light MITSUBISHI SPYDER 1990 Service User Guide

E N G I N E
(3) Install the timing belt so as not to be’
the sprockets, by the
Cautidn ,
If the timing belt is to be it that
the mark indicates the
,
1)Install the timing belt around the intake side cams haft
sprocket and fix it at indicated position by a bulldog
clip.
2)Install the timing belt around exhaust
et, aligning the timing marks with the cylinder hea d’
top surface using two wrenches.
3)Fix the belt at indicated position by another ‘bull dog
clip.
4)
Install the timing belt around the the oil
pump sprocket, the crankshaft, and the ten-
sioner pulleys in the order
5) Remove the two bulldog clips.
(4) Set the tension pulley so that the pin holes ar e
bottom, press the tension pulley lightly against the timing;
belt.
(5) Screw the tool into the engine left bracket until:
its end makes contact with the tensioner
point, screw the tool in some more then remove
the set wire attached to the auto tensioner:
(6) Remove the tool.
(7) Tighten the center bolt to the
torque.
Specified torque: 48 Nm (35
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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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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
11300850104
(1) Replace piston ii or seizure is evident
its surfaces (especially surface). Replace the
piston if it is cracked.
PISTON PIN
(1) the piston pin the pin hole a
You should feel a slight resistance. the
pin if it can be easily inserted or there ‘is .
(2) The piston and piston pin must be replaced
bly.
PISTON RING
(1) Check ‘the ring for
and replace if defects are evident: piston
has been replaced with a
one, the piston
also be replaced with new ones.
(2) Check for the clearance
the piston ring and
ring groove. If the limit is exceeded, replace the
or piston, or both.
Item
No. 1 ring
ring
Limit: 0.1 mm
in.)
-Standard value mm (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 ri ng.
Standard value mm (in.)
No. 1 ring
ring
ring
Limit:No. 1, No. 2 ring 0.8 mm in.)
Oil ring 1.0 mm in.)
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ENGINE On-vehicle Service
POWER STEERING OIL PUMP AND A/C
DRIVE BELT TENSION ADJUSTMENTTensionpulley nut1. Loosen the tension pulley nut.
Tension pulley2.. Adjust the belt deflection amount using the adj usting bolt.
Standard value:
Adjusting boltItems
Tension
(Ibs.)
Deflection
mm (in.) When a new belt is When a used belt is
installed
installed(136.7-158.7).( 9 2 . 6 - 1 1 4 . 6 )
3. Tighten the tension pulley nut.
Caution
Fix the power steering oil pump position
to the vehicle front.
IGNITION TIMING CHECK11100170044
It is not necessary to check ignition timing using a timing
light, because the crankshaft position is detected directly and
ignition timing is controlled electronically.
CURB IDLE SPEED CHECK
1. Before inspection and adjustment set vehicles in the
following condition.
lEngine coolant temperature:
lLight, electric cooling fan and all accessories: OF F
l Transaxle: Neutral (P range on vehicles with
2. Connect the scan tool to the data link connector .
3. Start the engine and run it at idle.
4. Run the engine at idle for 2 minutes.
5. Check the curb idle speed.
Standard value: 800
100
NOTE
The idle speed is controlled automatically by the i dle air
c o n t r o l s y s t e m . If the idle speed is outside the standard value, in spect
the
components by referring to GROUP
Troubleshooting.
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ENGINE On-vehicle Service
IDLE MIXTURE CHECK
11100210081
1.Before inspection, set vehicles in the following co ndition:
lEngine coolant temperature:
l Lights, electric cooling fan and all accessories: O FF
lTransaxle: Neutral (P range on vehicles with
2.After turning the ignition switch to OFF, connect t he scan
tool to the data link connector.
3.Start the engine and run it at 2,500 for 2 minutes.
4. Set the CO, HC tester.
5. Check the CO contents and the HC contents at idl e.
Standard value:
CO contents: 0.5% or less
HC contents: 100 ppm or less
6. If the idle speed is outside the standard value, check
the following items: l Diagnostic output
l Closed-loop control (When the closed-loop control
is carried out normally, the output signal of the h eated
oxygen sensor repeats between and
,000 at idle.)
l Fuel pressure
I n j e c t o r
lIgnition coil, spark plug cable, spark plug
lEGR system and the EGR valve leak
l Evaporative emission control system
Compression pressure
NOTE
Replace the three-way catalyst whenever the CO and
HC contents do not remain inside the standard value .
(even though the result of the inspection is normal on
all items.)
COMPRESSION PRESSURE CHECK
1.Before inspection, check that the engine oil, start er and
battery are normal. Also, set the vehicle to the fo llowing
condition:
lEngine coolant temperature:
lLights, electric cooling fan and all accessories: O FF
lTransaxle: Neutral (P range on vehicle with
2. Disconnect the spark plug cables.
3. Remove all spark plugs.
4.Disconnect the relay (ASD relay) connector to prevent
a spark.
4 4
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ENGINE On-vehicle.’
