Overhaul - Lancer (2.0l) Mitsubishi Lancer Evolution IX

SPECIAL TOOLS

SPECIAL TOOLS SPECIFICATIONS TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MD998781 Flywheel stopper General service tool Holding flywheel MB990767 End yoke holder Use with MD998719 MB990767-01 Use with MIT308239 Holding camshaft sprocket when loosening or torquing bolt MD998719 Pin (2) MIT308239 MD998716 Crankshaft wrench MD998716-01 Turning crankshaft MD998443 Lash adjuster holder (8) MD998443-01 Supporting lash adjuster to prevent it from falling when rocker arm shaft assembly is removed or installed. MD998713 Camshaft oil seal installer MD998713-01 Installation of camshaft oil seal MD998442 Air bleed wire General service tool Air bleeding of lash adjuster MB991653 Cylinder head bolt wrench General service tool Loosening and torquing of cylinder head bolt MD998772 Valve spring compressor General service tool Compressing valve spring MD998735 Valve spring compressor MD998735-01 Compression of valve spring MB991999 Valve stem seal installer - Installation of valve stem seal MD998717 Crankshaft front oil seal installer MD998717-01 Installation of crankshaft front oil seal MD998780 Piston pin setting tool MIT216941 Removal and installation of piston pin MB991659 Guide D - Removal of piston pin (Use with MD998780) MD998776 Crankshaft rear oil seal installer Use with MB990938 MD998376-01 Use with MB990938-01 Installation of crankshaft rear oil seal MB990938 Handle MB990938-01 Installation of crankshaft rear oil seal

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Required Special Tool

1. MD998781: Flywheel Stopper

<< A >> CRANKSHAFT BOLT REMOVAL

Lock the flywheel or drive plate in position using the special tool MD998781 shown in the illustration, then loosen the crankshaft bolt.

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1. Clean the sealant application surfaces of camshaft position sensor support and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the camshaft position sensor support.
3. After installation, wait at least one hour. Never start the engine or let engine oil touch the adhesion surface during that time.

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1. Lock the flywheel or drive plate in position using the special tool MD998781 shown in the illustration.
2. Clean the bolt hole in crankshaft bolt and crankshaft pulley's seating surface.
3. Degrease the cleaned seating surface of the crankshaft pulley.
4. Install the crankshaft pulley.
5. Apply oil to the threads of crankshaft bolt and the outer surface of washer.
6. Tighten the crankshaft bolt to the specified torque. Tightening torque: 182 +/- 4 N.m (134 +/- 3 ft-lb)

REMOVAL AND INSTALLATION

Required Special Tools

1. MB990767: End Yoke Holder
2. MD998719: Pin (2)
3. MD998716: Crankshaft Wrench

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1. Mark the belt running direction for reference in reinstallation.
2. Loosen the tensioner mounting bolt.
3. Insert a cross-tip screwdriver into the hole of the tensioner arm as shown illustration.
4. Move the screwdriver all the way in the direction of the arrow, and tighten the tensioner mounting bolt to hold this position.
5. Remove the timing belt. NOTE: Water oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent. NOTE: If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.

<< B >> CAMSHAFT SPROCKET BOLT LOOSENING

Use special tools MB990767 and MD998719 to prevent the camshaft sprocket from turning, and then loosen the camshaft sprocket bolt.

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>>A<< CAMSHAFT SPROCKET BOLT TIGHTENING

Use special tools MB990767 and MD998719 to prevent the camshaft sprocket from turning, and then tighten the camshaft sprocket bolt.

Tightening torque: 88 +/- 10 N.m (65 +/- 7 ft-lb)

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>>B<< CRANKSHAFT SENSING BLADE/CRANKSHAFT SPACER/CRANKSHAFT SPROCKET INSTALLATION

1. Clean the hole in the crankshaft sprocket.
2. Clean and degrease the mating surfaces of the crankshaft sprocket; sensing blade; and spacer

Note. Degreasing is necessary to prevent decrease in friction between the mating surface due to presence of oil.

