.Water pipe 8.Gasket24.Water pipe9.Oil pipe “A”25. Water hose10.Oil pipe 26.Water hose11.Oil return pipe27. Water hose12.Gasket28.Water hose13.Turbocharger assembly29. O-ring14.Gasket30.Water inlet pipe15.Ring31.Water pump16.Water pipe “A”32.Gasket
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ENGINE OVERHAUL Exhaust Manifold and
O-ring
Identificationhole
Exhaust
manifold
INSTALLATION SERVICE
WATER PIPE/O-RING
Wet the O-ring (with water) to facilitate assembly .
C a u t i o n
Keep the O-ring free of oil or grease.
TURBOCHARGER
(1) the cone disc spring in shown direction.
(2) Tighten the turbocharger mounting bolts and
to
27
31 Nm 22
(3) Use the special tool orsimilar tighten more.
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ENGINE OVERHAUL Rocker Arms and
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
2014
8,I!
Removal steps
1. Bearing cap rear 2. Bearing cap front 3. Camshaft oil seal4. BearingcapNo. 55.Bearingcap No. 26.BearingcapNo.4
7. cap No. 3 8. Camshaft9. Rocker arm 10. Lash adjuster
11. Oil delivery body
.
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ENGINE OVERHAUL Rocker, Arms
Camshaft sprocket side
sidecamshaft
Dowel pin
n0
Cap number
Symbol identifying
intake or exhaust
0
Camshaft sprocket side1197 810 12
2 6
I N S T A L L A T I O N S E R V I C E
L A S H A D J U S T E R
(1) the lash adjuster in clean diesel fuel.
(2) Using a special tool, move the plunger up and down
4 or 5 times while pushing down lightly on the chec k
ball in order to bleed out the air.
,
CAMSHAFT INSTALLATION
(1) Apply engine oil to journals and cams of the
(2) Install the camshafts on the cylinder head. Use care not to confuse the intake camshaft with th e
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
(3) Install the crankshaft sprocket
or spacer and flange
to an end of the crankshaft, and turn the until
the timing marks are lined up, setting No. cylinder to
the TDC.
(4)Place the camshafts so that their dowel pins are po sitioned
at top.
BEARING CAPS INSTALLATION
(1) According to the identification mark stamped on top of
each bearing cap,
the caps to the cylinder head.
Only
or is stamped on No. 1 bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing
No.
6 bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(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 ensure that the rocker arm is held in position
on the lash adjuster and valve. stem end.
.
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ENGINE OVERHAUL R o c k e r
OIL
INSTALLATION
SEAL PACKING
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11 ENGINE OVERHAUL Rocker
.
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Roller
Standard value mm (in.)Limit mm (in.)
Intake 34.91 (1.37) 34.41 (1.36)
Exhaust
34.91 (1.37)34.41
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not ro tate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
LASH ADJUSTER LEAK DOWN TEST
Caution
1. The lash adjuster is a precision part. Keep it f ree
from dust and other foreign matter.
2. Do not disassemble lash adjuster.
3. When
lash adjuster, use diesel fuel
(1) Immerse the lash adjuster in clean diesel fuel.
(2)While lightly pushing down inner steel ball using t he special
tool, move the plunger up and down four or five tim es
to bleed air. Use of the special tool helps facilitate the air bl eeding
of the rocker arm mounted type lash adjuster.
(3) Remove the special tool and press the plunger. If the
plunger is hard to be pushed in, the lash adjuster is normal.
If the plunger can be pushed in all the way readily, bleed
the lash adjuster again and test again. If the plun ger
is still loose, replace the lash adjuster.
Caution
Upon completion of air bleeding, hold lash adjuster
upright to prevent inside diesel fuel from
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ENGINE OVERHAUL Rocker Arms and
(4) After air bleeding, place lash adjuster on the
(Leak down tester).
(5) After plunger has down
measure time taken for it to go down 1mm. Replace
if measured time is out of specification.
Standard
seconds mm in.)
[Diesel fuel at
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11E N G I N E O V E R H A U L
CYLINDER HEAD AND VALVES11300690201
REMOVAL AND INSTALLATION
Removal steps1. Cylinder head bolt
head assembly
Retainer lock
5. Valve spring retainer
6. Valve spring
7. Intake valve 8. Retainer lock
9. Valve spring retainer
10. Valve spring
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11.Exhaust valve
12. Valve stem seal 13. Valve spring seat
14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20.Cylinderhead