Engine Overhaul - 2.0l (evolution) Mitsubishi Lancer Evolution VIII

Scheme 907

Scheme 908

Scheme 909

Scheme 910

Scheme 911

Scheme 912

Required Special Tools

1. MD998738: Adjusting Screw
2. MD998767: Tensioner Pulley Wrench
3. MD998778: Crankshaft Sprocket Puller
4. MD998781: Flywheel Stopper
5. MD998785: Sprocket Stopper

Scheme 913

Scheme 914

1. If the timing belt is to be reused, make an arrow mark with something like chalk on the back of the belt indicating the direction of rotation so it may be reinstalled in the same direction. CAUTION: Never remove the timing belt with any piston at the top dead center (TDC). If a piston is at TDC, the exhaust valves of the cylinder are pushed by the exhaust cams, compressing the valve springs. If the belt is removed under this condition, the sprocket will be turned in the reverse direction by the force of the springs, incurring risk of injury to person.
2. Set the timing mark of the exhaust camshaft sprocket to a point about one tooth before the TDC of the No. 1 cylinder piston on compression stroke.
3. Loosen the lock nut of the tensioner pulley, then remove the timing belt.

Scheme 915

Scheme 916

1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips crosspoint screwdriver [shank diameter 8 mm (0.3 inch)] through the plug hole to block the left counterbalance shaft.
3. Loosen the nut, and then remove the oil pump sprocket.

Scheme 917

1. Install special tool MD998781 to hold the flywheel or drive plate.
2. Loosen and remove the crankshaft bolt and washer.

Scheme 918

1. Set special tool MD998778 as shown in the illustration. (Scheme 918)
2. Screw in the center bolt of the special tool to remove the crankshaft sprocket.

<< E >> TIMING BELT "B" REMOVAL

Scheme 919

1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove the timing belt "B."

Scheme 920

1. Set special tool MD998785 as shown to prevent the counterbalance shaft sprocket from turning together.
2. Loosen the bolt and remove the sprocket.

Scheme 921

1. Set special tool MD998778 as shown in the illustration. (Scheme 921)
2. Screw in the center bolt of the special tool to remove crankshaft sprocket "B."

<< H >> CAMSHAFT SPROCKET REMOVAL

Remove the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.

Scheme 922

>> A << CAMSHAFT SPROCKET INSTALLATION

Tighten the camshaft sprocket bolt while preventing the camshaft from rotation using a wrench fitted on the hexagonal portion of the camshaft.

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

Scheme 923

Scheme 924

>> B << ENGINE SUPPORT BRACKET INSTALLATION<

Coat the threads of the seal bolt A in the illustration with 3M™ AAD Part number 8672 or equivalent before tightening. (Scheme 925)

1. Tightening torque: 49 +/- 5 N.m (36 +/- 3 ft-lb)

Scheme 925

Scheme 926

Scheme 927

1. Remove thoroughly the old sealant remaining on the semicircular packing, cylinder head, and rocker cover.
2. Apply sealant 3M™ AAD Part number 8672 or equivalent to the surface indicated in the drawing of the semicircular packing.
3. Install the semicircular packing on the cylinder head.
4. Apply sealant 3M™ AAD Part number 8660 or equivalent to the area indicated in the drawing of the semicircular packing and cylinder head.

Scheme 928

Scheme 929

1. Apply beads of sealant MITSUBISHI Genuine Part number MD970389 or equivalent on the surfaces of the rocker cover indicated in the drawing.
2. Install the rocker cover gasket A on the rocker cover before the FIPG hardens.
3. Apply beads of sealant MITSUBISHI Genuine Part number MD970389 or equivalent to the surfaces of the rocker cover indicated in the drawing.
4. Install the rocker cover on the cylinder head before the FIPG hardens.

>> E << CRANKSHAFT SPROCKET "B" INSTALLATION

Clean and then degrease the front case of the front case, crankshaft sprocket "B" and crankshaft surface on which sprocket "B" is attached.

Note. Degreasing is necessary to prevent decrease in the friction between contacting surfaces.

Scheme 930

Scheme 931

1. Apply a thin coat of clean engine oil to the lip area of the oil seal.
2. Install the spacer with the chamfered end facing toward the oil seal.

Scheme 932

1. Install the counterbalance shaft sprocket and screw in the bolt.
2. Install special tool MD998785 as shown in the illustration to lock the counterbalance shaft. (Scheme 932)
3. Tighten the bolt, and then remove the special tool. Tightening torque: 45 +/- 3 N.m (33 +/- 2 ft-lb)

Scheme 933

Scheme 934

Scheme 935

Scheme 936

1. Align timing marks on the crankshaft sprocket "B" and counterbalance shaft sprocket with the marks on the front case.
2. Install the timing belt "B" on the crankshaft sprocket "B" and counterbalance shaft sprocket. There should be no slack on the tension side.
3. Make sure that the relationship between the tensioner pulley center and the bolt center is as shown in the illustration. (Scheme 934)
4. Move tensioner "B" in the direction of the arrow while lifting with your finger to give sufficient tension to the tension side of timing belt. In this condition, tighten the bolt to secure tensioner "B." When the bolt is tightened, use care to prevent the tensioner pulley shaft from turning with the bolt. If the shaft is turned with the bolt, the belt will be over tensioned. Tightening torque: 19 +/- 3 N.m (14 +/- 2 ft-lb)
5. Check that timing marks on the sprockets are aligned with the timing marks on the front case.
6. With your index finger, press the midway of the span on the tension side of timing belt "B." The bolt must deflect 5 to 7 mm (0.20 to 0.28 inch).