M A N I F O L D V A C U U M
1.Before inspection, set vehicles. in the condition:
Engine coolant
lLights, electric cooling and
lTransaxle: Neutral (P
2. Connect the scan tool to the data link connector.
,
3. Attach a three-way joint to the vacuum
the fuel pressure regulator and the intake manifold, and
connect a vacuum gauge.
4.Start the engine and check that idle speed is withi n specifi-
cation.
Standard value: 800 100
5. Check the manifold vacuum.
Limit: min. 60
(18
LASH CHECK
A tappet-like may be produced from several items.
Check the following items. 1. Engine oil level too high or too low.
This may cause, aerated oil to enter, the adjusters and
cause them to be spongy.
2.Insufficient running time after rebuilding the cyli nder head.
Low speed running up to 1 hour may be required.
3. Low oil pressure.
4. The oil restrictor pressed in to the vertical oi l passage
to the cylinder head is plugged with debris.
5.Air ingested in to oil due to broken or cracked oil pump
pick up.
6. Worn valve guide.
7. Faulty hydraulic lash adjuster. (1) Check for sponginess while still installed in e ngine.
Depress part of the cam follower just over the adju ster.
Normal adjusters should be free and very firm.
Spongy adjusters can be depressed to the bottomed
position easily.
(2) Remove a suspected hydraulic lash adjuster asse m-
bly.
(3) Clean out dirt and varnish with solvent.
(4) Reassemble with engine oil.
(5) Check for sponginess.
(6) If still spongy, replace
new adjuster
assembly. .
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ENGINE OVERHAUL
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place gaskets are used on the engine. Care must be
when applying form-in-place gaskets to assure obtaining the desired results. size, continuity, ‘and
location are of great importance. Too thin a bead can result in leakage
too much can result’ in
spill-over which can break off and obstruct fluid f eed lines.
A continuous bead of the proper width
essential to obtain a leak-free joint.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be d isassembled without unusual effort’
it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between
the mating surfaces.A flat gasket scraper may also be lightly tapped in to the joint but care be
taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasketsurfaces removing all loose material. Inspect
assure gasket rails are flat.
Flatten rails with a hammer on a flat plate if
must be free of oil and dirt. Make sure old gasket material is removed from blind
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Gasket material should be applied sparingly 1 mm
inch.) diameter or less to one
surface, Be certain the material surrounds each mou nting hole.
Excess material can easily be
‘off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommen ded
during assembly, to prevent smearing the material off location.
Loctite 18718 gasket material or equivalent should be applied in a continuous bead
3
mm
inch.) in diameter. All mounting holes must be circled.
For corner sealing, 3.17 or 6.35
mm
or inch.) drop is placed in the center of the gasket contact area. Uncured may
be removed with a shop towels. Components should be torqued in place while the sea lant
wet
to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to
prevent smearing of material off location.
MOPAR TORQUE CURE GASKET MAKER
Mopar torque cure gasket maker is a unique anaerobi c type gasket material to be used ONLY
the and engine block. The material cures in the absenc e of air when. two
metallic surfaces. It will not cure if left in the uncovered tube. This anaerobic material
specially made
to seal the area between the
and cylinder block without disturbing the bearing’ or
alignment of these components.. .
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11 ENGINE OVERHAUL Cooling System
(1) Install switch.
(2) Install engine coolant
lighten sensor
to 7 Nm (5
torque.
Overflownipple
Pressure cap
Impeller
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O-ring
(3) Place a new gasket (dipped in clean water) on water
box surface, center thermostat in water
gasket.
Place housing over gasket and thermostat; making su re
thermostat is in the thermostat housing. Bolt housing
to water box. Tighten bolts to 22 Nm
(4) Install O-ring.
(5) Install water pipe.
(6) Install water hose.
( 7 ) I n s t a l l e x h a u s t m a n i f o l d c o v e r :
(8) Install oil level gauge.
(9) Install new O-ring gasket in water pump body O- ring
groove.
Caution
Make sure O-ring is properly seated in water pump
groove before tightening screws. An improperly
located O-ring may cause damage to the O-ring and
cause a coolant leak.
pump body to block and tighten screws to 12
Nm (9
(ll)Rotate pump by hand to check for freedom of mov ement.
INSPECTION
Replace water pump body assembly if it has any of these
defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by c oolant
traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the engine bl ock.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.

ENGINE, OVERHAUL Fuel and Emission Control,,
INSTALLATION
(1) Apply a light coating of clean engine,, oil to the upper
O-ring.
(2) Install injector in cup on fuel
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to ‘the -O-ring
on the nozzle end of each
Insert fuel injector nozzle into openings in manifold.
Seat the injectors in place. rail
screws.
(6) Connect fuel supply tube to fuel rail.
(7) Install throttle body and new gasket on intake manifold.
T i g h t e n m o u n t i n g b o l t s .
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Connect purge hose nipple on throttle body.
Loosely install EGR valve with a gasket. Install
new gasket between EGR tube and
(lO)Finger tighten EGR tube fasteners.
(ll)Tighten EGR valve mounting screws to 22
(16
EGR tube fasteners to 11 torque.
vacuum supply tube to solenoid.;