engine MITSUBISHI SPYDER 1990 Service Repair Manual

ENGINE OVERHAUL Rocker and Camshaft
Caution
Upon completion of air bleeding’
upright to prevent inside’ diesel
(4) After air bleeding, set lash adjuster on the special tool
(Leak down tester).
(5) After plunger has gone down somewhat
mm),
measure time taken for it to go down 1.
Replace
if measured time is out of
Standard value: seconds 1 mm in.)
[Diesel fuel at
TSB Revision

11ENGINE OVERHAUL Cylinder Head
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION2 - ,
10
Removal steps
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket 4. Retainer lock5. Valve spring
retainer 6. Valve spring7. Intake valve
8. Retainer lock 9. Valve springretainer 10. Valve spring ii. 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. Cylinder head
Revision

ENGINE OVERHAUL Cylinder Head . .
RETAINER LOCK INSTALLATION
valve spring, if excessively compressed, causes the
bottom end of retainer to be, in contact,
and
the stem seal. ,
Identification markI
I4
CYLINDER HEAD GASKET
I d e n t i f i c a t i o n m a r k :
HEAD INSTALLATION
(1) When installing the cylinder head bolts, check
that the’
shank length of each bolt meets the limit. If the
is’
exceeded, replace the bolt.
Limit: Max. 99.4 mm (3.91 in.)
(2) Apply engine oil to the threaded of bolts
to the washers.
(3) According to the tightening tighten the bolts
to the specified torque 78 (58 using the special
tool
654).
(4) Loosen bolts completely.
(5) Retighten the loosened bolts to 20 in’
the specified tightening sequence.
(6) Make a paint mark across each bolt head and cyl inder’
head.
(7) a turn to the bolts in the tightening,
sequence.
(8) Give another turn to the bolts and make sure that
the paint mark on the, head of each bolt. and that on
the
head are on same straight line.
Caution
1.If the bolt is turned less than
performance may not be expected.W h e n
tightening the bolt, to give
a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from. step (1).
TSB Revision

ENGINE OVERHAUL Cylinder Head and Valves
Removalinstallation
Press
A
Press
A
Push rod
Valve
guide Push rod
Valve
guide
(2) Rebore the valve seat hole in the a
selected oversize valve seat diameter.
Intake seat ring hole diameters’
0.3 mm in.)
0.6
mm (1.3622-1.3634 in.)
Exhaust seat ring hole
0.3 mm in.)
0.6 O.S.
mm in.)
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately
or cool the valve seat
in liquid nitrogen, to prevent the cylinder head bo re from
galling.
(4)Using a valve seat cutter, correct the valve seat t o the
specified width and angle.
See SEAT RECONDITIONINGPROCEDURE”.
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Using the push rod and a press, remove the valv e guide
toward cylinder head gasket surface.
(2) Rebore valve guide hole to the new oversize val ve guide
outside diameter.
Valve guide hole diameters
0.05
0.25 O.S.
mm
0.50
11.25-11.27 mm in.)
mm in.)
NOTE
Do not install a valve guide of the same size
(3) Using the special tool, press-fit the guide, working
from the cylinder head top surface.
(4) After installing valve guides, insert new valve s in them
to check for sliding condition.
(5) When valve guides have been, replaced, check fo r valve
contactand correct valve seats as
TSB Revision

Front Case, ENGINE OVERHAUL Shaft and
FRONT CASE, COUNTERBALANCE SHAFT AND OIL
REMOVAL AND INSTALLATION
q 27 during reassembly.
2417
107
23
q 24
I
16
I
I1914
24. .
17
Removal steps
1. Oil filter2.Drain plug 3. Drain plug gasket 4. Oil pan5.Oil screen
6. Oil screen gasket
7. P l u g8.O-ring 9. Flange bolt 10. Oil pressure switch11.Relief plug12.Gasket13.Relief spring14.Relief plunger15. Oil filter bracket
16. Oil filter bracket gasket 19
14
I
l b7
75
17. Oil pump cover 18. Oil pump driven gear 19. Oil drive gear 20. Crankshaft front oilseal
21. Oil pump oil seal 22. Counterbalance shaft oil seal 23. Front case
24. Front case gasket
25. Counterbalance shaft, left
26. Counterbalance shaft, right
27. Counterbalance shaft, front bearing 28. shaft, rear
29. shaft, rear bearing,
TSB Revision