Scheme 937

Scheme 938

1. Clean and then degrease the contacting surfaces of the crankshaft sprocket, sensing blade and crankshaft. NOTE: Degreasing is necessary to prevent decrease in the friction between contacting surfaces.
2. Clean the bolt hole in the crankshaft, the crankshaft contacting surface of the crankshaft sprocket, and the washer.
3. Install the sensing blade and the crankshaft sprocket to the crankshaft.
4. Apply small amount of oil to the threads and seating surface of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with its largely chamfered side toward the bolt head.
6. Lock the flywheel using the special tool MD998781.
7. Tighten the crankshaft bolt to the specified torque. Tightening torque: 167 N.m (123 ft-lb)

Scheme 939

1. Insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] through the plug hole on the left side of the cylinder block to block the left counterbalance shaft.
2. Install the oil pump sprocket.
3. Apply a thin coat of engine oil to the seating surface of the nut.
4. Tighten the nut to the specified torque. Tightening torque: 54 +/- 5 N.m (40 +/- 3 ft-lb)

Scheme 940

Scheme 941

1. If the auto-tensioner rod remains in its fully extended position, reset it to the retracted position as follows: Clamp the auto-tensioner in a vise at right angles to the jaws. Push in the rod little by little with the vise until the set hole A in the rod is aligned with the set hole B in the cylinder. Insert a piece of wire [1.4 mm (0.055 inch) diameter] into the set holes. Remove the auto-tensioner from the vise.
2. Install the auto-tensioner in position. Leave the wire installed until the auto-tensioner is completely installed.

>> L << TENSIONER PULLEY INSTALLATION

Install the tensioner pulley with its holes aligned as shown in the drawing.

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

Scheme 955

Scheme 956

Scheme 957

1. Bring the timing mark on the exhaust camshaft sprocket to a point one sprocket tooth away from the timing mark on the rocker cover in the counterclockwise direction. NOTE: If the timing marks were aligned, the exhaust camshaft would be turned counterclockwise by one sprocket tooth and stay there by the force of the valve springs.
2. Align the timing mark on the intake camshaft sprocket with that on the rocker cover. NOTE: The intake camshaft will be turned slightly clockwise from where the timing marks are aligned by the force of the valve springs and stay there.
3. Bring the timing mark on the crankshaft sprocket to a point one sprocket tooth away from the mating timing mark in the counterclockwise direction like in the operation with the exhaust camshaft sprocket.
4. Align the timing mark on the oil pump sprocket with that on the cylinder block. Remove the plug from the cylinder block. Insert a crosspoint screwdriver with a shank diameter of 8 mm through the plug hole. If it can be inserted 60 mm (2.36 inches) or more, the sprocket is in the correct phase. If the insertion depth is up to 20-25 mm (0.78-0.98 inch), the screwdriver is blocked by the counter balancer shaft. Then turn the oil pump sprocket one turn and realign the timing marks. Then check that the screwdriver can be inserted 60 mm (2.36 inches) or more. Keep the screwdriver inserted until installation of timing belt is finished. Turn the oil pump sprocket counterclockwise by one sprocket tooth.
5. Install the timing belt on the exhaust camshaft sprocket, and hold it in place with a paper clamp at the point indicated in the drawing.
6. Turn the intake camshaft sprocket counterclockwise to bring the timing mark on it one sprocket tooth away from the mating timing mark in the counterclockwise direction. Then install the timing belt on the sprocket and hold it in place with a paper clamp. NOTE: The timing marks will be aligned when the belt is installed since the intake camshaft is turned slightly clockwise by the force of the valve springs.
7. Turn the exhaust camshaft sprocket clockwise to align the timing marks, and make sure that the intake camshaft sprocket timing marks are also aligned.
8. Install the timing belt on the idler pulley, oil pump sprocket, and crankshaft sprocket, in this order. NOTE: There should be no slack in the installed portion of the belt.
9. Install the timing belt on the tensioner pulley. NOTE: Turning slightly the intake camshaft sprocket counterclockwise will facilitate installation of the belt on the tensioner pulley.
10. Turn the crankshaft sprocket slightly clockwise to take up the slack in the idler pulley portion of the timing belt.
11. Check that each of the timing marks on the crankshaft, oil pump, and exhaust camshaft sprockets is one sprocket tooth away from its mating timing mark in the counterclockwise direction.
12. Turn the tensioner pulley counterclockwise using the special tool MD998767 to give tension to the belt and hold the tensioner in position by temporarily tightening the tensioner lock bolt. NOTE: Take up the slack in the belt portion between the intake and exhaust camshaft sprockets.
13. Turn the crankshaft clockwise to make the timing mark align with the No. 1 cylinder top dead center mark.
14. Install the special tool MD998738 and turn down the tool until the wire (inserted in the auto-tensioner when it was installed) can be moved freely. CAUTION: Prevent the timing belt from slipping as it becomes loose following rotation of the intake and exhaust camshafts.
15. Loosen the tensioner pulley lock bolt.
16. Turn the torque wrench attached to the special tool MD998767 counterclockwise until the slack in the timing belt is taken up.
17. Turn the torque wrench clockwise from the position of step 16 until the torque wrench reading becomes 3.5 N.m (31 in-lb), then tighten the tensioner pulley lock bolt.
18. Remove the special tool that was installed in step 14.
19. Turn the crankshaft clockwise two turns, then let it alone for approx. 15 minutes.
20. Check that the wire (inserted in the auto-tensioner when it was installed) can be moved freely. If the wire can be pulled freely, the belt tensioner is adjusted properly. Remove the wire. Check that the auto-tensioner rod extends by the specified amount. Standard value: 3.8-4.5 mm (0.15-0.18 inch) CAUTION: Be sure to check the tightening torque of the crankshaft bolt anytime the crankshaft has been turned counterclockwise. If the torque lower than specification, tighten the bolt to the specified torque.
21. If the wire cannot be pulled out freely, perform the steps 14 through 18 again to make the belt tension proper.

