Engine Overhaul <2.0l Turbo> - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT

Plastic region tightening bolts are used in some parts of the engine. Install these bolts according to the method described in the service information because the tightening method of these bolts are different from the conventional method. The service limit is determined for these bolts. Be sure to strictly follow the service limit described in the service information.

1. Parts to be used Cylinder head bolt Bearing cap bolt Connecting rod cap bolt
2. Tightening method After tightening to the specified torque, further tighten 45° and 90°, or 180° (90° + 90°). Follow the tightening method described in the service information because the tightening method differs from part to part.

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES

Note. The number in square brackets shows the part number.

LIQUID GASKET (FIPG)

FIPG is used for some parts in the engine. It is necessary to pay attention to an application amount, application procedure and applied surface condition for this gasket to fully achieve its purpose.

Too small application amount of FIPG or the dirty surface where the FIPG is applied might cause the FIPG leakage. Too large application amount of FIPG overflows and might clog or narrow the passage of water or oil. It is absolutely essential that the surface where the FIPG is applied must be cleaned and the appropriate amount of FIPG must be evenly applied to prevent the leakage from the connected area.

FIPG used for engine parts hardens reacting with moisture in the air, and is usually used for metal flanges.

DISASSEMBLY

Parts assembled with FIPG can be easily disassembled without using a special method. In some cases, however, it is necessary to lightly tap parts with a wooden hammer or similar tool to break sealant between mating surfaces. Or lightly driving a smooth and thin gasket scraper in mating surfaces is useful, but full care must be exercised not to damage mating surfaces. As special tool oil pan FIPG cutter (MD998727) is set, use this tool.

CLEANING OF GASKET SURFACE

Completely remove all deposits from the gasket surface with a gasket scraper or wire brush. Make sure that the surface to which FIPG is applied is smooth. The gasket surface must be free from grease and foreign substances. Be sure to remove old FIPG that has entered mounting holes and screw holes.

APPLICATION PROCEDURE

Apply FIPG in a determined diameter and continuously without break. Completely enclose the periphery of mounting holes. FIPG can be wiped off if it is not hardened. Install parts in place while FIPG is still wet. Take care not to allow FIPG to adhere to other locations than necessary locations during installation. Do not pour oil or water on applied locations or do not start the engine until sufficient time (approximately one hour) passes. The application procedure of FIPG may differ depending on areas. Follow the procedure in the service information to apply FIPG.

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB991883 Flywheel stopper - Securing of flywheel MB990767 Front hub and flange yoke holder MB990767-01 Holding the crankshaft pulley MD998719 Pin MIT308239 MB991398 Spark plug wrench - Removal and installation of spark plug MB992106 O-ring installer - Installation of O-ring on injector injection nozzle side MB991614 Angle gauge General service tool Installation of turbocharger and pipe assembly bolt and nut MB991610 Oil filter wrench General service tool Removal and installation of oil filter MD998727 Oil pan FIPG cutter MD998727-01 Removal of oil pan MB991448 Bushing remover and installer base MB991448-01 Press fit of front oil seal MD998735 Valve spring compressor MD998735-01 Compression of valve spring MB992089 Retainer holder C MB992089-01 MB992085 Valve stem seal pliers - Extraction of valve stem seal MD998737 Valve stem seal installer MD998737-01 Installation of valve stem seal MB992236 Circlip installer - Installation of circlip MD998780 Piston pin setting tool MIT216941 MB991346 Top cover wrench - Holding the oil pump sprocket

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Scheme 510

Required Special Tools

1. MB990767: Front Hub And Flange Yoke Holder
2. MB991398: Spark Plug Wrench
3. MB991883: Flywheel Stopper
4. MD998719: Pin

Scheme 511

Scheme 512

1. Use special tool MB991883 to secure the flywheel. Use the special tool MB990767 and MD998719 to insert the pin into the crankshaft pulley hole and prevent it from rotating.
2. Remove the crankshaft pulley center bolt.

<< B >> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

Scheme 513

>> A << SPARK PLUGS INSTALLATION

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

Specified torque: 18 ± 2 N.m (13 ± 1 ft-lb)

Scheme 514

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Scheme 518

1. Use special tool MB991883 to secure the flywheel. Use the special tool MB990767 and MD998719 to insert the pin into the crankshaft pulley hole and prevent it from rotating.
2. Wipe off the dirt on the crankshaft pulley washer and on the thread hole of the crankshaft using a rag.
3. Wipe off the dirt on the crankshaft pulley and the crankshaft sprocket using a rag, and then remove the grease from the portion shown in the illustration. NOTE: Remove grease to prevent the coefficient of friction of the pressing portion from declining due to adhesion of oil.
4. Install the crankshaft pulley.
5. Apply an appropriate and minimum amount of engine oil to the threaded portion of the crankshaft and lower part of the flange.
6. With off the chamfered side on the inside of the washer facing the bolt top, install the washer to the crankshaft pulley center bolt.
7. Tighten the crankshaft pulley center bolt to 250 N.m (164 ft-lb)
8. Loosen the crankshaft pulley center bolt fully.
9. Tighten the crankshaft pulley center bolt to 110 N.m (81 ft-lb).
10. As shown in the illustration "A," apply the paint mark to the crankshaft pulley on the extended line of the corner adjacent to the one of the crankshaft pulley center bolt corners. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
11. Tighten the crankshaft pulley center bolt by 60° once more. Make sure the paint mark of crankshaft pulley center bolt is aligned with the paint mark of crankshaft pulley as shown in the illustration "B."

