engine MITSUBISHI SPYDER 1990 Service Repair Manual

Front
ENGINE OVERHAUL Shaft and
I N S P E C T I O N
FRONT CASE
(1) Check oil holes for clogging and -clean if nece ssary.
(2) Check left counterbalance shaft front bearing
wear, damage and seizure. If there is anything ‘wro ng
with the section, replace the front case.
(3) Check the front case for cracks and other ‘dama ge. Re-
place cracked or damaged front case.
OIL SEAL
(1) Check the oil seal lip for wear and damage. Replace
oil seal if necessary.
(2) Check the
seal lip for deterioration. Replace oil seal
if necessary.
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journal for seizure, damage and contact w ith bear-
ing. If there is anything wrong with the journal, replace
counterbalance shaft, bearing or front case assembl y.
OIL PUMP
(1) Assemble the-oil pump gear to the front case an d rotate
it to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the conta ct surface
between the front case and the gear surface of the oil
pump cover,
(3) Check the side clearance
Standard value: Drive gear
mm in.)
Driven gear
mm in.)
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ENGINE OVERHAUL Piston and Connecting Rod
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Lubricate allI
Removal steps
1.Nut
2. Connecting rod cap 3. Connecting rod bearing 4. Piston and connecting rod assembly 5. Connecting rod bearing6.Pistonring No.1
7.Pistonring No.2 8. Oil ring 9. Piston pin10. Piston 11. Connecting rod
12.
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ENGINE OVERHAUL Piston and
number
Piston Din tool
11
REMOVAL SERVICE POINTS
ROD CAP REMOVAL
Mark the cylinder number on the side of
rod big end for correct reassembly..
(2) Keep the removed connecting rods, caps, and bearings
in order according to the cylinder
PISTON PIN REMOVAL
1
2I Connecting Pin
4
5 Rod
Piston Support
7Connecting Pin
8
Piston Support
9 43P r e s s P i n
10216943Stop Screw
1110396Nut
(1) Remove the stop screw from the base.
(2) Select the correct piston support for your appl ication
above). Fit the piston support the base. Place the’
base
press support blocks.
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ENGINE OVERHAUL Piston and Rod
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(3) Insert the press pin through the piston! pin Select
the correct connecting rod guide pin Thread
the guide pin onto the threaded portion of the pres s pin.
(4) Position the piston assembly on the piston., support in
the press. With the press pin up
Figure 4,
insert the guide pin through the hole, in the pisto n and
through the hole in the piston support.
(5) Press the piston pin out of the assembly.
IMPORTANT: To avoid piston damage,
l The piston support must seat against
the piston.
lVerify that the piston pin will slide
hole in the piston support.
(6) Remove the piston pin from the press pin.
,
INSTALLATION SERVICE POINTS
PISTON PIN INSTALLATION
(1) Thread the stop screw and lock nut assembly int o the
base. Fit the correct piston support on top of the base.
Insert the press pin, thregded end up, into the hol e in
the piston support until
press pin stop
screw.
(2) Using the markings on the press pin, the stop
screw to the depth as shown below:““’
Depth:
Refer
tothe operating instructions on the special tool.

ENGINE OVERHAUL Piston and
Piston pin
Piston pin
Front mark
Stop Lock nut
Connecting rod
guide pin
Place the base on
Slide the piston pin over the of the press
pin, and thread the correct
it.
Coat the piston pin with oil, aiid with the
rod
held in position, slide the guide pin through the p iston
and connecting rod. ,
(6) Press the piston pin
the connecting until the
guide pin contacts the stop screw.
(7) Remove the piston assembly from the base. Remov e
the guide pin and press pin from the assembly.
IMPORTANT: Due to production tolerance variations,
it is necessary to visually inspect the piston
depth
after installation to verify that the piston pin is cen-
tered. Adjust if necessary.
(8) Check that the piston moves. smoothly.
OIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston rihg
NOTE
1. The side rails and spacer may be installed either
direction.
2. New spacers and side rails are colored for identification of their sizes.
Size Identification
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11ENGINE OVERHAUL Piston and Connecting R o d
Side rail gap
9
Identification mark “1
Identification mark Size mark
side
ring gap
and gap Lower siderail
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(2) the upper side rail.
To install the side rail, first fit one
the rail into
the piston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to
the side rail end gap
can break the side rail, unlike other
rings.
Caution
Do not use piston ring expander side
rail.
(3) Install the lower side rail in the as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.,
PISTON RING NO. 2 PISTON NO. 1
INSTALLATION
Using piston ring expander, fit No. 2 and ‘then 1 piston
ring into position.
NOTE
1. The ring end is provided with mark.
Identification mark:
ring
ring
2. Install piston rings with identification mark fa cing up, to’
the piston crown side.
3. Size marks on piston rings are as follows..
Size Size mark
StandardNONE
0.50mm oversize50
1 mm oversize100
II
PISTON AND CONNECTING ROD INSTALLATION
(1)Liberally coat engine oil on the circumference of t he piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3)Rotate crankshaft so that crank pin is on center of cylinder
bore.