TIMING BELT

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

Scheme 958

Scheme 959

Scheme 960

Scheme 961

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.

Scheme 962

Scheme 963

1. Check the auto-tensioner for leaks from the sealed sections. Replace it if leaky.
2. Check the rod end for wear and other damage. Replace the auto-tensioner if the rod is badly worn or damaged.
3. Measure the extension length of the rod. If it is not within the standard value range, replace the auto-tensioner. Standard value: 12 mm (0.5 inch)
4. Press the rod with a force of 98 to 196 N (22 to 44) and measure the amount of retraction. If the measurement exceeds the standard value, replace the auto-tensioner. Standard value: 1.0 mm (0.04 inch) or less

Scheme 964

>> A << INJECTOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring. CAUTION: Prevent engine oil from getting into the delivery pipe.
2. Insert the injector into the delivery pipe while turning it in both directions carefully not to damage the O-ring.
3. Check that the injector turns smoothly. If it does not, the O-ring may be pinched, so remove the injector and check the O-ring for damage. If the O-ring is intact, insert the injector into the delivery pipe and check it for smooth rotation again.

>> B << FUEL PRESSURE REGULATOR INSTALLATION

1. Apply a thin coat of engine oil to a new O-ring. CAUTION: Prevent engine oil from getting into the delivery pipe.
2. Insert the fuel pressure regulator into the delivery pipe while turning it in both directions carefully not to damage the O-ring.
3. Check that the fuel pressure regulator turns smoothly. If it does not, the O-ring may be jamming, so remove the fuel pressure regulator and check the O-ring for damage. If the O-ring is intact, insert it into the delivery pipe and check it for smooth rotation again.

>> C << THROTTLE BODY GASKET INSTALLATION

Install the throttle body gasket with its tab located as shown in the drawing.

Scheme 965

Scheme 966

>> A << INTAKE MANIFOLD STAY INSTALLATION

Tighten the bolts to the specified torque on both ends after making sure that the stay is in close contact with the bosses on the intake manifold and cylinder block.

Scheme 967

1. Tightening torque: 31 +/- 3 N.m (23 +/- 2 ft-lb)

>> B << MDP SENSOR INSTALLATION

Scheme 968

1. Temporarily tighten the air control valve bracket and engine hanger together with the intake manifold using a jointly fastened bolt.
2. Tighten the bolt number 1 to the specified torque. Tightening torque: 23 +/- 4 N.m (17 +/- 2 ft-lb)
3. Tighten the bolt number 2 to the specified torque. Tightening torque: 36 +/- 6 N.m (26 +/- 4 ft-lb)
4. Tighten the bolt number 3 together with the engine hanger to the specified torque. Tightening torque: 22 +/- 4 N.m (17 +/- 2 ft-lb)

Scheme 969

Scheme 970

1. Hand tighten all the exhaust manifold mounting nuts.
2. Tighten the M8 nuts to 29 +/- 3 N.m (21 +/- 2 ft-lb) in the indicated sequence.
3. Tighten the M10 nuts to 49 +/- 5 N.m (36 +/- 3 ft-lb) in the indicated sequence.
4. Tighten the M8 nuts again to 29 +/- 3 N.m (21 +/- 2 ft-lb) in the indicated sequence.
5. Finally tighten the M10 nuts and the M8 nuts to the specified torque, both in the indicated sequence. Tightening torque: M8: 33 +/- 6 N.m (24 +/- 4 ft-lb) M10: 55 +/- 10 N.m (41 +/- 6 ft-lb)

>> B << OIL RETURN PIPE GASKET INSTALLATION

Install the oil return pipe gasket with its tab located as shown in the drawing.