Scheme 519

1. Temporarily tighten power steering pump bracket bolts. CAUTION: Always loosen the power steering pump bracket bolt, and temporarily install the generator. Then tighten each bolt.
2. Loosen the power steering pump bracket bolts and make the power steering pump bracket unfixed.
3. Temporarily install the generator with the generator bolts.
4. Tighten them to the specified torque according to the order as illustrated in the figure. Specified torque Power steering pump bracket: M8 23 ± 2 N.m (17 ± 1 ft-lb) M10 44 ± 8 N.m (32 ± 5 ft-lb) Generator: 44 ± 10 N.m (32 ± 7 ft-lb)

Scheme 520

>> A << MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSTALLATION

>> B << THROTTLE BODY GASKET INSTALLATION

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

Scheme 521

Scheme 522

Required Special Tool

1. MB992106: O-ring Installer

>> A << ENGINE OIL PRESSURE SWITCH INSTALLATION

Scheme 523

1. Completely remove sealant adhering to the engine oil pressure switch and cylinder block threaded holes.
2. Apply sealant (Three bond 1215, Three bond 1212D or equivalent) of 5 mm (0.2 inch) to the threaded portion of the engine oil pressure switch shown in the illustration.
3. Tighten the engine oil pressure switch to the cylinder block to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)

>> B << KNOCK SENSOR INSTALLATION

Align the knock sensor connector with the position shown in the illustration, and then tighten it to the specified torque.

Specified torque: 20 ± 2 N.m (15 ± 1 ft-lb)

Scheme 524

>> C << INTAKE MANIFOLD STAY INSTALLATION

Make sure that the intake manifold stay is in intimate contact with the intake manifold and cylinder block boss before tightening it to the specified torque.

Specified torque: 23 ± 6 N.m (17 ± 4 ft-lb)

Scheme 525

>> D << O-RING INSTALLATION

When inserting an O-ring into the injector on the injection nozzle side, use special tool MB992106 to gradually expand the O-ring, and fit it in place.

Scheme 526

>> E << INJECTOR/O-RING/INJECTOR SUPPORT INSTALLATION

Scheme 527

Scheme 528

1. Apply gasoline to the O-ring of the injector.
2. Insert the injector into the fuel rail while rotating the injector from side to side, taking care not to damage the O-ring.
3. Check that the injector rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the injector and check the O-ring for damage. Then, insert it again into the fuel rail and check.
4. Make sure that the protrusion of the injector is at the center as shown in the illustration.
5. Securely assemble the injector to the injector groove and fuel rail collar.

>> F << FUEL RAIL ASSEMBLY INSTALLATION

1. Apply gasoline to the pressure side O-ring of the injector.
2. Tighten the fuel rail assembly to the intake manifold to the specified torque. Specified torque: 12 ± 3 N.m (106 ± 26 in-lb)

>> G << FUEL PRESSURE REGULATOR INSTALLATION

1. Apply gasoline to the new O-ring. CAUTION: Do not allow gasoline to enter the fuel rail.
2. Insert the fuel pressure regulator into the fuel rail while rotating the injector from side to side, taking care not to damage the O-ring.
3. Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the fuel pressure regulator and check the O-ring for damage. Then, insert it again into the fuel rail and check.

Scheme 529

1. Apply gasoline to the new O-ring.
2. Check that the fuel pressure regulator rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the fuel pressure regulator and check the O-ring for damage. Then, insert it again into the fuel rail and check.

Scheme 530

Required Special Tool

1. MB991614: Angle Gauge

>> A << AIR OUTLET FITTING GASKET INSTALLATION

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

Scheme 531

>> B << WATER PIPE B INSTALLATION

Make sure the bracket of water pipe "B" is inserted into the hole of turbocharger as shown in the illustration, and then install the eye bolt.

Note. Be sure to install the gasket.

Scheme 532

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Scheme 534

1. Make sure the identification hole is properly in position as shown in the illustration, and then install the coned disc spring in the appropriate installation direction.
2. Tighten the bolts and nuts to the specified torque. Specified torque: 29 ± 2 N.m (21 ± 1 ft-lb)
3. Use special tool MB991614 to tighten bolts and nuts 65° ± 5°. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt and nut to start from the beginning again according to the procedure.

Scheme 535

1. After temporarily tightening the turbocharger bracket with the installation bolts, check the exhaust manifold fastens securely to the cylinder block and the turbocharger.
2. Tighten the cylinder block side bolt to the specified tightening torque. Specified torque: 51 ± 7 N.m (38 ± 4 ft-lb)
3. Tighten the turbocharger side bolt to the specified tightening torque. Specified torque: 64 ± 5 N.m (47 ± 3 ft-lb)

>> E << OIL RETURN PIPE GASKET INSTALLATION

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

Scheme 536

Scheme 537

1. After temporarily tightening the exhaust fitting bracket with the installation bolts, check the exhaust manifold fastens securely to the cylinder block and the exhaust fitting.
2. Tighten the cylinder block side bolt to the specified tightening torque. Specified torque: 51 ± 7 N.m (38 ± 4 ft-lb)
3. Tighten the exhaust fitting bracket side bolt to the specified tightening torque. Specified torque: 64 ± 5 N.m (47 ± 3 ft-lb)

Scheme 538

>> A << CRANKSHAFT POSITION SENSOR INSTALLATION

Tighten the crankshaft position sensor to the specified torque.

Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)

Scheme 539

1. Assemble the thermostat housing and water pipe
2. Install the thermostat housing gasket.
3. Install a new water pipe gasket so that the tab is positioned as shown in the illustration.
4. Temporarily tighten them to the cylinder head and water pump. Then tighten them to the specified torque. Specified torque: 24 ± 3 N.m (18 ± 1 ft-lb)

>> C << THERMOSTAT INSTALLATION

Install the thermostat with the jiggle valve facing almost straight upwards.

Scheme 540

>> D << WATER OUTLET FITTING GASKET INSTALLATION

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

Scheme 541

>> E << ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

Scheme 542

1. Apply an appropriate and minimum amount of sealant (LOCTITE 262, Three bond 1324N or equivalent) to the engine coolant temperature sensor, taking care not to allow sealant to squeeze out.
2. Tighten the engine coolant temperature sensor to the cylinder block to the specified torque. Specified torque: 30 ± 9 N.m (22 ± 6 ft-lb)

Scheme 543

Required Special Tools

1. MB991610: Oil Filter Wrench
2. MD998727: Oil Pan FIPG Cutter
3. MB991448: Bushing Remover And Installer Base

<< A >> OIL FILTER REMOVAL

Use special tool MB991610 to remove the oil filter.

Scheme 544

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Scheme 546

1. Remove oil pan tightening bolts. CAUTION: Lightly tap the oil pan FIPG cutter to drive in, taking care not to damage the ladder frame and oil pan sealed area.
2. Lightly tap special tool MD998727 to drive in the illustrated groove of the oil pan and ladder frame.
3. Lightly tap and slide special tool MD998727 to remove the oil pan.

<< C >> TIMING CHAIN CASE REMOVAL

If the timing chain case is difficult to remove, insert a hammer handle as shown in the illustration and lightly pry it.

Scheme 547

>> A << TIMING CHAIN CASE INSTALLATION

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Scheme 550

1. Completely remove liquid gasket adhering to the timing chain case, cylinder block and cylinder head.
2. Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and the cylinder head. CAUTION: Install the timing chain case within three minutes after applying liquid gasket.
3. Apply liquid gasket (Three bond 1217G or exact equivalent) of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) in thickness to the timing chain case. For illustrated A locations in the figure, however, apply liquid gasket of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) in diameter or liquid gasket of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) by putting one on top of another as shown in the illustration.
4. Completely remove the sealant remaining on the gasket which is the three-plane mating surface between the cylinder head and the cylinder block.
5. The engine oil remaining at the cylinder gasket overflows from the three-plane mating surface. Apply the liquid gasket (Three bond 1217G or exact equivalent) to this area as soon as grease is removed.
6. Install the timing chain case.
7. Tighten timing chain case mounting bolts to the specified torque. NOTE: Be careful when install mounting bolts as they are different in length. Specified torque 24 ± 4 N.m (18 ± 2 ft-lb) 10 ± 2 N.m (89 ± 17 in-lb) 10 ± 2 N.m (89 ± 17 in-lb) 13 ± 1 N.m (115 ± 8 in-lb)

Scheme 551

1. Apply engine oil to the internal circumference of the oil seal.
2. Use special tool MB991448 to install the front oil seal on the timing chain case.

Scheme 552

Scheme 553

1. Completely remove liquid gasket adhering to the cylinder block and oil pan.
2. Degrease the cylinder block and oil pan. CAUTION: Install the oil pan within three minutes after liquid gasket is applied.
3. Apply liquid gasket (Three bond 1217G [Mitsubishi Part No. 1000A923] or exact equivalent) of f2.5 ± 0.5 mm (0.10 ± 0.02 inch) of thickness in diameter to the illustrated area of the oil pan shown in the figure.
4. Tighten the oil pan to the specified torque. Specified torque M6: 10 ± 2 N.m (89 ± 17 in-lb) M8: 29 ± 2 N.m (21 ± 1 ft-lb)

Scheme 554

Scheme 555

1. Completely remove liquid gasket adhering to the cylinder head cover, timing chain case and cylinder head.
2. Degrease the cylinder head cover, timing chain case and cylinder head. CAUTION: Install the cylinder head cover immediately after liquid gasket is applied.
3. Appropriately use a minimum amount of sealant. Be careful not to allow sealant to squeeze out from the application area. Apply liquid gasket (Three bond 1217G [Mitsubishi Part No. 1000A923] or exact equivalent) of 4.0 mm (0.16 inch) of thickness in diameter.
4. Tighten the cylinder head cover to the tightening torque of 3.0 ± 1.0 N.m (27 ± 8 in-lb) in the order shown in the illustration.
5. Then, tighten it to the specified torque in the same order. Specified torque: 5.5 ± 0.5 N.m (49 ± 4 in-lb)

Scheme 556

1. Clean the oil filter mounting surface of the ladder frame.
2. Apply engine oil to the O-ring of the oil filter. CAUTION: Use special tool MB991610 to install the oil filter. Tightening it by hand causes oil leakage due to lack of torque.
3. Screw in the oil filter. When the O-ring contacts the mounting surface, use a filter wrench to tighten it specified torque. Specified torque: 3/4 turn (14 ± 2 N.m [124 ± 17 in-lb])

Scheme 557

Scheme 558

1. Insert a flatblade screwdriver into the release hole of the timing chain tensioner to release the latch.
2. Push the tensioner lever by hand and push in the plunger of the timing chain tensioner until it hits the bottom. Then, insert a hard wire (piano wire or the like) of f1.5 or hexagonal bar wrench (1.5 mm [0.05 inch]) into the fixing hole of the plunger.
3. Remove the timing chain tensioner.