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>>C<< TIMING BELT TENSIONER INSTALLATION

Install the timing belt tensioner in the illustrated position, and then tighten the tensioner mounting bolt.

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1. Install the tensioner spring onto the boss of the front case, and then hook the spring end "A" (shorter one) to the front case rib.
2. Grip the spring end "B" (longer one), and then hook it onto the tensioner arm.

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1. Align the crankshaft sprocket timing mark with the timing mark on the front case, and then rotate the crankshaft sprocket three teeth counterclockwise. CAUTION: Aligning the timing marks positions the piston to the top dead center. Then, if the camshaft turns, the valves might interfere and damage the pistons.
2. Align the camshaft sprocket timing mark with the timing mark on the cylinder head.
3. Rotate the crankshaft sprocket three teeth counterclockwise, and align the crankshaft sprocket timing mark with the timing mark on the front case.
4. Keeping the tension side of the timing belt tight, fit the timing belt onto the crankshaft sprocket, water pump sprocket, camshaft sprocket and tensioner puller in that order.
5. Slightly loosen the timing belt tensioner bolt to tension the belt by a force of the tensioner spring.
6. Using special tool MD998716 turn the crankshaft twice in the clockwise direction. CAUTION: This procedure utilizes the camshaft's driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft counterclockwise.
7. Check that the timing marks are correctly aligned.
8. Tighten the timing belt tensioner locking bolt to the specified torque.

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1. When installing the timing belt front lower cover, insert the terminal boss of the sensor securely into crankshaft angle sensor connector.
2. Tighten bolt "B" first and then tighten other bolts to specified torque.

TIMING BELT

Check the timing belt closely. Replace the belt with a new one if any of the following defects are evident

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1. Hardening of rubber backing. Back side is glossy without resilience and leaves no indent when pressed with fingernail.
2. Surface cracks on the backing rubber.
3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
6. Abnormal wear on the belt sides. NOTE: The sides of the belt are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth. Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Final stage: Canvas worn, exposing rubber (tooth width reduced)
8. Missing teeth.

TENSIONER PULLEY

Check the pulley for smooth rotation, without play and are not noisy.

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1. Fit a new O-ring and grommet onto the injector.
2. Apply clean engine oil or gasoline to the injector O-ring.
3. Fit the injector onto the fuel rail, turning it to the left and right as it goes in.
4. Check that the injector rotates smoothly.
5. Check that the clearance between the injector connector and the fuel rail is uniform (A = B).

>>B<< GASKET INSTALLATION

Position the projection as shown in the illustration.

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1. Clean the sealant application surfaces of the water pump case and cylinder block.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the water pump.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.

>>B<< WATER INLET PIPE/O-RING INSTALLATION

Replace the water inlet pipe O-ring with new ones, then apply water to the O-rings so that they can be inserted easily into the cylinder block and the thermostat case.

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1. Clean the sealant application surfaces of the thermostat case and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the thermostat case.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.

>>D<< THERMOSTAT INSTALLATION

Install the thermostat so that the jiggle valve is at the top.

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1. Clean the sealant application surfaces of the water outlet fitting and cylinder head.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the water outlet fitting.
3. After installation, wait at least one hour. Never start the engine or let coolant touch the adhesion surface during that time.

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1. When reusing the gauge unit, clean its thread.
2. Apply the sealant (3M™ AAD Part number 8672 or equivalent) to the engine coolant temperature gauge unit.

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1. When reusing the sensor, clean its thread.
2. Apply the sealant (3M™ AAD Part number 8731 or equivalent) to the engine coolant temperature sensor.