Note. The gasket on the turbocharger end of the pipe does not require special alignment for installation.

Scheme 971

>> C << AIR OUTLET FITTING GASKET INSTALLATION

Install the air outlet fitting gasket with its tab located as shown in the drawing.

Scheme 972

Scheme 973

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

Replace the water inlet pipe O-ring with new one, then apply water to the O-ring so that they can be inserted easily into the water pump.

Scheme 974

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

Scheme 975

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

Scheme 976

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

Scheme 977

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

Scheme 978

Required Special Tools

1. MD998442: Air Bleed Wire
2. MD998713: Camshaft Oil Seal Installer

<< A >> LASH ADJUSTER REMOVAL

>> A << LASH ADJUSTER INSTALLATION

Install the lash adjuster into the rocker arm, being careful not to spill the diesel fuel it contains.

>> B << CAMSHAFT INSTALLATION

Scheme 979

Scheme 980

Scheme 981

Scheme 982

1. Set each camshaft with its dowel pin at the top.
2. The bearing caps Nos. 2-5 are identical in shape for both intake and exhaust camshafts. Check the identification mark on each cap before installation. Identification mark (stamped on front and Nos. 2-5 bearing caps) I: intake side E: exhaust side
3. Remove completely any sealant remaining on the bearing caps and cylinder head.
4. Apply sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the surfaces indicated in the drawing. (Scheme 982)
5. Install each bearing cap and tighten its bolts in two or three passes.
6. Finally, tighten the bolts to the specified torque. Tightening torque: 20 +/- 1 N.m (15 +/- 1 ft-lb)
7. Check that the rocker arms are correctly installed. NOTE: Wipe off any squeezed out sealant completely.

>> D << CAMSHAFT OIL SEAL INSTALLATION

Use the special tool MD998713 to drive each oil seal into position in the cylinder head.

Scheme 983

>> E << CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

Apply a 3 mm (0.12 inch) bead of sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the area shown.

Scheme 984

Scheme 985

1. Turn the exhaust camshaft to the No. 1 cylinder top dead center position. NOTE: The camshaft will turn slightly counterclockwise by the force of the exhaust valve spring.
2. Install the camshaft position sensing cylinder with the smaller vane located as shown in the drawing. (Scheme 985)

CAMSHAFT

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

1. Standard value
2. Intake: 35.79 mm (1.41 inches)
3. Exhaust: 35.49 mm (1.40 inches)
4. Limit
5. Intake: 35.29 mm (1.39 inches)
6. Exhaust: 34.99 mm (1.38 inches)

Scheme 986

LASH ADJUSTERS

Scheme 987

Scheme 988

Scheme 989

Scheme 990

Scheme 991

Scheme 992

Scheme 993

Scheme 994

Scheme 995

1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.
2. Place the lash adjuster in container A and wash its outside surface. NOTE: Use a nylon brush if there are hard-to-remove deposits. CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
3. While gently pushing the internal steel ball using the special tool MD998442, move the plunger in and out 5-10 times to eliminate stiffness in the plunger and expel contaminated oil. NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster. CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it toward any person.
4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber. CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5-10 times by gently pushing the internal steel ball using the special tool MD998442 until the plunger moves smoothly to wash the lash adjuster's CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it toward any person.
6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the 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. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool MD998442.
8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.
9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all. NOTE: If the lash adjuster contracts, perform the operations 7 through 9 again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled).
10. Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.

Scheme 996

Required Special Tools

1. MB991654: Cylinder Head Bolt Wrench (12)
2. MD998735: Valve Spring Compressor
3. MD998737: Valve Stem Seal Installer
4. MD998772: Valve Spring Compressor

<< A >> CYLINDER HEAD BOLT REMOVAL

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

Scheme 997

Scheme 998

Scheme 999

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.