<< B >> EXHAUST V.V.T. SPROCKET BOLT REMOVAL

Hold the hexagonal portion of the exhaust camshaft with a wrench and loosen the exhaust V.V.T. sprocket bolt.

Scheme 559

<< C >> INTAKE V.V.T. SPROCKET BOLT REMOVAL

Hold the hexagonal portion of the intake camshaft with a wrench and loosen the intake V.V.T. sprocket bolt.

Scheme 560

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Scheme 562

1. Assemble the intake V.V.T. sprocket assembly in the following procedure. Make sure that the knock pin of the inlet camshaft assembly is positioned facing straight upward. Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the intake V.V.T. sprocket assembly and the entire circumference of the area into which the intake V.V.T. sprocket assembly is inserted. Slowly insert the intake V.V.T. sprocket assembly into the normal position of the inlet camshaft assembly with its knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into the bottom and that the V.V.T. sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench.
4. Hold the hexagonal portion of the camshaft with a wrench and tighten the intake V.V.T. sprocket bolt to the specified torque. Specified torque: 85 ± 5 N.m (63 ± 3 ft-lb)

Scheme 563

1. Assemble the exhaust V.V.T. sprocket assembly in the following procedure. Make sure that the knock pin of the exhaust camshaft assembly is positioned facing straight upward. Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the exhaust V.V.T. sprocket assembly and the entire circumference of the area into which the exhaust V.V.T. sprocket assembly is inserted. Slowly insert the exhaust V.V.T. sprocket assembly into the normal position of the exhaust camshaft assembly with its knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into the bottom and that the V.V.T. sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench.
4. Hold the hexagonal portion of the camshaft with a wrench and tighten the camshaft sprocket bolt to the specified torque. Specified torque: 85 ± 5 N.m (63 ± 3 ft-lb)

Scheme 564

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Scheme 566

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Scheme 568

1. Align the timing mark of the V.V.T. sprocket.
2. Align the crankshaft sprocket key with illustrated positions in the figure.
3. Align the link plate (orange) with the timing mark of the exhaust V.V.T. sprocket and loop the timing chain.
4. Align the link plate (blue) with the timing mark of the intake V.V.T. sprocket to loop the timing chain. Rotate the intake V.V.T. sprocket by one or two teeth to align with the timing mark.
5. Align the timing mark of the crankshaft sprocket with the link plate (blue) to loop the timing chain. Because of timing chain slacks, hold it to prevent the timing mark from coming off the link plate (blue).
6. Make sure that the timing mark of each sprocket is aligned with the link plate (blue and orange) of the timing chain at all of three locations.
7. Install the timing chain guide and tensioner lever.

>> D << TIMING CHAIN TENSIONER INSTALLATION

1. Install the timing chain tensioner on the cylinder block and tighten it to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)
2. Remove the hard wire (piano wire or the like) of f1.5 or hexagonal bar wrench (1.5 mm [0.05 inch]) from the timing chain tensioner. This enables the plunger of the timing chain tensioner to push the tensioner lever to keep the timing chain tight.

INTAKE V.V.T. SPROCKET

Scheme 569

Scheme 570

Scheme 571

1. Seal with a tape all the intake camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the advanced angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the intake camshaft on a vise, install the intake V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the advanced angle, remove the stopper pin.
5. Turn the intake V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 12.5°) NOTE: The stopper pin is locked in the most retarded angle position.
6. After the check, remove the intake V.V.T. sprocket from the intake camshaft
7. Completely remove the tape sealing the intake camshaft ports for the advanced angle and for the retarded angle.

EXHAUST V.V.T. SPROCKET

Scheme 572

Scheme 573

Scheme 574

1. Seal with a tape all the exhaust camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the retarded angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the exhaust camshaft on a vise, install the exhaust V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the retarded angle, remove the stopper pin.
5. Turn the exhaust V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 17.5°) NOTE: The stopper pin is locked in the most advanced angle position.
6. After the check, remove the exhaust V.V.T. sprocket from the exhaust camshaft
7. Completely remove the tape sealing the exhaust camshaft ports for the advanced angle and for the retarded angle.

VALVE CLEARANCE ADJUSTMENT

Measure valve clearance as described in the following procedure.

Check and adjust the valve clearance with the timing chain installed.

