Overhaul - 2.4l (except Evolution & Sportback) Mitsubishi Lancer Evolution VIII

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Required Special Tools

1. MB991398: Spark Plug Wrench
2. MD998781: Flywheel Stopper

<< A>> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

Scheme 584

Scheme 585

1. Using special tool MD998781, hold the flywheel or drive plate.
2. Removal the camshaft position sensing cylinder.

Scheme 586

1. Using special tool MD998781, hold the flywheel or drive plate.
2. Tighten the camshaft position sensing cylinder to the specified torque. Tightening torque: 22 +/- 4 N.m (17 +/- 2 ft-lb)

<< B>> CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

Apply a 3 mm (0.12 inch) bead of sealant (MITSUBISHI Genuine Part number MD970389) in the groove shown.

Scheme 587

<< C>> SPARK PLUG INSTALLATION

Using special tool MB991398, tighten the spark plug to the specified torque.

Tightening torque: 25 +/- 5 N.m (19 +/- 2 ft-lb)

Scheme 588

Scheme 589

Scheme 590

Required Special Tools

1. MB990767: End Yoke Holder
2. MD998719: Pins
3. MD998767: Tensioner Pulley Wrench
4. MD998778: Crankshaft Sprocket Puller
5. MD998781: Flywheel Stopper
6. MD998785: Sprocket Stopper

REMOVAL SERVICE POINTS

Scheme 591

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

Scheme 592

1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips 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 593

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

Scheme 594

1. Set special tool MD998778 as shown in the illustration (Scheme 594)
2. Screw in the center bolt of the special tool to remove the crankshaft sprocket. CAUTION: Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed or immersed in solvent. Replace parts if contaminated. If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water pump for leaks.

Scheme 595

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

Scheme 596

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 597

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

Scheme 598

1. While holding the camshaft sprocket with special tools MB990767 and MD998719, loosen the camshaft sprock bolt.
2. Remove the camshaft sprocket.

Scheme 599

1. Fit the camshaft sprocket to the front of the camshaft.
2. While holding the camshaft sprocket with special tools MB990767 and MD998719, tighten the camshaft sprock bolt. Tightening torque: 88 +/- 10 N.m (65 +/- 7 ft-lb)

>> B << ENGINE SUPPORT BRACKET INSTALLATION

Coat the threads of the seal bolt in the illustration with 3M TH AAD Part number 8672 or equivalent before tightening.

Tightening torque: 49 +/- 5 N.m (36 +/- 4 ft-lb)

Scheme 600

>> C << CRANKSHAFT SPROCKET "B" INSTALLATION

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

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

Scheme 601

Scheme 602

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 603

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

Scheme 604

Scheme 605

Scheme 606

Scheme 607

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 tensioner pulley center and the bolt center are positioned as shown in the illustration.
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 span on the tension side of timing belt "B." The bolt must deflect 5 to 7 mm (0.20 to 0.28 inch).

Scheme 608

Scheme 609

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 a small amount of engine oil to the threads and seating surface of the crankshaft bolt.
5. Install the washer to the crankshaft bolt with the larger chamfered side toward the bolt head.
6. Lock the flywheel or drive plate using the special tool MD998781.
7. Tighten the crankshaft bolt to the specified torque. Tightening torque: 167 N.m (123 ft-lb)

Scheme 610

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 +/- 4 ft-lb)

>> I << AUTO-TENSIONER INSTALLATION

If the auto-tensioner rod is fully extended, reset it as follows

Scheme 611

Scheme 612

Scheme 613

1. Clamp the auto-tensioner in a vise with soft jaws.
2. Push in the rod little by little with the vise until the set hole A in the rod is aligned with hole B in the cylinder.
3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes. This auto-tensioner setting wire will be used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise. CAUTION: Leave the wire installed in the auto-tensioner.
5. Install the auto-tensioner onto the front case and tighten to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

>> J << TENSIONER PULLEY INSTALLATION

Set the tensioner pulley so that the holes for attaching a wrench are positioned as shown in the illustration.