Scheme 1000

<< D >> VALVE HANDLING PRECAUTIONS

1. Handling of Sodium-filled Exhaust Valves Sodium-filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken. Never try to break the valves and expose sodium to the air. When worn exhaust valves are to be discarded, have them disposed of by a salvage company equipped with special disposal system, notifying them that the valves contain sodium. Should the exhaust valves be broken, neutralize sodium using the method described below, and discard the valves in the same way as ordinary valves. CAUTION: Do not let the solution contact the eyes or the skin. Should it get in the eyes, immediately flush them with clean water thoroughly, and receive medical attention. When it contacts he skin, wash with ample amounts of clean water.
2. How to Neutralize Sodium Place a container filled with more than 10 liters (10.6 qt) of water in a well ventilated large space. Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. CAUTION: Valves must be neutralized one at a time. Put a valve in the container only after sodium in the preceding one has completely reacted with water.
3. Put a broken valves in the water-filled container and quickly get away from the container at least 2 or 3 m (6.6 or 9.8 ft)
4. Keep fire away from the container during the neutralization. The resulting hydrogen gas is highly explosive. NOTE: The reaction occurs when water enters the cavity in the valve. Hydrogen gas may be trapped inside the valve, temporarily blocking the water passage. In such a case, wait until hydrogen gas in released and remaining sodium reacts with water.
5. After the neutralization of sodium, water in the container contains sodium hydroxide and is highly alkaline. The water solution should be disposed of according to local regulations.

Scheme 1001

Note. Do not confuse the stem seals for intake valves with

Scheme 1002

1. Install the valve spring seat.
2. Using special tool MD998737, 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.

Scheme 1003

>> 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.

Scheme 1004

Scheme 1005

Scheme 1006

Scheme 1007

Scheme 1008

Scheme 1009

1. When the removed cylinder head bolts are to be reused, check that the shank length of each bolt meets the limit. If it exceeds the limit, replace the bolts. Limit: 99.4 mm (3.91 inches)
2. Apply engine oil to the thread of the bolts and to the washers.
3. Using special tool MB991654 tighten the bolts to the specified torque 78 +/- 2 N.m (58 +/- 1 ft-lb), using the tightening sequence shown.
4. Loosen all bolts fully in the reverse order of tightening.
5. Retighten the loosened bolts to 20 +/- 2 N.m (15 +/- 1 ft-lb) in the tightening sequence shown. CAUTION: If the bolt is turned less than 90 degree angle, proper fastening performance may not be achieved. Be careful to turn each bolt exactly 90 degree angle. If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step 1.
6. Make a paint mark across each bolt head and cylinder head.
7. Tighten the cylinder head bolts 90 degree angle in the specified order.
8. Tighten the bolts another 90 degree angle in the same order as in step 7, and check that the paint marks on the cylinder head bolt are aligned with the paint marks on the cylinder head.

Scheme 1010

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: 0.05 mm (0.0020 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):131.9-132.1 mm (5.193-5.201 inches)

Scheme 1011

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: 1.5 mm (0.059 inch) Limit: Intake: 0.5 mm (0.020 inch) Exhaust: 1.0 mm (0.039 inch)
3. Measure the valve length. If the measurement is less than specified, replace the valve. Standard value: Intake: 109.50 mm (4.311 inches) Exhaust: 109.70 mm (4.319 inches) Limit: Intake: 109.00 mm (4.291 inches) Exhaust: 109.20 mm (4.299 inches)

Scheme 1012

1. Measure the valve spring free height. If the measurement is less than specified, replace the spring. Standard value: 50.4 mm (1.98 inches) Limit: 49.4 mm (1.94 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.

Scheme 1013

1. Standard value: Intake: 0.02-0.05 mm (0.0008-0.0020 inch) Exhaust: 0.05-0.09 mm (0.0020-0.0035 inch)
2. Limit: Intake: 0.10 mm (0.0039 inch) Exhaust: 0.15 mm (0.0059 inch)

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.

1. Standard value: Intake: 49.20 mm (1.9370 inches) Exhaust: 48.40 mm (1.9055 inches)
2. Limit Intake: 49.70 mm (1.9567 inches) Exhaust: 48.90 mm (1.9252 inches)

Scheme 1014

Scheme 1015

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/viii-2003-2005/remont/mechanical/#engine-overhaul-20l-evolution__valve-seat) in INSPECTION).

Scheme 1016

Scheme 1017

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: 35.30-35.33 mm (1.3898-1.3909 inches) 0.6 oversize: 35.60-35.63 mm (1.4016-1.4028 inches) Exhaust valve seat hole diameter 0.3 oversize: 33.30-33.33 mm (1.3110-1.3122 inches) 0.6 oversize: 33.60-33.63 mm (1.3228-1.3240 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/viii-2003-2005/remont/mechanical/#engine-overhaul-20l-evolution) ).

Scheme 1018

1. Using a press, push the valve guide out toward the cylinder block side.
2. Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. CAUTION: Do not install a valve guide of the same size again. Valve guide hole diameters in cylinder head 0.05 oversize: 12.05-12.07 mm (0.4744-0.4751 inch) 0.25 oversize: 12.25-12.27 mm (0.4823-0.4831 inch) 0.50 oversize: 12.50-12.52 mm (0.4921-0.4929 inch)
3. Press-fit the valve guide until it projects by the specified amount. Standard value: 19.5 mm (0.768 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)
4. After press-fitting the valve guide, insert a new valve and check that it slides smoothly.