Scheme 575

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Scheme 578

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Scheme 580

1. Rotate the crankshaft clockwise to align the timing mark of the V.V.T. sprocket with the top surface of the cylinder head as illustrated in the figure. (Set the No. 1 piston at top dead center on the compression stroke.)
2. Valve clearance can be measured at the illustrated location in the figure in this condition.
3. Use a thickness gauge to measure clearance between the camshaft and valve tappet. Standard value (when engine is cold) Intake side: 0.20 ± 0.03 mm (0.008 ± 0.001 inch) Exhaust side: 0.30 ± 0.03 mm (0.012 ± 0.001 inch)
4. If measured values are out of the standard value, record measured values.
5. Rotate the crankshaft by one turn clockwise to set the No. 4 piston at top dead center on the compression stroke. NOTE: The timing mark of the V.V.T. exhaust sprocket must be at the illustrated position in the figure.
6. Valve clearance can be measured at the illustrated location in the figure in this condition.
7. If measured values are out of the standard value, record measured values.
8. If the measured value is out of the standard value, replace the valve tappet. NOTE: There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 (0.1181 inch) and 3.690 mm (0.1453 inch).
9. Use the following procedure select a valve tappet. Measure thickness of a removed valve tappet. Calculate thickness of a valve tappet so that valve clearance meets the standard value. Thickness of valve tappet to be selected Thickness of removed valve tappet Measured valve clearance Formula Intake side: A = B + (C - 0.20 mm [0.008 inch]) Exhaust side: A = B + (C - 0.30 mm [0.012 inch])

Refer to " REMOVAL AND INSTALLATION " for removal, installation and inspection procedure of valve tappets.

Scheme 581

<< A >> FRONT CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

First remove a mounting bolt of the front camshaft bearing cap and then a mounting bolt of each camshaft bearing cap in the order shown in the illustration.

Scheme 582

<< B >> VALVE TAPPET REMOVAL

Pick out valve tappets with fingers and store removed valve tappets with tags describing the installed position attached for reassembly.

>> A << VALVE TAPPET INSTALLATION

Install valve tappets at the same position based on tags describing the installed position for reassembly.

Scheme 583

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Scheme 587

1. When replacing a camshaft bearing, select a bearing with the size corresponding to the identification mark in the table below.
2. Install camshaft bearings on the cylinder head. FRONT CAMSHAFT BEARING CAP SPECIFICATIONS Front camshaft bearing cap Camshaft bearing Identification mark Inner diameter mm (in) Identification mark 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3
3. The identification mark of the camshaft bearing is stamped at the illustrated position in the figure.
4. Set the dowel pins of the camshaft at the illustrated positions in the figure.
5. Install them upon checking the identification mark so as not to misidentify cap No. and to confuse the intake side with the exhaust side. Identification mark I: Intake side E: Exhaust side
6. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps. Specified torque: 12 ± 1 N.m (107 ± 8 in-lb)
7. Tighten each front camshaft bearing cap mounting bolt to the temporarily torque of 17 ± 3 N.m (14 ± 2 ft-lb) in the order shown (1) in the illustration.
8. Tighten each front camshaft bearing cap mounting bolt to the specified torque in the order shown (2) in the illustration. Specified torque: 30 ± 2 N.m (22 ± 1 ft-lb)

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

Scheme 588

1. Apply a small amount of engine oil to the O-ring of the engine oil control valve.
2. Install the engine oil control valve on the cylinder head.
3. Tighten the engine oil control valve to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)

CAMSHAFT

Measure camshaft height (camshaft major axis). If the height is less than the limit, replace the camshaft.

Standard value

Intake: 44.1 mm (1.74 inches)

Exhaust: 45.0 mm (1.77 inches)

Limit

Intake: 43.6 mm (1.72 inches)

Exhaust: 44.5 mm (1.75 inches)

Scheme 589

Scheme 590

Scheme 591

1. Thoroughly wipe oil on the outside diameter of the camshaft and the inside diameter of the bearing.
2. Install the bearing to the camshaft.
3. Put straightly the plastigage having the length of the bearing width on the journal axis, centering the axis.
4. Carefully install the bearing cap. Tighten the bolt as instructed in >> B << Bolt Installation Point.
5. Remove the bolt and the bearing cap carefully.
6. Measure the plastigage whose width is most compressed using the scale printed on the plastigage bag. When the measured value deviates from the standard one, replace the bearing. Standard value: 0.035 - 0.072 mm (0.0014 - 0.0028 inch) CAUTION: When the bearing is used again, be careful not to reverse the cylinder head side and the camshaft side during installation.

Scheme 592

1. Measure the valve tappet at the illustrated position in the figure. If the measured value is not in agreement with the value in the table corresponding to the identification mark, replace the valve tappet.
2. The valve tappet has an identification mark and stamping of thickness at illustrated positions in the figure. There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 mm (0.1181 inch) and 3.690 mm (0.1453 inch).

VALVE TAPPET THICKNESS SPECIFICATIONS

Scheme 593

Required Special Tools

1. MD998735: Valve Spring Compressor
2. MB992089: Retainer Holder C
3. MB992085: Valve Stem Seal Pliers
4. MD998737: Valve Stem Seal Installer

<< A >> RETAINER LOCK REMOVAL

Use a special tool MD998735 and MB992089 to compress the valve spring and to remove the retainer lock.

Note. Store removed parts such as valves and springs with tags describing cylinder No. and installed position attached for reassembly.

Scheme 594

<< B >> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to firmly pinch the base (larger external shape) of the stem seal and twist it right and left for pulling out.

Scheme 595

>> A << VALVE STEM SEAL INSTALLATION

Scheme 596

Scheme 597

1. Apply a thin coat of engine oil to a new valve stem seal.
2. Use special tool MD998737 to press fit the valve stem seal into the valve guide with the valve stem used as a guide.