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

1. Align the timing mark on the camshaft sprocket with the timing mark on the rocker cover.
2. Align the timing mark on the crankshaft sprocket with the timing mark on the front case.
3. Align the timing mark on oil pump sprocket with its mating mark.
4. Remove the plug on the cylinder block and insert a Phillips head screwdriver [shank diameter 8 mm (0.3 inch)] through the hole. If it can be inserted as deep as 60 mm (2.4 inches) or more, the timing marks are correctly aligned. If the inserted depth is only 20 to 25 mm (0.8 to 0.9 inch), turn the oil pump sprocket one turn and realign the timing marks, then check to ensure that the screwdriver can be inserted 60 mm (2.4 inches) or more. Keep the screwdriver inserted until the timing belt is completely installed.
5. Set special tool MD998738 as shown and screw it in up to the position where the wire inserted in the auto-tensioner can be moved lightly.
6. Install the timing belt on the crankshaft sprocket, oil pump sprocket, idler pulley, camshaft sprocket, and tensioner pulley in that order.
7. Lift up the tensioner pulley in the direction of the arrow and tighten the center bolt.
8. Check that all timing marks are aligned.
9. Remove the screwdriver inserted in step 5 and install the plug.
10. Turn the crankshaft a quarter turn counterclockwise. Then, turn it clockwise until the timing marks are aligned again.
11. Install special tool MD998767, socket wrench and torque wrench, onto the tensioner pulley, and loosen the tensioner pulley center bolt. NOTE: Use a torque wrench that can measure 0 to 5.0 N.m (0 - 44 in-lb).
12. Torque to 3.5 N.m (31 in-lb) with the torque wrench.
13. Holding the tensioner pulley with special tool MD998767 and torque wrench, tighten the center bolt to specification. Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
14. The wire inserted at the auto-tensioner installation is pulled out and then the special tool MD998738 is removed by hand.
15. Give two clockwise turns to the crankshaft. Wait for 15 minutes, then proceed with the following inspection steps.
16. Check to see whether the metal wire (inserted when the auto-tensioner was installed) can be removed without any resistance. If the metal wire can be removed without any resistance, it means that the belt has a proper tension. Therefore, remove the metal wire. In this condition, check that the rod protrusion of the auto-tensioner is within the standard value. Standard value: 3.8 - 4.5 mm (0.15 - 0.17 inch)
17. If the metal wire offers resistance when removed, repeat the previous steps 10 through 15 until the standard value is obtained as measured by the rod projection of the auto-tensioner rod.

TIMING BELT

Replace the belt if any of the following conditions exist

Scheme 624

Scheme 625

Scheme 626

Scheme 627

1. Hardening of rubber backing. Back side should be glossy without resilience and leave no indent when pressed with fingernail.
2. Cracks on rubber back.
3. Cracks or peeling of canvas.
4. Cracks at bottom of ribs.
5. Cracks on belt sides.
6. Abnormal wear of belt sides. Normal wear is indicated if the sides are sharp as if cut by a knife. Abnormal wear is indicated if the sides are ragged.
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 tooth.

Scheme 628

Scheme 629

1. Check for oil leaks. If oil leaks are evident, replace the auto-tensioner.
2. Check the rod end for wear or damage and replace the auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of specification, 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 pound) and measure the movement of the rod. If the measured value is out of the standard value, replace the auto-tensioner. Standard value: 1.0 mm (0.03 inch) or less

VALVE CLEARANCE ADJUSTMENT

Scheme 630

Scheme 631

Scheme 632

1. Rotate crankshaft clockwise and then align the timing mark on the camshaft sprocket with the timing mark on the rocker cover. (Place No.1 cylinder on the top dead center of compression stroke.)
2. Remove the rocker cover.
3. Measure the valve clearances marked with arrows shown in the figure. A: When No. 1 cylinder is on the top dead center of compression stroke. B: When No.4 cylinder is on the top dead center of compression stroke.
4. Using a thickness gauge, adjust the clearance between the valve shaft end and the adjusting screw. Standard value (in cold state): < Vehicles for CALIFORNIA emission> Intake side: 0.11 mm (0.004 inch) Exhaust side: 0.21 mm (0.008 inch) < Vehicles for except CALIFORNIA emission> Intake side: 0.11 mm (0.004 inch) Exhaust side: 0.22 mm (0.009 inch) NOTE: After the engine assembly is installed on the vehicle, check the valve clearance again with the engine warmed up. Adjust if necessary.
5. Hold the adjusting screw with a screw driver so it does not rotate then tighten the lock nut.
6. Rotate the crankshaft one time clockwise and then align the timing mark with the timing mark on the crankshaft sprocket. (Place No.4 cylinder on the top dead center of compression stroke.)
7. Adjust the valve clearance for the rest of the valves.
8. Install the rocker cover.