Scheme 1019

Required Special Tools

1. MB991603: Bearing Installer Stopper
2. MD998162: Plug Wrench
3. MD998285: Crankshaft Front Oil Seal Guide
4. MD998371: Silent Shaft Bearing Puller
5. MD998372: Silent Shaft Bearing Puller
6. MD998375: Crankshaft Front Oil Seal Installer
7. MD998705: Silent Shaft Bearing Installer
8. MD998727: Oil Pan Remover
9. MD998783: Plug Wrench Retainer

Scheme 1020

1. Remove all oil pan bolts.
2. Drive in special tool MD998727 between the cylinder block and oil pan. NOTE: Never use a screwdriver or chisel to remove the oil pan. It will deform the oil pan flange and result in oil leakage.
3. Gently hit the special tool on its corner (shoulder), then slide it along the oil pan to remove it.

Scheme 1021

1. Fit special tool MD998162 on the plug cap, and then hold it in position with special tool MD998783.
2. Loosen the plug.
3. Remove special tools MD998783 and MD998162, and then the plug cap.

Scheme 1022

Scheme 1023

1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.3 inch)] into the plug hole to lock the counterbalance shaft.
3. Loosen the flange bolt.

<< D >> COUNTERBALANCE SHAFT FRONT BEARING REMOVAL

Using special tool MD998371, remove the counterbalance shaft front bearing from the cylinder block.

Note. Be sure to remove the front bearing first. If it has not been removed, special tool MD998372 cannot be used for rear balance shaft bearing removal.

Scheme 1024

Scheme 1025

1. Install special tools MB991603 and MD998372 in front of the cylinder block when removing the left counterbalance shaft rear bearing.
2. Using special tool MD998372, remove the right counterbalance shaft rear bearing from the cylinder block.

Scheme 1026

Scheme 1027

1. Install special tool MB991603 to the cylinder block.
2. Apply engine oil to the rear bearing outer surface and bearing hole in the cylinder block.
3. Using special tool MD998705, install the rear bearing. NOTE: The left rear bearing has no oil holes.

Scheme 1028

Scheme 1029

1. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
2. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with that of the cylinder block.

Scheme 1030

Scheme 1031

1. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.
2. Using special tool MD998705, install the front bearing. Make sure that the oil hole of the bearing is aligned with that of the cylinder block.

>> D << COUNTERBALANCE SHAFT OIL SEAL INSTALLATION

Using a suitable socket wrench, install the counterbalance shaft oil seal into the front case.

Scheme 1032

>> E << OIL PUMP OIL SEAL INSTALLATION

Using a suitable socket wrench, install the oil pump oil seal into the front case.

Scheme 1033

>> F << CRANKSHAFT FRONT OIL SEAL INSTALLATION

Using special tool MD998375, install the crankshaft front oil seal into the front case.

Scheme 1034

>> G << OIL PUMP DRIVEN GEAR/OIL PUMP DRIVE GEAR INSTALLATION

Install the oil pump gears into the front case and line up the alignment marks.

Scheme 1035

Scheme 1036

Scheme 1037

1. Set special tool MD998285 on the front end of crankshaft and apply a thin coat of engine oil to the outer surface of special tool MD998285.
2. Apply engine oil to the lip of the crankshaft front oil seal.
3. Install the oil pump case assembly together with the new front case gasket.
4. Install the oil filter bracket together with the new gasket.
5. Tighten the all flange bolts to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

Scheme 1038

Scheme 1039

1. Insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] into the hole in the left side of the cylinder block to lock the counterbalance shaft.
2. Secure the oil pump driven gear onto the left counterbalance shaft by tightening the flange bolt to the specified torque. Tightening torque: 36 +/- 3 N.m (27 +/- 1 ft-lb)
3. Pull out the screwdriver and screw in the plug.

Scheme 1040

1. Install a new O-ring to the groove of the front case.
2. Install the plug cap to the front case.
3. Fit special tool MD998162 on the plug cap, and then hold it in position with special tool MD998783.
4. Tighten the plug cap to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
5. Remove special tools MD998783 and MD998162.

Scheme 1041

Scheme 1042

1. Apply 3M™ AAD Part number 8672 or equivalent to the thread of oil pressure switch.
2. Tighten the oil pressure switch together with the oil filter bracket to the specified torque using the special tool MD998054. Tightening torque: 19 +/- 3 N.m (14 +/- 2 ft-lb)

Scheme 1043

Scheme 1044

1. Clean both gasket surfaces of oil pan and cylinder block.
2. Apply a 4 mm (0.15 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the flange of the oil pan. Apply sealant as indicated by the broken line in the illustration; the grooves must be traced and the bolt holes must be surrounded with a bead of sealant. (Scheme 1043)
3. Install the oil pump case assembly to the front side of the cylinder block. NOTE: Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
4. Fit an 8 mm (0.30 inch) long bolt in each of the two holes identified by the letter "S" in the illustration and a 10 mm (0.39 inch) long bolt in each of the remaining 17 holes. Tighten all bolts to the specified torque. (Scheme 1044) Tightening torque: 9.0 +/- 3.0 N.m (80 +/- 26 in-lb) NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

Scheme 1045

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: 14 +/- 2 N.m (124 +/- 17 in-lb)
4. If no torque wrench is available for tightening, use the following procedure: Screw in the oil filter until its o-ring contacts the oil filter bracket. Tighten the oil filter 3/4 turn.