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Required Special Tools

1. MD998442: Air Bleed Wire
2. MD998443: Lash Adjuster Holder (8)
3. MD998713: Camshaft Oil Seal Installer

<< A >> ROCKER ARM AND ROCKER ARM SHAFT REMOVAL

Set special tool MD998443 to prevent the lash adjuster coming free and falling to the floor.

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>>A<< LASH ADJUSTER INSTALLATION

Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit special tool MD998443 to prevent the lash adjuster coming free and falling to the floor.

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>>B<< ROCKER ARM SHAFT INSTALLATION

Install the rocker arm shafts, place the end with notched side toward the timing belt side as shown.

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>>C<< ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION

Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts.

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1. Insert the rocker shaft spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide.
2. Remove the special tool from rocker arms.

>>E<< OIL SEAL INSTALLATION

Use special tool MD998713 to install the camshaft oil seal.

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CAMSHAFT

Measure the cam height and replace the camshaft if any height exceeds the specified limit.

Standard value

Intake: 37.80 mm (1.49 inches)

Exhaust: 37.54 mm (1.48 inches)

Limit

Intake: 37.30 mm (1.47 inches)

Exhaust: 37.04 mm (1.46 inches)

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LASH ADJUSTERS

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1. Prepare three containers and approximately 5 dm 3 (30.5 quart) of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.
2. Place the lash adjuster in container A and clean its outside surface. NOTE: Use a nylon brush if deposits are hard to remove. CAUTION: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.
3. While gently pushing down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will removed dirty oil. NOTE: If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.
4. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. CAUTION: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.
5. Place the lash adjuster in container B. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster's pressure chamber.
6. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. CAUTION: Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.
7. Place the lash adjuster in container C. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.
8. Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
9. Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster's height matches that of a new lash adjuster. NOTE: If lash adjuster contracts, perform the operations 7 through 9 again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.
10. Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.

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Required Special Tools

1. MB991653: Cylinder Head Bolt Wrench
2. MD998772: Valve Spring Compressor
3. MD998735: Valve Spring Compressor
4. MB991999: Valve Stem Seal Installer

<< A >> CYLINDER HEAD BOLT REMOVAL

Using the special tool MB991653 to loosen the cylinder head bolts.

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1. Using special tool MD998735 or MD998772, compress the retainer locks.
2. Remove the retainer locks. NOTE: Tag removed valves, springs and other components, noting their cylinder numbers and locations to facilitate reassembly. Store these components safely.

<< C >> VALVE STEM SEAL REMOVAL

Do not reuse removed valve stem seal.

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1. Install the valve spring seat. CAUTION: Do not reuse removed valve stem seals. The valve stem seal must be installed using the correct special tool. Incorrect installation could result in oil leaking past the valve guide.
2. Using special tool MB991999, install a new stem seal to the valve guide.

>>B<< VALVE SPRING INSTALLATION

Install the valve spring so that the painted end is on the rocker arm side.

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>>C<< RETAINER LOCK INSTALLATION

Using special tool MD998735 or MD998772, compress the valve spring and insert the retainer lock into position.

Note. The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with the stem seal, and damage it.

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1. Before reusing the cylinder head bolt, measure that its shank length does not exceed the specified limit. Replace the bolt if this measurement exceeds the limit. Limit: Max. 96.4 mm (3.795 inches)
2. Fit the washer as shown.
3. Apply engine oil to the bolt thread and washer.
4. Tighten the bolts in the sequence shown until each is torqued to 74 +/- 4 N.m (55 +/- 3 ft-lb) using the cylinder head bolt wrench special tool MB991653.
5. Loosen all bolts fully.
6. Retighten the bolts in the sequence shown until each is torqued to 20 +/- 2 N.m (15 +/- 1 ft-lb).
7. Make paint marks on the cylinder head bolt heads and cylinder head as shown. CAUTION: If the bolts are tightened by an angle of less than 90 degrees, they may not hold the cylinder head with sufficient strength. If the bolts are tightened by an angle exceeding 90 degrees, completely remove them and repeat the installation procedure.
8. In accordance with the tightening sequence, tighten each bolt by 90 degrees.
9. Tighten each bolt by further 90 degrees and check that the paint marks on the bolt head and cylinder head are aligned.