Scheme 633

>> A << EXHAUST GAS RECIRCULATION VALVE INSTALLATION

Install a new gasket in the position shown in the illustration.

Scheme 634

Scheme 635

1. Apply clean engine oil to the O-ring.
2. Insert the injector into the fuel rail.
3. Make sure the injector rotates smoothly. If not, remove the injector to check the O-ring for damage, and replace the O-ring if necessary. Then, reinstall the injector and check that it rotates smoothly.
4. Confirm the protrusion of injector is at center. If not, rotate the injector for protrusion to be center.

>> C << THROTTLE BODY GASKET INSTALLATION

Install a new gasket so that the projection is positioned as shown in the illustration.

Scheme 636

Scheme 637

Required Special Tool

1. MD998054: Oil Pressure Switch Wrench

<< A>> ENGINE OIL PRESSURE SWITCH REMOVAL

Using special tool MD998054, remove the engine oil pressure switch.

Scheme 638

Scheme 639

1. Apply a 3 mm (0.12 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD970389) to the groove as shown in the illustration.
2. Install the housing quickly (within 15 minutes) while the sealant is wet and tighten the bolts to the specified torque. Tightening torque: 13 +/- 2 N.m (115 +/- 17 in-lb) NOTE: After installation, keep the sealed area away from the coolant for approximately one hour.

>> B << SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR

Apply 3M™ AAD Part number 8731 or equivalent to the engine coolant temperature sensor.

Scheme 640

>> C << SEALANT APPLICATION TO ENGINE OIL PRESSURE SWITCH

Apply 3M™ AAD Part number 8672 or equivalent to the threads of the engine oil pressure switch.

Scheme 641

>> D << SEALANT APPLICATION TO ENGINE OIL

Scheme 642

Scheme 643

1. Apply 3M™ AAD Part number 8672 or equivalent to the threads of the engine oil pressure switch.
2. Using special tool MD998054, tighten the engine oil pressure switch to the specified torque. Tightening torque: 19 +/- 3 N.m (14 +/- 2 ft-lb)

Scheme 644

Scheme 645

1. Apply a 3 mm (0.12 inch) diameter bead of sealant MITSUBISHI Genuine Part number MD970389 or equivalent to the groove as shown in the illustration.
2. Coat the threads of the seal bolt in the illustration with 3M™ AAD Part number 8672 or equivalent before tightening.
3. Install the housing quickly (within 15 minutes) while the sealant is wet and tighten the bolts to the specified torque. Tightening torque: 24 +/- 4 N.m (18 +/- 2 ft-lb) NOTE: After installation, keep the sealed area away from the coolant for approximately one hour.

Scheme 646

1. Check that the rubber ring is undamaged and seated correctly in the thermostat flange.
2. Install the thermostat as shown in the illustration. The jiggle valve must be at the top position.

>> G << SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT

Apply 3M™ AAD Part number 8672 or equivalent to the engine coolant temperature gauge unit.

Scheme 647

Scheme 648

1. Install the intake manifold stay and tighten the bolts just finger tight.
2. Check to ensure that the stay is in close contact with the bosses of the intake manifold and cylinder block.
3. First tighten the intake manifold side bolts to the specified torque, then the cylinder block side bolts to the specified torque. Tightening torque: 31 +/- 3 N.m (23 +/- 2 ft-lb)

Scheme 649

1. Attach a new O-ring to each end of the water inlet pipe.
2. Wet the O-ring with water.
3. Insert the rear end of the pipe into the thermostat housing.