>> N << DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction shown.

Scheme 1046

Scheme 1047

1. Check that the oil holes are not blocked. Clean if necessary.
2. Check the journals for seizure, damage and defective contact with bearings. If any of these faults is found, replace the counterbalancer shaft, bearings and/or oil pump case assembly.

Scheme 1048

1. Install the drive and driven gears in the oil pump case.
2. Measure the gear side clearance using a straight edge and thickness gauge. Standard values: Driver gear 0.08-0.14 mm (0.0031-0.0055 inch) Driven gear 0.06-0.12 mm (0.0023-0.0047 inch)

Scheme 1049

Required special tool

1. MIT216941: Piston Pin Setting Tool

Scheme 1050

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 that order according to the cylinder number.

Scheme 1051

Scheme 1052

Scheme 1053

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. CAUTION: To avoid piston damage, the piston support must seat squarely against the piston. Verify that the piston pin will slide through the hole in the piston support.
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.
5. Press the piston pin out of the assembly.
6. Remove the piston pin from the press pin.

Scheme 1054

Scheme 1055

Scheme 1056

Scheme 1057

Scheme 1058

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 flowing figure. (Scheme 1054) 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 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 engine oil. 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.

Scheme 1059

Scheme 1060

Scheme 1061

1. Fit the oil ring spacer into the piston ring groove. NOTE: The side rails and spacer may be installed in either direction. NOTE: New spacers and side rails are colored for identification of their sizes. CAUTION: Do not use a piston ring expander when installing side rail.
2. Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into position by finger. See illustration. (Scheme 1061)
3. Install the lower side rail in the same procedure as described in step 2.
4. Make sure that the side rails move smoothly in both directions.

Scheme 1062

Scheme 1063

Scheme 1064

1. To prevent wrong installation, check the identification mark of each piston ring. The identification mark is stamped near the ring gap: Identification mark: Number 1 ring: 1R Number 2 ring: 2R NOTE: Size marks on piston rings are as follows.
2. Using the piston ring expander, fit number 2 into the number 2 groove of piston. NOTE: Install piston rings with identification mark facing up, to the piston crown side.
3. Install the number 1 piston ring in the same manner as step 2.

Scheme 1065

Scheme 1066

Scheme 1067

1. Measure the crankshaft pin diameter and confirm its classification from the following figure. In the case of a crankshaft supplied as a service part, identification marks of its pins are stamped at the positions shown in the illustration. (Scheme 1066)
2. If the crankshaft pin outside diameter identification mark is "1," for example, select a bearing whose identification mark is "0." If there is no identification mark or no identification color paint on the crankshaft, measure the pin outside diameter and select a bearing appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of the connecting rod.

Scheme 1068

Scheme 1069

1. Apply engine oil on the circumference of the piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. (Scheme 1068)
3. Rotate the crankshaft so that crank pin is on the center of the cylinder bore.
4. Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin.
5. Insert the piston and connecting rod assembly into the cylinder with front mark on the piston crown pointing to the timing belt side. CAUTION: Make sure that the piston and connecting rod do not touch the oil jet during installation.
6. Using a suitable piston ring compressor tool, Install the piston and connecting rod assembly into the cylinder block.

Scheme 1070

Scheme 1071

1. Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches are on the same side as shown.
2. Make sure that the connecting rod big end side clearance meets the specification. Standard value: 0.10-0.25 mm (0.004-0.009 inch) Limit: 0.4 mm (0.015 inch)

Scheme 1072

1. The connecting rod bolts should be examined before reuse. If the bolt threads are damaged, the bolt should be replaced. Hand-thread the nut 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 oil 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 of 20 +/- 2 N.m (15 +/- 1 ft-lb) to install the cap properly.
5. Make a paint mark on the head of each nut. CAUTION: If the nut is turned less than 90 degree angle, proper fastening may not be achieved. Be careful to tighten the nut exactly at a 90 degree angle. If the nut is overtightened (exceeding 94 degree angle), loosen the nut completely and then retighten it by repeating the tightening procedure from step 3.
6. Make a paint mark on the bolt end at the position 90 degree angle to 94 degree angle from the paint mark made on the nut in the direction of tightening the nut.
7. Turn the nut further 90 degree angle to 94 degree angle and make sure that the paint marks on the nut and bolt are aligned.