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1. Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage.
2. Remove all oil, water scale, sealant, and carbon. After cleaning the oil passages, blow air through them to verify that they are not blocked.
3. Check the cylinder head gasket surface for flatness by using a straight edge and feeler gauge. Standard value: 0.03 mm (0.0012 inch) Limit: 0.2 mm (0.008 inch)
4. If flatness exceeds the specified limit, grind the gasket surface to specification. Grinding limit: *0.2 mm (0.008 inch) *Includes/combined with cylinder block grinding Cylinder head height (Specification when new): 119.9 - 120.1 mm (4.720 - 4.728 inches)

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1. Check the valve face for correct contact. If contact is uneven or incomplete, reface the valve seat.
2. If the margin is less than specified, replace the valve. Standard value: Intake: 1.0 mm (0.039 inch) Exhaust: 1.3 mm (0.051 inch) Limit: Intake: 0.5 mm (0.020 inch) Exhaust: 0.8 mm (0.031 inch)
3. Measure the valve length. If the measurement is less than specified, replace the valve. Standard value: Intake: 110.15 mm (4.337 inches) Exhaust: 113.70 mm (4.476 inches) Limit: Intake: 109.65 mm (4.317 inches) Exhaust: 113.20 mm (4.457 inches)

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1. Measure the valve spring free height. If the measurement is less than specified, replace spring. Standard value: 49.5 mm (1.95 inches) Limit: 48.5 mm (1.91 inches)
2. Measure the squareness of the spring. If the measurement is less than specified, replace the spring. Standard value: 2° or less Limit: 4°

VALVE GUIDE

Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace the valve guide or valve, or both.

Standard value

Intake: 0.020 - 0.047 mm (0.0008 - 0.0019 inch)

Exhaust: 0.035 - 0.062 mm (0.0014 - 0.0024 inch)

Limit

Intake: 0.10 mm (0.0039 inch)

Exhaust: 0.15 mm (0.0059 inch)

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VALVE SEAT

Assemble the valve, then measure the valve stem projection between the end of the valve stem and the spring seating surface. If the measurement exceeds the specified limit, replace the valve seat.

Standard value

Intake: 49.30 mm (1.9409 inches)

Exhaust: 49.35 mm (1.9429 inches)

Limit

Intake: 49.80 mm (1.9606 inches)

Exhaust: 49.85 mm (1.9626 inches)

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1. Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary, replace the valve guide.
2. Using the appropriate special tool or seat grinder, correct the valve seat to achieve the specified seat width and angle.
3. After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection. (refer to «VALVE SEAT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical/#overhaul-lancer-20l__valve-seat) in INSPECTION)

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1. Cut the valve seat to be replaced from the inside to reduce the wall thickness. Then, remove the valve seat.
2. Rebore the valve seat hole in the cylinder head to match the selected oversize valve seat diameter. Intake valve seat hole diameter 0.3 oversize: 31.80 - 31.83 mm (1.2520 - 1.2531 inches) 0.6 oversize: 32.10 - 32.13 mm (1.2638 - 1.2650 inches) Exhaust valve seat hole diameter 0.3 oversize: 29.30 - 29.32 mm (1.1535 - 1.1543 inches) 0.6 oversize: 29.60 - 29.62 mm (1.1654 - 1.1661 inches)
3. Prevent galling of the cylinder head bore by cooling the valve seat with liquid nitrogen before press-fitting it.
4. Correct the valve seat to achieve the specified width and angle, (refer to «VALVE SEAT RECONDITIONING PROCEDURE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical/#overhaul-lancer-20l) )