REMOVAL AND INSTALLATION

Scheme 650

Required Special Tools

1. MD998713: Camshaft Oil Seal Installer

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

When the rocker arm is removed from the rocker shaft, tag them to show the installation location for the reinstallation of the rocker arm, the T-lever, the piston arm assembly and so on.

>> A << ENGINE OIL CONTROL / O-RING VALVE INSTALLATION

Scheme 651

1. Apply a little amount of engine oil to the O-ring of engine oil control valve.
2. Install the engine oil control valve to the cylinder head.
3. Tighten the engine oil control valve to the specified torque of 11 +/- 1 N.m.

>> B << ADJUSTING SCREW INSTALLATION

When installing provisionally the screw to rocker arm, project it slightly 3mm (0.12 in) from the same face level of the rocker arm end.

Scheme 652

Scheme 653

Scheme 654

1. In accordance with the tags made during removal, install the rocker arm, and other parts to the rocker arm shaft.
2. Install the more chamfered rocker arm shaft to the timing belt.
3. Install the rocker arm shaft with oil hole to the lower (cylinder head) side.
4. Temporarily install the rocker arm, rocker arm shaft assembly and intake.
5. Temporarily install the rocker arm, rocker arm shaft assembly and exhaust.
6. Confirm the each rocker arm and rocker arm shaft assembly are in position and then tighten to the specified torque. Tightening torque: M6: 13 +/- 1 N.m M8: 31 +/- 3 N.m

Scheme 655

1. Apply engine oil to the lip area of the oil seal and the front end outside diameter of camshaft.
2. Using special tool MD998713, install the camshaft oil seal.

CAMSHAFT

Measure the cam height. If it is below the limit, replace the camshaft.

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Required Special Tools

1. MB991654: Cylinder Head Bolt Wrench (12)
2. MD998735: Valve Spring Compressor
3. MD998774: Valve Stem Seal Installer

<< A>> CYLINDER HEAD BOLTS REMOVAL

Using special tool MB991654, loosen the cylinder head bolts.

Loosen each bolt evenly, little by little, in two or three steps.

Scheme 660

Scheme 661

1. Set special tool MD998735 as illustrated to compress the valve spring. Remove the retainer lock.
2. Relieve the spring tension and remove the valve, retainer, spring, etc. Tag the removed valves, springs, and other parts, to indicate their cylinder number and location for reassembly.

INSTALLATION SERVICE POINTS

Scheme 662

1. Install the valve spring seat.
2. Using special tool MD998774, install a new valve stem seal.

>> B << VALVE SPRING INSTALLATION

Install the valve spring with its identification color painted end (larger pitch side) upward (toward the valve spring retainer).

Identification

< Intake> Light blue

< Exhaust> Orange

Scheme 663

Scheme 664

1. Set special tool MD998735 as illustrated to compress the valve spring. Install the retainer locks.
2. Relieve the spring tension. Check that the retainer locks are seated correctly.

Scheme 665

Scheme 666

Scheme 667

Scheme 668

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, using the tightening sequence shown. Tightening torque: 78 +/- 2 N.m (58 +/- 2 ft-lb)
4. Loosen all bolts fully in the reverse order of tightening.
5. Retighten the loosened bolts to the specified torque in the tightening sequence shown. Tightening torque: 20 +/- 2 N.m (15 +/- 1 ft-lb)
6. Make a paint mark across each bolt head and cylinder head.
7. Tighten the cylinder head bolts 90 degrees in the specified order. CAUTION: If the bolt is turned less than 90 degrees, proper fastening performance may not be achieved. Be careful to turn each bolt exactly 90 degrees. If the bolt is overtightened, loosen the bolt completely and then retighten it by repeating the tightening procedure from step 1.
8. Tighten the bolts another 90 degrees 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 669

1. Check the cylinder head gasket surface for flatness by using a straight edge and feeler gauge. Standard value: 0.03 mm (0.001 inch) Limit: 0.2 mm (0.007 inch)
2. If it exceeds the limit, correct to meet specification. Grinding limit: *0.2 mm (0.007 inch) * Includes combined with cylinder block grinding. Cylinder head height (Specification when new): 120 mm (4.7 inches)