ENGINE OVERHAUL Piston Rod
Timing belt side
Identification mark
(4) thread protectors on the connecting
before inserting piston and assembly into
the. block.
Care’ must be taken not to nick crank
Using a suitable piston. the
piston and connecting rod block.
CONNECTING ROD
When the bearing needs replacing, select and a, proper
bearing by the following procedure.
(1) the crankshaft pin diameter and
from the following In a
supplied as a service part, identification of its,
are painted at the the
. .,
(2) The connecting rod bearing identification mark is stamped
at the position shown in the illustration.
NoneYellow1
2None None21.491-1.495
(1.7711-1.7715)
3 None‘White3
C o n n e c t i n g I.D.: mm in.)
(3) Select a bearing from the above table on the basic
of the identification data confirmed under
and (2).
[Example]
(1) If the measured value of a crankshaft pin outer diameter is between 44.995 and 45.000 mm (1.7715
and 1.7717 in.), the pin is classified as “1” in th e
table. In case the crankshaft is also replaced by
a spare part, check the identification colors of th e
painted on the new crankshaft. If the color is
yellow, for example, the pin is as “1”. In
the above cases, select, the connecting rod bearing
having identification mark “1”.
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11ENGINE OVERHAUL P i s t o n
ylinder No.
CONNECTING ROD CAP INSTALLATION
(1) Verifying the mark made during disassembly, ins tall the
bearing cap to the connecting rod. If the connectin g rod
is new with no index mark, make sure that the beari ng
locking notches come on the same side as shown.
(2) Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.1 mm
Limit: 0.4 mm in.)
ROD CAP NUT INSTALLATION
NOTE
Installation of the connecting rod nut should be performed
with the cylinder head or the spark plug removed.
(1) Since the connecting rod bolts and nuts are tor qued using
the plastic area tightening method, the bolts should be
examined BEFORE reuse. If threads are “necked
down”, the bolt should be replaced.
Necking can be checked by running a nut with finger s
to the full length of the bolt threads. If the nut does
not run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine o il to the
threaded portion and bearing surface of the nut.
(3) Loosely tighten each nut to the bolt.
(4) Then tighten the nuts alternately to a torque o f 20 Nm
(14.5
to install the cap properly.
(5) Make a paint mark on the head of each nut.
(6) Make a
mark on the bolt end at the position
to from the paint mark made on the nut in the directi on
of the nut.
(7) Give a
to turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. the nut is turned less than proper fastening
performance may not be expected.When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2.If the nut is (exceeding loosen
the nut completely and then retighten it by repeating the tightening procedure from step
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ENGINE OVERHAUL Piston and Rod
INSPECTION
PISTON RING (1) Check the piston ring for
excessive and
breakage and replace if defects. If the’ piston
has been replaced with ,a new one, the piston rings must
also be replaced with, new. ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring
or piston, or both.
Standard value:
mm
Limit: 0.1 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:
ring mm
ring mm in.)
Oil ring
mm
Limit:
No. 1, No. 2 ring 0.8 mm in.)
Oil ring 1.0 mm
in.)
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CRANKSHAFT PIN OIL CLEARANCE
(PLASTIGAGE METHOD)
(1) Remove oil from crankshaft pin and connecting r od
bearing.
(2) Cut the Plastigage to the same length as the width of
bearing and place it on crankshaft pin in parallel with
its axis.

ENGINE OVERHAUL and
(3) Install the connecting rod cap carefully and tighten’
nuts to specified torque.
(4) Carefully remove the
(5) Measure the width of the its widest part
by using a scale printed on the
package.
Standard value:
mm in.)
Limit: 0.1 mm
in.)
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