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1. Using a press, push the valve guide out toward the cylinder block side. CAUTION: Do not install a valve guide of the same size again.
2. Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. Valve guide hole diameters in cylinder head 0.05 oversize: 11.05 - 11.07 mm (0.4350 - 0.4358 inch) 0.25 oversize: 11.25 - 11.27 mm (0.4429 - 0.4337 inch) 0.50 oversize: 11.50 - 11.52 mm (0.4528 - 0.4535 inch) CAUTION: The valve guide must be installed from the upper side of the cylinder head. The valve guides differ in length on the intake and exhaust sides. Valve guide length Intake: 45.5 mm (1.791 inches) Exhaust: 50.5 mm (1.988 inches)
3. Press-fit the valve guide until it projects by the specified amount. Standard value: 14.0 mm (0.551 inch)
4. After press-fitting the valve guide, insert a new valve and check that it slides smoothly.

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Required Special Tool

1. MD998717: Crankshaft Front Oil Seal Installer

<< A >> UPPER OIL PAN/LOWER OIL PAN REMOVAL

<< B >> OUTER ROTOR/INNER ROTOR REMOVAL

Make alignment dots on the outer and inner rotors for reference in reassembly.

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>>A<< INNER ROTOR/OUTER ROTOR INSTALLATION

Apply engine oil to the rotors. Then, install the rotors ensuring that the alignment dots made at disassembly are properly aligned.

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1. Clean the sealant application surfaces on the cylinder block and oil pump case.
2. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the oil pump case.
3. Tighten the oil pan bolts to the specified torque. Tightening torque: 14 +/- 1 N.m (124 +/- 9 in-lb)
4. After installation, wait at least one hour. Never start the engine or let engine oil touch the adhesion surface during that time.

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1. Place the special tool MD998717 on the crankshaft front end and apply engine oil to the its outer diameter.
2. Apply engine oil to the oil seal lip, then push the oil seal along the guide by hand until it touches the oil pump case. Tap the oil seal into place using the special tool.

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1. Clean the mating surfaces of the upper oil pan and lower oil pan and cylinder block.
2. Apply a 4 mm (0.16 inch) diameter bead of sealant (MITSUBISHI Genuine Parts number MD970389 or equivalent) to the upper oil pan and lower oil pan. NOTE: Install the oil pan within 15 minutes after applying liquid gasket. NOTE: Then wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
3. Tighten the lower oil pan mounting bolts in the sequence shown in the illustration. Tightening torque: 11 +/- 1 N.m (98 +/- 8 in-lb)

>>E<< DRAIN PLUG GASKET INSTALLATION

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>>F<< OIL FILTER INSTALLATION

1. Clean the filter mounting surfaces on the front case.
2. Apply clean engine oil to the O-ring of the oil filter. CAUTION: The oil filter must be tightened using a commercially available filter wrench. If the filter is tightened by hand only, it will be insufficiently torqued, resulting in oil leaks.
3. Screw on the oil filter until its O-ring is seated on the mounting surface. Then, give the oil filter one further turn.

>>G<< ENGINE OIL PRESSURE SWITCH INSTALLATION

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1. Apply the sealant (3M™ AAD part number 8672 or equivalent) to the engine oil pressure switch. CAUTION: If the switch is tightened with a spanner or offset wrench, an over-torque may be applied and the switch to be damaged.
2. Install and tighten the switch to the specified torque by using a socket wrench and torque wrench.

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1. Fit the rotors into the oil pump case.
2. Check the tip clearance, using a feeler gauge. Standard value: 0.03 - 0.08 mm (0.0012 - 0.0032 inch)
3. Check the side clearance, using a straight edge and feeler gauge. Standard value: 0.04 - 0.10 mm (0.0016 - 0.0039 inch)
4. Check the body clearance, using a feeler gauge. Standard value: 0.10 - 0.18 mm (0.0039 - 0.0071 inch) Limit: 0.35 mm (0.0138 inch)

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Required special tool

1. MIT216941: Piston Pin Setting Tool

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1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.