Scheme 670

Scheme 671

1. Check the valve seat contact. Valve seat contact should be uniform at the center of the valve face. If incorrect, reface using a valve reface.
2. If the margin is below the limit, replace the valve. Standard value: < Intake> 1.0 mm (0.03 inch) < Exhaust> 1.2 mm (0.04 inch) Minimum limit: < Intake> 0.5 mm (0.02 inch) < Exhaust> 1.0 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less than the limit, replace the valve. Standard value: < Intake> 111.33 mm (4.383 inches) < Exhaust> 113.54 mm (4.470 inches) Minimum limit: < Intake> 110.83 mm (4.363 inches) < Exhaust> 113.04 mm (4.450 inches)

Scheme 672

1. Measure the free height of the spring. If it is less than the limit, replace. Standard value: < Intake> 54.8 mm (2.16 inches) < Exhaust> 56.1 mm (2.21 inches) Minimum limit: < Intake> 53.8 mm (2.12 inches) < Exhaust> 55.1 mm (2.17 inches)
2. Measure the squareness of the spring. If it exceeds the limit, replace. Standard value: 2 degrees or less Limit: 4 degrees

VALVE GUIDE

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

Scheme 673

Standard value

< Intake> 0.02 - 0.04 mm (0.0008 - 0.0016 inch)

< Exhaust> 0.04 - 0.06 mm (0.0016 - 0.0024 inch)

Limit

< Intake> 0.10 mm (0.003 inch)

< Exhaust> 0.15 mm (0.005 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.

Scheme 674

Standard value

< Intake> 48.33 mm (1.902 inches)

< Exhaust> 48.34 mm (1.903 inches)

Limit

< Intake> 48.83 mm (1.922 inches)

< Exhaust> 48.84 mm (1.923 inches)

Scheme 675

1. Before correcting the valve seat, check for clearance between the valve guide and valve and, if necessary, replace the valve guide.
2. Using the seat grinder, correct to obtain 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.

Scheme 676

Scheme 677

1. Cut the valve seat from the inside to thin the wall thickness. Then, remove the valve seat.
2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. Intake seat ring hole diameters 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 seat ring hole diameters 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. Before fitting the valve seat, either heat the cylinder head up to approximately 250°C (482°F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the specified width and angle. See «VALVE SEAT RECONDITIONING PROCEDURE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#overhaul-24l-except-evolution-sportback) .

Scheme 678

1. Using a press, remove the valve guide toward the cylinder block. CAUTION: Do not install a valve guide of the same size again.
2. Rebore the valve guide hole of the cylinder head so that it fits the press-fitted oversize valve guide. Valve guide hole diameters 0.05 oversize 11.05 - 11.07 mm (0.4350 - 0.4358 inch) 0.25 oversize 11.25 - 11.27 mm (0.4429 - 0.4437 inch) 0.50 oversize 11.50 - 11.52 mm (0.4528 - 0.4535 inch)
3. Press-fit the valve guide until it protrudes 14.0 mm (0.55 inch) from the cylinder head top surface as shown in the illustration. NOTE: When press-fitting the valve guide, work from the cylinder head top surface. NOTE: Pay attention to the difference in length of the valve guides. [Intake side: 45.5 mm (1.79 inches); exhaust side: 50.5 mm (1.99 inches)] NOTE: After installing the valve guides, insert new valves in them to check for smooth operation.

Scheme 679

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 Cutter
9. MD998783: Plug Wrench Retainer

Scheme 680

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 681

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

Scheme 682

Scheme 683

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.

Scheme 684

Scheme 685

Scheme 686

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 687

Scheme 688

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 689

Scheme 690

Scheme 691

Scheme 692

1. Install the guide pin of the special tool MD998705 in the threaded hole of the cylinder block as shown.
2. Align the ratchet ball of the special tool MD998705 with the oil hole in the rear bearing to install the bearing of the special tool MD998705.
3. Apply engine oil to the bearing outer surface and bearing hole in the cylinder block.
4. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole of the cylinder block.

