engine MITSUBISHI SPYDER 1990 Service Manual PDF

ENGINE Cylinder Head Gasket
i n . )
Mating marks
(2) Apply specified sealant to the thermostat case
in the places shown in the illustration.
Specified
MITSUBISHI GENUINE PART equiva-
lent
(3) Apply a small amount of water to the O-ring water
inlet pipe, and then press the thermostat case
into the water inlet pipe.
(4) Tighten the thermostat case assembly mounting b olts.
(5) Tighten the water inlet pipe bolts.
RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION
(1) Insert each hose as far as the projection of th e water
outlet fitting or water inlet fitting.
(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
HIGH-PRESSURE FUEL CONNECTION
When connecting the fuel hose to the fuel rail,
apply a small amount of clean engine oil to the hos e union
and then insert, being careful not to damage the
Caution
Do not let engine oil get into the fuel rail.
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E N G I N E Timing Belt
TIMING BELT
REMOVAL AND INSTALLATION
l Engine Mount Bracket Removal(Refer to GROUP 32 Engine Mounting.)
Post-installation Operationl Under Cover Installation(Refer to GROUP 42 Under Cover.)l Engine Adjustmentl Engine Mount Bracket (Refer to GROUP 32 Engine Mounting.)
4817
6.86.52
25
Removal steps
l Drive Belt Tension Adjustment
1. Drive belt (Generator)
2. Drive belt (Power steering)
3. Tensioner pulley bracket4. Drive belt (A/C)
5. Water pump pulley
6. Water pump pulley (Power
steering)
7. Crankshaft pulley 8. Timing belt front upper cover 9. Timing belt front center cover 10. Timing belt front lower. cover l Timing belt tension adjustment 11. Timing belt12. Tension pulley 13. Auto tensioner
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ENGINE Timing
(22-44
A
tensioner
marks Cylinder headI surface
I I I
REMOVAL SERVICE POINTS
BELT FRONT CENTER COVER
Remove the stud bolt of the engine support bracket, and
remove the timing belt front center cover.
TIMING BELT REMOVAL
(1) Turn the crankshaft in the forward direction (t o the right)
to align the camshaft sprocket timing marks.
Caution
Always turn the crankshaft in the forward direction
only.
(2) Loosen the tension pulley center bolt.
(3) Move the tension pulley to the water pump side, and
then remove the timing belt.
Caution
If the timing belt is to be reused, use chalk to ma rk
(on its flat side) an arrow indicating the
direction.
INSTALLATION SERVICE
AUTO TENSIONER
(1) Apply 98-196 (22-44 force to the auto tensioner
by pressing it against a metal (cylinder
‘and
measure the movement of the push rod.
Standard value: Within 1 mm
in.)
A: Length when it is free (not pressed) B: Length when it is pressed
A-B: Movement
(2)If it is out of the standard value, replace the aut o tensioner.
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ENGINE Timing Belt
,Set pin
I
Timing marksCylinder had
Itop surface
Crankshaft
sprocket
60 mm
60 mm
(2.36 in.)
(2.36 in.)
or more
or more in.) in.)
(3) Use a press or vise to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
of the tensioner cylinder are aligned.
C a u t i o n If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this opera-
tion slowly.
(4) Once the holes are aligned, insert the set pin.
NOTE
When replacing the auto tensioner a new part, the
pin will be in the auto tensioner.
(5) Install the auto tensioner to the engine.
TIMING BELT INSTALLATION’
(1) Align the timing marks on the camshaft sprocket , crank-
shaft sprocket and oil pump
(2) After aligning the timing mark on the oil pump sprocket,
remove the cylinder block plug and insert a Phillips screw-
driver with a diameter of 8 mm in.), and check to
be sure that the screwdriver goes in 60 mm (2.36 in .)
or more. If the screwdriver will only go in 20
25 mm
in.) before striking the counterbalance shaft,
turn the sprocket once, realign the timing mark and check
that the screwdriver goes in 60 mm (2.36 in.) or mo re.
Do not take out the screwdriver until thet i m i n g b e l t i s
installed.
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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 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
__
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.
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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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