<< B >> PISTON PIN REMOVAL

PISTON PIN REMOVAL

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1. Remove the stop screw from the base.
2. Select the correct piston support for your application (See above). Fit the piston support onto the base. Place the base on press support blocks.
3. Insert the press pin through the piston pin hole. Select the correct connecting rod guide pin (See above). Thread the guide pin onto the threaded portion of the press pin.
4. Position the piston assembly on the piston support in the press. With the press pin up as shown, insert the guide pin through the hole in the piston and through the hole in the piston support. CAUTION: The piston support must seat squarely against the piston. Verify that the piston pin will slide through the hole in the piston support.
5. Press the piston pin out of the assembly.
6. Remove the piston pin from the press pin.

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1. When replacing the piston, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table. CYLINDER BORE SIZE MARK AND PISTON SIZE MARK CYLINDER BORE SIZE MARK PISTON SIZE MARK A A B None C C NOTE: The piston size mark shows on the top of the piston.
2. Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw.
3. Using the markings on the press pin, adjust the stop screw to the depth as shown on the instruction for special tool MIT216941.
4. Place the base on press support blocks.
5. Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it.
6. Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod.
7. Press the piston pin through the connecting rod until the guide pin contacts the stop screw. CAUTION: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.
8. Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly.
9. Check that the piston moves smoothly.

>>B<< OIL RING INSTALLATION

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1. Fit the oil ring spacer into the piston ring groove. Then fit the upper and lower side rails. NOTE: The spacer and side rails may be fitted in either direction. No distinction is made between top and bottom. NOTE: Spacer and side rail sizes are color-coded as follows: SPACER AND SIDE RAIL SIZES COLOR-CODED SIZE IDENTIFICATION COLOR Standard size None 0.50 mm (0.020 in) oversize diameter Blue 1.00 mm (0.040 in) oversize diameter Yellow To install a side rail, fit one end of the rail into the groove, then press the rest of the rail into position by hand as shown.
2. After installing the side rails, check that they more smoothly in both directions.

>>C<< PISTON RING NO.2/PISTON RING NO.1 INSTALLATION

Using a ring expander, fit ring No.2 and ring No.1 with their identification marks facing upward (on the piston crown side).

Identification mark

No.1 ring: T

No.2 ring: T2

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Note. The piston ring is stamped with the following size mark.

PISTON RING SPECIFICATION

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1. Apply oil to the piston, piston ring, and oil ring.
2. Align the gaps of the piston rings and oil rings (side rails and spacer) as shown.
3. With the piston crown's front arrow mark pointing toward the timing belt side, press the piston and connecting rod assembly into the cylinder from the top of the cylinder.
4. Compress the piston rings tightly with a suitable ring compression tool, then press the piston and connecting rod fully into the cylinder. Do not strike the piston hard since the piston rings may break and the crank pin may be nicked.

>>E<< CONNECTING ROD BEARING INSTALLATION

When replacing the bearings and/or crankshaft, read off the identification mark on the crankshaft (as illustrated), and select a bearing according to the following table.

CRANKSHAFT DIAMETER

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1. Aligning the marks made during disassembly, fit the bearing cap onto the connecting rod. If the connecting rod is new and has no index mark, ensure that the bearing locking notches are both on the same side.
2. Check that the connecting rod big end side clearance confirms with specification. Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 inch) Limit: 0.4 mm (0.016 inch)

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1. Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined before reuse. If the bolt threads are "necked down," the bolt should be replaced. Necking can be checked by running a nut with your fingers 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 oil to the nut.
3. Install each nut to the bolt and finger-tighten it. Then tighten the nuts alternately to install the cap properly.
4. Tighten the nuts to a torque of 20 +/- 2 N.m (15 +/- 1 ft-lb).
5. Make a paint mark on the head of each nut. CAUTION: If the nut is turned less than 90 degrees, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it. If the nut is overtightened (exceeding 94 degrees), loosen the nut completely and then retighten it by repeating the tightening procedure from step 1.
6. Make a paint mark on the bolt end at the position 90 degrees to 94 degrees from the paint mark made on the nut in the direction of tightening the nut.
7. Give a 90 degrees to 94 degrees turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment.