Front Case, ENGINE OVERHAUL Shaft and
603
Rear
COUNTERBALANCE SHAFT REAR BEARING
REMOVAL
Using the special tool, remove the left counterbalance
shaft rear bearing from the cylinder block.
NOTE
When removing the left counterbalance shaft rear be aring,
install the special tool
in front of the
block.
INSTALLATION
R I G H T C O U N T E R B A L A N CE R E A R
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearin g.
(2) Using special tools, install right rear bearing . Make sure
that oil hole of bearing is aligned with oil hole o f cylinder
block.
LEFT COUNTERBALANCE REAR
BEARING INSTALLATION
(1) Install the special tool (GUIDE PLATE) tool to the
block.
(2) Apply engine oil to the rear bearing outer
and bearing hole in cylinder block.
(3) Using the special tool, install the rear bearing..
NOTE
The left rear bearing has no oil holes.
TSB Revision

Front Case,
ENGINE OVERHAUL Shaft and
Socket wrench
SHAFT
I N S T A L L A T I O N
Using special tools,
front bearing,
FRONT CASE
(1) Set the special tool on the front end of cranks haft and
apply a thin coat of engine oil to the outer circum ference
of the special tool to install the front case.
(2) Install the front case assembly new front
gasket and temporarily tighten, the flange bolts (o ther
than those for tightening the filter bracket).
SHAFT OIL SEAL
INSTALLATION
TSB Revision

11ENGINE OVERHAUL Shaft and
Front Case, Counterbalance
Socket
gnment
- -
OIL PUMP OIL SEAL INSTALLATION
FRONT OIL SEAL INSTALLATION
Using the special tool, install the crankshaft fron t oil
into the front case.
OIL PUMP DRIVEN GEAR PUMP
GEAR INSTALLATION
Apply engine oil to the gears and line up the
marks.
SEALANT APPLICATION TO OIL PRESSURE
S W I T C H
Coat the threads of switch with sealant and
using the special tool.
Specified sealant: ATD equivalent
Caution
1. Keep the end of threaded clear of sealant. ,
2. Avoid an .
F L A N G E B O L T I N S T A L L A T I O N
(1)
a Phillips screwdriver into a hole in the left sid e
of the cylinder block to lock the silent shaft.
TSB Revision

ENGINE OVERHAUL Shaft and Can
Case,
62
Crank pulley side
0
mm bolts
0
Oil pan viewed from lower side
(2) Secure the oil pump driven gear onto the left counterbal-
ance shaft by tightening the flange bolt to specified torque.
PLUG INSTALLATION
(1) Install a new O-ring to the of front case.
(2)Using the special tool, plug and tighten to speci-
fied torque.
OIL PAN INSTALLATION
(1) Clean both mating surfaces of oil pan and cylin der block.
(2) Apply a 4 mm in.) wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
MITSUBISHI GENUINE PART No. or
equivalent
NOTE
(1) Be sure to install the oil pan quickly while th e sealant
is wet (within 15 minutes).
(2) After installation, keep the sealed area awayfrom
the oil and coolant for approx.
hour.
(3) Note the difference in bolt lengths at the loca tion shown.
TSB Revision

Front Case,
ENGINE OVERHAUL Shaft
Drain pigasket
side
DRAIN PLUG GASKET
Install the drain plug gasket in
. .
, I..
OIL INSTALLATION
(1) Clean the installation
of bracket.
Apply engine oil to the O-ring of, the oil filter.
(3) Screw the oil filter in until the the bracket.
Then tighten
torque: 7 Nm (12,
NOTE
For 35737, tighten
14 Nm (10 after the O-ring the
,
TSB Revision