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

1. Remove the rear bearing installing portion from the special tool MD998705.
2. Install the guide pin of special tool MD998705 in the threaded hole of the cylinder block as shown.
3. Align the ratchet ball of the special tool MD998705 with the oil hole in the rear bearing to install the bearing of the special tool MD998705.
4. Apply engine oil to the front bearing outer surface and bearing hole in the cylinder.
5. Using special tool MD998705, install the rear bearing. Make sure that the oil hole of the bearing is aligned with the oil hole 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 698

>> E << OIL PUMP OIL SEAL INSTALLATION

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

Scheme 699

>> F << CRANKSHAFT FRONT OIL SEAL INSTALLATION

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

Scheme 700

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

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

Scheme 701

Scheme 702

Scheme 703

Scheme 704

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 front case carefully to prevent damaging the oil seal. CAUTION: Carefully install the tightening bolts paying attention to their different lengths, respectively.
4. Tighten all flange bolts to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

Scheme 705

Scheme 706

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 707

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

Scheme 708

Scheme 709

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.
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) bolt in each of the two holes identified by the letter "S" in the illustration and a 10 mm (0.39 inch) bolt in each of the remaining 17 holes. Tighten all bolts to the specified torque. Tightening torque: 9.0 +/- 3.0 N.m (80 +/- 26 in-lb) NOTE: After installation, keep the sealed area away from oil for approximately one hour.

>> L << DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction shown.

Scheme 710

Scheme 711

Scheme 712

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the o-ring of the oil filter.
3. Using general service tool, install the oil filter to the bracket and tighten it to the specified torque. Tightening torque: Part number MD356000 filter: 14 +/- 2 N.m (124 +/- 17 in-lb) Other Mitsubishi Genuine filter: 17 +/- 3 N.m (13 +/- 1 ft-lb)
4. If a torque wrench cannot be used, use the following procedure: Screw in the oil filter until its o-ring contacts the oil filter bracket. Tighten the oil filter as follows: Part number MD356000 filter: one turn Other Mitsubishi Genuine filter: 3/4 turn

FRONT CASE

1. Check the oil passage for clogging. Clean if necessary.
2. Check the left counterbalance shaft front bearing for wear, damage and seizure. If the bearing is damaged, replace the front case.
3. Check the front case for cracks and other damage. Replace cracked or damaged front case.

OIL SEAL

1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.

Scheme 713

1. Check the oil holes for clogging and clean if necessary.
2. Check the journal for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the counterbalance shaft, bearing or front case assembly if required.

Scheme 714

1. Assemble the oil pump gears to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover.
3. Check the side clearance. Standard value: Drive gear 0.08 - 0.14 mm (0.0031 - 0.0055 inch) Driven gear 0.06 - 0.12 mm (0.0024 - 0.0047 inch)

Scheme 715

Required Special Tool

1. MIT216941: Piston Pin Setting Tool

Scheme 716

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 717

Scheme 718

Scheme 719

1. Remove the stop screw from the base.
2. Select the correct piston support for your application (Scheme 717) 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 (Scheme 718) 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: 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.
5. Press the piston pin out of the assembly.
6. Remove the piston pin from the press pin.

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

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. 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.

>> B << OIL RING INSTALLATION

Scheme 725

Scheme 726

Scheme 727

1. 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 hand. (Scheme 725) 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 (Scheme 726)
2. Install the lower side rail in the same manner as described in step 2.
3. Make sure that the side rails move smoothly in both directions.

Scheme 728

Scheme 729

Scheme 730

1. 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.
2. Install the number 1 piston ring in the same manner as step 1. Identification mark: Number 1 ring: None Number 2 ring: 2R NOTE: Confirm the profile for No. 1 and No. 2 piston rings carefully. Install them correctly by paying careful attention to the direction of the top and bottom. NOTE: The identification mark and the size mark are stamped on the upper plane of the piston ring (piston top side).
3. To prevent incorrect installation, check the identification mark of each piston ring. The identification mark is stamped near the ring gap.