Scheme 334

Scheme 335

1. Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. Standard value: No.1: 0.04 - 0.08 mm (0.0016 - 0.0032 inch) No.2: 0.02 - 0.06 mm (0.0008 - 0.0024 inch) Limit: No.1, No.2: 0.1 mm (0.004 inch)
2. Install the piston ring into the cylinder bore. Force the ring down with a piston, the piston 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 end gap is excessive, replace the piston ring. Standard value: No.1 ring: 0.15 - 0.30 mm (0.0059 - 0.0118 inch) No.2 ring: 0.40 - 0.55 mm (0.0157 - 0.0217 inch) Oil ring: 0.10 - 0.35 mm (0.0039 - 0.0138 inch) Limit: No.1, No.2 ring: 0.8 mm (0.031 inch) Oil ring: 1.0 mm (0.039 inch)

Scheme 336

1. Remove oil from the crankshaft pin and connecting rod bearing.
2. Cut the plastic gauging material to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified torque. (See "Connecting rod cap nut tightening" procedure.)
4. Carefully remove the connecting rod cap.
5. Measure the width of the plastic gauging material at its widest part by using a scale printed on its package. Standard value: 0.02 - 0.04 mm (0.0008 - 0.0016 inch) Limit: 0.1 mm (0.004 inch)

Scheme 337

Required Special Tools

1. MD998776: Crankshaft Rear Oil Seal Installer
2. MB990938: Handle

Scheme 338

Scheme 339

Scheme 340

1. When replacing the bearings, crankshaft and/or cylinder block, read off the identification mark on the crankshaft and cylinder block (as illustrated), and select a bearing according to the following table. BEARING SPECIFICATION CRANKSHAFT JOURNAL OUTSIDE DIAMETER CYLINDER BLOCK BEARING BORE INSIDE DIAMETER CRANKSHAFT BEARING IDENTIFICATION MARK IDENTIFICATION MARK IDENTIFICATION MARK OR COLOR 1 0 S1 or Brown 1 S2 or Black 2 S3 or Green 2 0 S2 or Black 1 S3 or Green 2 S4 or Yellow 3 0 S3 or Green 1 S4 or Yellow 2 S5 or Pink
2. Install bearings having an oil groove to the cylinder block.
3. Install bearings having no oil groove onto the bearing caps.
4. Install the thrust bearings at the No.3 upper bearing with the grooved side toward the crankshaft web.

Scheme 341

Scheme 342

Scheme 343

Scheme 344

1. Install the bearing cap so their arrow is positioned on the timing belt side.
2. When reusing the bearing cap bolt, measure that its shank length dose not exceed the specified limit. Replace the bolt if this measurement exceeds the limit. Limit: max. 71.1 mm (2.799 inches)
3. Apply engine oil to the bolt thread and flange of the bolt.
4. Tighten the bearing cap bolts to 25 +/- 2 N.m (18 +/- 1 ft-lb) torque in the sequence shown.
5. Make a paint mark on the head of each bolt. CAUTION: If the bolt is turned less than 90 degrees, proper fastening performance may not be expected. When tightening the bolt, therefore, be careful to give a sufficient turn to it. If the bolt is overtightened (exceeding 100 degrees), loosen the bolt completely and then retighten it by repeating the tightening procedure from step 1.
6. Make a paint mark on the bearing cap at the position 90 degrees to 100 degrees from the paint mark on the bolt head in the direction of tightening the bolt.
7. Give a 90 degrees to 100 degrees turn to the bolt in the tightening sequence. Make sure that the paint mark on the bolt and that on the bearing cap are in alignment.
8. Check that the crankshaft rotates smoothly.
9. Measure the end play in the crankshaft. If the measurement exceeds the specified limit, replace the crankshaft bearings. Standard value: 0.05 - 0.25 mm (0.0020 - 0.0098 inch) Limit: 0.4 mm (0.016 inch)

>>C<< REAR OIL SEAL INSTALLATION

Using special tools MD998776 and MB990938, press-fit the oil seal in the case.