>> B << VALVE SPRING INSTALLATION

Install the valve spring so that the painted side faces toward the camshaft.

Scheme 598

>> C << RETAINER LOCK INSTALLATION

Use a special tool MD998735 and MB992089 to compress the valve spring and to install the retainer lock.

Scheme 599

Scheme 600

1. Completely remove the liquid gasket on the upper plane of the cylinder block and the lower plane of the cylinder head. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Degrease the place specified in the illustration.
3. As shown in the illustration, apply a f2.0 to 3.0 mm (0.08 to 0.12 inch) of sealant (Three bond 1217G [Mitsubishi Part No. 1000A923] or exact equivalent) to the top face of cylinder block.
4. Install the cylinder head gasket. NOTE: Check that the center of the liquid gasket is located toward the cylinder gasket in the position specified in the illustration.
5. As shown in the illustration, apply a f2.0 to 3.0 mm (0.08 to 0.12 inch) of sealant (Three bond 1217G [Mitsubishi Part No. 1000A923] or exact equivalent) to the top face of cylinder head gasket.
6. Install the cylinder head assembly.

Scheme 601

Scheme 602

Scheme 603

1. Install new cylinder head bolts and washers in the following procedure. NOTE: Cylinder head bolts and washers must not be reused.
2. Apply an appropriate amount of engine oil to top and bottom surfaces of washers and threaded portion of bolts.
3. Install cylinder head bolts to the cylinder head. NOTE: Bolts and washers are different parts for bolts on the timing chain side.
4. Tighten cylinder head bolts in several steps to the specified torque according to the assembly order shown in the illustration. Specified torque: 35 ± 2 N.m (26 ± 1 ft-lb)
5. Put a paint mark on all of cylinder head bolt heads and cylinder head. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
6. Tighten the cylinder head 90° according to the tightening order. Tighten it further 90° and make sure that the paint mark on the cylinder head bolt is in a straight line with that on the cylinder head.

Scheme 604

1. Check the cylinder head for water leakage, gas leakage, damage or cracks before cleaning.
2. Completely remove oil, scale, sealant, carbon, etc. After cleaning oil passages, blow air to make sure that they are not clogged. CAUTION: The grinding limit shall be within 0.2 mm (0.01 inch) in combination with the cylinder block to be assembled.
3. For the flatness on the cylinder head bottom, measure distortion using a straight edge and thickness gauge. If the distortion exceeds the limit, grind and repair it. Distortion on bottom Standard value: Within 0.05 mm (0.002 inch) Limit: 0.2 mm (0.01 inch) Grinding limit: 0.2 mm (0.01 inch) Cylinder head height: 128.5 mm (5.06 inches)

Scheme 605

Scheme 606

1. Repair the valve seat if contact with the valve seat is poor, uneven or broken.
2. Measure the margin. If the limit is exceeded, replace the valve. Standard value: Intake 1.022 mm (0.0402 inch) Exhaust 1.094 mm (0.0431 inch) Limit: Intake 0.522 mm (0.0206 inch) Exhaust 0.594 mm (0.0234 inch)
3. Measure overall length of the valve. If the limit is exceeded, replace the valve. Standard value: Intake 113.18 mm (4.456 inches) Exhaust 105.89 mm (4.169 inches) Limit: Intake 112.68 mm (4.436 inches) Exhaust 105.39 mm (4.149 inches)

Scheme 607

1. Measure free height of the spring. If the limit is exceeded, replace the spring. Standard value: 51.5 mm (2.03 inch) Limit: 51.0 mm (2.01 inch)
2. Measure squareness of the spring. If the inclination exceeds the limit, replace the spring. Standard value: 2° or less Limit: 4°

VALVE GUIDE

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

Standard value

Intake 0.020 - 0.047 mm (0.0008 - 0.0019 inch)

Exhaust 0.030 - 0.057 mm (0.0012 - 0.0022 inch)

Limit

Intake 0.10 mm (0.004 inch)

Exhaust 0.15 mm (0.006 inch)

Scheme 608

VALVE SEAT

Assemble the valve, then measure the contact width. If the measurement exceeds the specified limit, replace the valve seat.

Standard value

Intake: 1.16 - 1.46 mm (0.046 - 0.058 inch)

Exhaust: 1.35 - 1.65 mm (0.053 - 0.065 inch)

Scheme 609

Scheme 610

1. Check clearance between valve guide and valve and replace the valve guide if necessary before repairing the valve seat.
2. Repair the valve seat so that seat width and seat angle are to the specified shape.
3. Lap valve and valve seat with lapping compound after repairing valve seat.

Scheme 611

Scheme 612

1. Scrape the valve seat to be replaced from inside to make its wall thickness thin before pulling out.
2. Repair the valve seat hole of the cylinder head to match it with the diameter of the oversize valve seat to be press fitted. Intake valve seat bore diameter: 0.3 O.S.: 36.22 - 36.24 mm (1.426 - 1.427 inches) Exhaust valve seat bore diameter: 0.3 O.S.: 30.22 - 30.24 mm (1.190 - 1.191 inches)
3. Press fit the valve seat, taking care not to score the cylinder head bore at room temperature.
4. Ream the valve seat. Refer to " «REPAIR PROCEDURE OF VALVE SEAT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-turbo-except-lancer-evolution) ."