Scheme 1073

Scheme 1074

1. Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. Standard value: No.1: 0.03-0.07 mm (0.0012-0.0028 inch) No.2: 0.02-0.06 mm (0.0008-0.0024 inch) Limit: No.1: 0.1 mm (0.0039 inch) No.2: 0.1 mm (0.0039 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: 0.20-0.30 mm (0.0079-0.0118 inch) No.2 ring: 0.35-0.50 mm (0.0128-0.0197 inch) Oil ring: 0.10-0.40 mm (0.0039-0.0157 inch) Limit: No.1, No.2 ring: 0.8 mm (0.031 inch) Oil ring: 1.0 mm (0.039 inch)

Scheme 1075

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: 0.03-0.05 mm (0.0012-0.0020 inch) Limit: 0.1 mm (0.004 inch)

Scheme 1076

Required Special Tools

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

Scheme 1077

1. Install the two thrust bearings in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings; this will help hold them in position.
2. The thrust bearings must be installed with their groove side toward the crankshaft web.

>> B << CRANKSHAFT BEARING INSTALLATION

When bearing replacement is required, select and install the correct bearing by the following procedure.

Scheme 1078

Scheme 1079

Scheme 1080

Scheme 1081

Scheme 1082

1. Measure the crankshaft journal diameter and confirm its classification from the following figure. In the case of a crankshaft supplied as a service part, identification marks of its journals are stamped at the positions shown in the illustration. (Scheme 1078)
2. The cylinder block bearing bore diameter identification marks are stamped at the position shown in the illustration from left to right, beginning at No.1. (Scheme 1078) For example, if the crankshaft journal outside diameter identification mark is "0" and cylinder block bearing bore identification mark is "1," select a bearing whose identification mark is "1." If there is no identification mark stamp on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured value.
3. Install the bearings have an oil groove to the cylinder block.
4. Install the bearings having no oil groove to the bearing cap.

Scheme 1083

Scheme 1084

Scheme 1085

Scheme 1086

1. Install the bearing caps so that the arrow points to the timing belt side.
2. Before installing the bearing cap bolts, check that the shank length of each bolt meets the limit. If it exceeds the limit, replace the bolt. Limit (A): 71.1 mm (2.79 inches)
3. Apply engine oil to the threaded portion and bearing surface of the bolt.
4. Tighten the bolts to 25 +/- 2 N.m (18 +/- 1 ft-lb) in the tightening sequence shown.
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap at the position 90 degree angle from the paint mark made on the bolt in the direction of tightening the bolt. CAUTION: If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step 4. If the bolt is turned less than 90 degree angle, proper fastening performance may not be achieved. Be sure to turn the bolt exactly 90 degree angle.
7. Turn each bolt 90 degree angle in the tightening sequence specified in step 4, and make sure that the paint marks on the bolt and cap are aligned.
8. Make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace the number 3 crankshaft bearings. Standard value: 0.05-0.25 mm (0.002-0.009 inch) Limit: 0.40 mm (0.0015 inch)

>> D << OIL SEAL INSTALLATION

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

Scheme 1087

Scheme 1088

1. Apply sealant (MITSUBISHI Genuine Part number MD970389 or equivalent) to the gasket surface of oil seal case. NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes).
2. Apply engine oil to the oil seal lip, and then install the oil seal case onto the cylinder block. NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

Scheme 1089

Scheme 1090

1. Remove oil from the crankshaft journal and crankshaft bearing.
2. Install the crankshaft.
3. Cut the plastic gauging material to the same length as the width of bearing and place it on 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 plastic gauging material at its widest part by using a scale printed on the plastic gauging material package. Standard value: 0.02-0.04 mm (0.0008-0.0015 inch) Limit: 0.1 mm (0.003 inch)

Scheme 1091

Scheme 1092

1. Visually check for scratches, rust, and corrosion. Use also a flaw detecting agent for the check. If defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm (0.0020 inch) Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: 0.2 mm (0.007 inch) *Includes/combined with cylinder head grinding Cylinder block height (when new): 290 mm (11.4 inches)
4. Check cylinder walls for scratches and seizure. If defects are evident, replace or bore to oversize and replace pistons and piston rings.
5. Using a cylinder gauge, measure the cylinder bore and cylindrically. If worn badly, correct the cylinder to an oversize and replace the piston and piston rings. Measure at the points shown in the illustration. (Scheme 1092)Standard value: Cylinder inner diameter 85.0 mm (3.35 inches) Cylindrically 0.01 mm (0.0003 inch) or less

Scheme 1093

Scheme 1094

1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder. NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter (OD) of the piston to be used. Measure it in thrust direction as shown.
3. Based on the measured piston OD, calculate the boring finish dimension. Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin) CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from number 2 to number 4 to number 1 to number 3.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
6. Check the clearance between the piston and cylinder. Clearance between piston and cylinder: 0.02-0.04 mm (0.0008-0.0015 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

Identifying Fastener Tightening Specifications

Identifying Fastener Tightening Specifications

Identifying Fastener Tightening Specifications

GENERAL SPECIFICATIONS

Identifying General Specifications

Scheme 1095

Scheme 1096

Scheme 1097

Scheme 1098

See also:
• INSPECTION
• VALVE SEAT