Scheme 345

Scheme 346

1. Apply the sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the oil seal case.
2. Apply a small amount of engine oil to the entire circumference of the oil seal lip section, and place the oil seal case on the cylinder block.

Scheme 347

1. Remove all the remaining sealant from bolts and thread holes of crankshaft.
2. Apply engine oil to the flange of bolt.
3. Apply engine oil into the thread holes of crankshaft.
4. Apply the sealant (3M™ AAD part number 8672 or equivalent) to the drive plate bolt or flywheel bolt.
5. Tighten the bolts to specified torque. Tightening torque: 98 +/- 5 N.m (72 +/- 3 ft-lb)

Scheme 348

Scheme 349

1. Remove oil from the crankshaft journal and the crankshaft bearing.
2. Install the crankshaft.
3. Cut the Plastigage to the same length as the width of bearing and place it on the journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the Plastigage at its widest part by using a scale printed on the Plastigage package. Standard value: 0.02 - 0.03 mm (0.0008 - 0.0012 inch) Limit: 0.1 mm (0.004 inch)

Scheme 350

Scheme 351

1. Visually check for cracks, rust, and corrosion, and inspect the cylinder block using a flaw detecting agent. Rectify defects where possible or replace the cylinder block.
2. Ensure that the top surface is free of gasket chips and other foreign material. Check the cylinder block top surface for distortion using a straight edge and feeler gauge. Standard value: 0.05 mm (0.0020 inch) or less Limit: 0.1 mm (0.004 inch)
3. If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm (0.008 inch) The total thickness of the stock allowed to be removed from cylinder block and mating cylinder head 0.2 mm (0.008 inch) at maximum. Cylinder block height (when new): 286.7 mm (11.287 inches)
4. Check the cylinder walls for cracks and seizure marks. If defects are evident, bore all the cylinders to oversize or replace the cylinder block.
5. Using a cylinder gauge, measure each cylinder bore and cylindricity. If any cylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly. Take measurements at the points shown. Standard value: Cylinder bore inside diameter: 81.5 mm (3.21 inches) Cylindricity: 0.01 mm (0.0004 inch) or less

Scheme 352

1. Oversize pistons should be based on the largest bore cylinder. Piston size identification PISTON SIZE IDENTIFICATION SIZE IDENTIFICATION MARK 0.50 mm (0.20 in) oversize diameter 0.50 1.00 mm (0.40 in) oversize diameter 1.00 NOTE: The size mark is stamped on the piston top.
2. Measure the outside diameter of piston to be used. Measure it in thrust direction as shown.
3. Based on the measured piston outside diameter (O.D.), calculate the boring finish dimension. Boring finish dimension = Piston O.D. + (Clearance between piston O.D. and cylinder) - 0.02 mm (0.0008 inch) (honing margin) CAUTION: To prevent distortion caused by heat increased during boring, bore the cylinders in the following order: No.2, No.4, No.1, No.3.
4. Bore each cylinders to the calculated boring finish dimension.
5. Hone the cylinders to the final finish dimension (Piston O.D. + Piston-to-cylinder clearance).
6. Check the clearance between piston and cylinder. Standard value: 0.02 - 0.03 mm (0.0008 - 0.0012 inch) NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES SPECIFICATION

See also:
• LASH ADJUSTERS
• VALVE SEAT
• VALVE SEAT RECONDITIONING PROCEDURE