Scheme 613

1. Pull out the valve guide with a press toward the cylinder block side.
2. Ream the valve guide hole of the cylinder head to match it with the diameter of the oversize valve guide to be press fitted. CAUTION: Do not use a valve guide with the same size as that of the pulled out valve guide because it cannot be press fitted. Valve guide bore diameter 0.25 O.S.: 11.23 - 11.25 mm (0.442 - 0.443 inch)
3. Press fit the valve guide to the illustrated dimension in the figure. Standard value: 14.6 - 15.2 mm (0.57 - 0.60 inch) NOTE: Press fit the valve guide from the cylinder head top surface.
4. After pressing fit the valve guide, insert a new valve to check for sliding.

Scheme 614

Required Special Tools

1. MB991346: Top Cover Wrench
2. MB991883: Flywheel Stopper

<< A >> FLYWHEEL BOLT REMOVAL

1. Use special tool MB991883 to secure the flywheel.
2. Remove the flywheel bolts.

<< B >> OIL PUMP SPROCKET REMOVAL

Fix the oil pump sprocket with a special tool MB991346, loosen a center bolt, and remove the oil pump sprocket.

Scheme 615

Scheme 616

Scheme 617

1. Pry the illustrated position shown in figure with a screwdriver.
2. If the ladder frame does not come off, insert a flat blade screwdriver into the gap between the ladder frame and bearing cap as shown in the illustration and lightly pry it to remove the ladder frame.

>> A << LADDER FRAME INSTALLATION

Scheme 618

Scheme 619

1. Completely remove liquid gasket adhering to the cylinder block and ladder frame. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.
3. Squeeze liquid gasket (Three bond 1217G or exact equivalent) of ø2.0 to 3.0 mm (0.08 to 0.12 inch) in thickness and apply it to the illustrated position of the ladder frame in the figure.
4. Tighten the ladder frame to the specified torque in the order shown in the illustration. Specified torque: 26 ± 1 N.m (19 ± 1 ft-lb)

Scheme 620

1. Wipe off the dirt on the crankshaft sprocket and the crankshaft using a rag, and then remove the grease from the portion shown in the illustration. NOTE: Remove grease to prevent a drop in the coefficient of friction of the pressing portion caused by adhesion of oil.
2. Set the No. 1 piston at top dead center on the compression stroke.
3. Install the crankshaft sprocket to the crankshaft.

>> C << OIL PUMP SPROCKET/OIL PUMP CHAIN INSTALLATION

1. Set the No. 1 piston at top dead center on the compression stroke.
2. Using the special tool MB991346, install the oil pump sprocket to the oil pump case.
3. Install the oil pump chain to the crankshaft sprocket.
4. Install the oil pump chain to the oil pump sprocket.

>> D << REAR OIL SEAL CASE INSTALLATION

Scheme 621

Scheme 622

1. Completely remove liquid gasket adhering to the cylinder block, ladder frame and rear oil seal case. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.
3. Apply a small amount of engine oil to the oil seal lip. CAUTION: Install the timing chain case within three minutes after applying liquid gasket.
4. Squeeze liquid gasket (Three bond 1217G or exact equivalent) of ø2.0 to 3.0 mm (0.08 to 0.12 inch) in thickness and apply it to the illustrated position in the figure of the cylinder block and ladder frame.
5. Install the rear oil seal case aligned with the locating pin and tighten it to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 ft-lb)

Scheme 623

Scheme 624

Scheme 625

1. Clean off sealant and oil of thread of crankshaft and flywheel bolt.
2. Use special tool MB991883 to secure the flywheel.
3. Apply engine oil to thread of crankshaft and bolt seat area of flywheel.
4. Apply the sealant (Three bond 1324 or equivalent) to the thread of flywheel bolt.
5. Tighten flywheel bolts to temporary torque 40 N.m (30 ft-lb) in the order shown to illustration.
6. Tighten flywheel bolts to specified torque in the order shown in the illustration. Specified torque: 130 N.m (96 ft-lb)

Scheme 626

1. Check the oil jet and check valve for clogging
2. Check the oil jet for damage and deformation

Scheme 627

Required Special Tools

1. MB992236: Circlip Installer
2. MD998780: Piston Pin Setting Tool

<< A >> CONNECTING ROD REMOVAL

Mark the connecting rod on the big end with the cylinder number it is being removed from.

Scheme 628

<< B >> SNAP RING REMOVAL

Insert the precise screwdriver into the service hole to remove the snap ring.

Scheme 629

<< C >> PISTON PIN REMOVAL

Scheme 630

1. Into each container, pour enough engine oil to completely cover a piston.
2. Heat the engine oil to warm the piston to approximately 70°C (158°F), and then remove the piston pin.