Scheme 731

Scheme 732

Scheme 733

1. Measure the crankshaft pin diameter and confirm its classification from the following table. On a crankshaft supplied as a service part, identification marks of its pins are stamped at the positions shown in the illustration.
2. If the crankshaft pin outside diameter identification mark is "I," for example, select a bearing whose identification mark is "1." If there is 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 734

Scheme 735

1. Apply engine oil to 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.
3. Rotate the crankshaft so that the 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 the front mark on the piston crown pointing to the timing belt side.
6. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.

Scheme 736

Scheme 737

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 738

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 installing 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 the specified torque to install the cap properly. Tightening torque: 20 +/- 2 N.m (14 +/- 1 ft-lb)
5. Make a paint mark on the head of each nut.
6. Make a paint mark on the bolt end at the position 90 to 94 degrees from the paint mark made on the nut in the direction of tightening the nut. CAUTION: If the nut is turned less than 90 degrees, proper fastening performance may not be achieved. Be careful to tighten the nut exactly 90 degrees. If the nut is overtightened (exceeding 94 degrees), loosen the nut completely and then retighten it by repeating the tightening procedure from step 3.
7. Turn the nut 90 to 94 degrees and make sure that the paint marks on the nut and bolt are aligned.

PISTON

Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked.

PISTON PIN

1. Insert the piston pin into the piston pin hole with your thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is an excessive play.
2. The piston and piston pin must be replaced as an assembly.

Scheme 739

Scheme 740

1. Check the piston ring for damage, excessive wear, and breakage. Replace if defects are evident. If the piston has been replaced, the piston rings must also be replaced.
2. Check for clearance between the piston ring and ring groove. If it exceeds the limit, replace the ring or piston, or both. Standard value: Number 1: 0.03 - 0.07 mm (0.0012 - 0.0027 inch) Number 2: 0.02 - 0.06 mm (0.0008 - 0.0023 inch) Limit: 0.1 mm (0.003 inch)
3. Insert 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 ring gap is excessive, replace the piston ring. Standard value: Number 1: 0.15 - 0.30 mm (0.006 - 0.012 inch) Number 2: 0.28 - 0.43 mm (0.011 - 0.017 inch) Oil: 0.10 - 0.40 mm (0.003 - 0.015 inch) Limit: Number 1, Number 2: 0.8 mm (0.03 inch) Oil: 1.0 mm (0.03 inch)

Scheme 741

Scheme 742

1. Remove oil from the crankshaft pin and the connecting rod bearing.
2. Cut plastic gauging material to the same length as the width of the bearing and place it on the pin, parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified torque.
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 the plastic gauging material package. Standard value: 0.02 - 0.05 mm (0.0008 - 0.0019 inch) Limit: 0.1 mm (0.003 inch)

Scheme 743

Required Special Tools

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

Scheme 744

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 grooved side facing toward the crankshaft web.

>> B << CRANKSHAFT BEARING INSTALLATION

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

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

1. Measure the crankshaft journal diameter and confirm its classification from the following table. 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.
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. 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 "2" for number 1, 2, 4 and 5, and a bearing whose identification mark is "1" for number 3. If there is no identification mark on the crankshaft, measure the journal outside diameter and select a bearing appropriate for the measured value.
3. Install the bearings having an oil groove to the cylinder block.
4. Install the bearings having no oil groove to the bearing cap.

Scheme 750

Scheme 751

Scheme 752

Scheme 753

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: 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 the specified torque in the tightening sequence shown. Tightening torque: 25 +/- 2N.m (18 +/- 1 ft-lb)
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap 90 degrees 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 degrees, proper fastening performance may not be achieved. Be sure to turn the bolt exactly 90 degrees.
7. Turn each bolt 90 degrees 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 (0.015 inch)

>> D << OIL SEAL INSTALLATION

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

Scheme 754

Scheme 755

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 756

Scheme 757

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 758

Scheme 759

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. Standard value: Cylinder inner diameter 87.0 mm (3.43 inches) Cylindrically 0.01 mm (0.0003 inch) or less

Scheme 760

Scheme 761

1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification 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

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

General Specifications

Scheme 762

Scheme 763

Scheme 764

Scheme 765

See also:
• VALVE SEAT RECONDITIONING PROCEDURE