Scheme 631

Scheme 632

Scheme 633

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

1. When replacing a piston, check the cylinder bore size mark stamped on the illustrated position in the figure of the cylinder block and select a corresponding piston from the table below. CYLINDER BORE SIZE MARK SPECIFICATIONS Cylinder bore size mark Piston size mark A A B B or none C C NOTE: The piston size mark is indicated on the piston top face. CAUTION: The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure the heat the piston before pulling out the piston pin. Use care sine the piston is hot after heating.
2. Into each container, pour enough engine oil to completely cover a piston.
3. Heat the engine oil to warm the piston to approximately 70°C (158°F), and then remove the piston pin.
4. Sufficiently apply the engine oil to the outer circumference of piston pin and the small end hole of connecting rod.
5. Put the front mark of connecting rod and the front mark of piston toward the same side, and then insert the piston pin.
6. Install the circlip to the piston according to the following procedure: With the open side facing upward, install the new circlip to the special tool MB992236. Align the open side of circlip with the piston groove, and then set the circlip together with the special tool MB992236. Install the guide A (ø21.9 mm [0.88 inch]), to the push rod of special tool MD998780. Push the opposite side of open side with the special tool MD998780, and install the circlip to the piston groove. Make sure the circlip is seated into the groove. Unless seated into the groove, the circlip must be pushed with the special tool MD998780 again to be seated into the groove.
7. Check that the piston moves smoothly.

Scheme 640

Scheme 641

1. Assemble the spacer of the oil ring into the piston ring groove. Then, assemble the upper side rail, and after this assemble the lower side rail. NOTE: Install the side rail and end gap of the spacer so that they are at the position as shown in the illustration. CAUTION: The side rail may be broken if its end gap is widened by a ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, after fitting one end of the side rail into the piston groove, for easy assembly.
3. After assembling the oil ring into the piston, make sure that the side rail turns smoothly to either direction.

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

Use a piston ring expander to assemble piston rings with their identification marks facing upward. Piston rings can be assembled by hand without using the piston ring expander.

Scheme 642

Identification mark

No. 1 ring: 1R

No. 2 ring: 2R

Scheme 643

Scheme 644

Scheme 645

1. Apply a sufficient amount of engine oil to the circumference of the piston, piston rings and oil ring.
2. Arrange end gap positions of piston rings and oil ring (side rail and spacer) as shown in the illustration.
3. Insert the piston and connecting rod assembly from the top surface of the cylinder block with the front mark of the piston top face facing toward the timing chain side. CAUTION: Driving it in hard causes breakage of piston rings and damage to the crank pin.
4. Firmly tighten the piston ring with a ring band and insert the piston and connecting rod assembly.

Scheme 646

Scheme 647

1. When replacing a connecting rod bearing, select the bearing corresponding to the crankshaft pin outside diameter according to the crankshaft pin identification in the table below. CRANKSHAFT PIN SPECIFICATIONS Crankshaft pin Connecting rod bearing Identification mark Journal diameter mm (in) Identification color 1 51.966 - 51.972 (2.0459 - 2.0461) Black 2 51.960 - 51.966 (2.0457 - 2.0459) None 3 51.954 - 51.960 (2.0454 - 2.0457) Green
2. An identification mark of a crankshaft is stamped at the illustrated position in the figure by Number.
3. A connecting rod bearings an identification color at the illustrated position shown in the figure.

Scheme 648

Scheme 649

1. Assemble the bearing cap on the connecting rod by aligning it with the mark put during removal. If a new connecting rod without a mating mark is used, assemble so that the detent notch of the bearing is on the same side as illustrated in the figure.
2. Make sure that clearance of the thrust of the connecting rod big end is appropriate. Standard value: 0.10 - 0.25 mm (0.004 - 0.010 inch) Limit: 0.4 mm (0.02 inch)

Scheme 650

Scheme 651

1. Check in the following procedure before reusing the connecting rod bolt. Measure the outside diameter "A." Measure the smallest outside diameter "B" within the range "X" shown in the illustration. If the difference of outside diameter of thread exceeds the limit, replace the connecting rod bolt. Limit: 0.10 mm (0.004 inch)
2. Apply engine oil to the threaded portion and seat surface of the bolt before installing it.
3. After installing each bolt and tightening it by fingers, tighten bolts alternately to properly assemble the cap.
4. Tighten the bolt in several steps until the torque reaches 5.0 N.m (44 in-lb).
5. Tighten the bolt in several steps until the torque reaches 20 N.m (15 ft-lb).
6. Put a paint mark on the bolt head as illustrated in the figure.
7. Put a paint mark on the connecting rod at 90° position in the tightening direction of the bolt with reference to the paint mark position of the bolt. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
8. Tighten the bolt 90°, and make sure that the paint mark of the connecting rod is aligned with that of the bolt.

Scheme 652

Scheme 653

1. Check clearance between piston rings and ring grooves. If the limit is exceeded, replace piston rings or piston, or both. Standard value: No. 1 ring: 0.02 - 0.06 mm (0.001 - 0.002 inch) No. 2 ring: 0.02 - 0.06 mm (0.001 - 0.002 inch) Limit: 0.10 mm (0.004 inch)
2. Put piston rings into the cylinder bore, press them against the piston top face, and push them in. After achieving squareness, measure the end gap with a thickness gauge. If the end gap is excessive, replace piston rings. Standard value: No. 1 ring: 0.18 - 0.28 mm (0.007 - 0.011 inch) No. 2 ring: 0.28 - 0.43 mm (0.011 - 0.017 inch) Oil ring: 0.10 - 0.34 mm (0.004 - 0.013 inch) Limit: No. 1 ring: 0.8 mm (0.03 inch) No. 2 ring: 0.8 mm (0.03 inch) Oil ring: 1.0 mm (0.04 inch)

Scheme 654

Scheme 655

1. Wipe oil off the crankshaft pin and connecting rod bearing.
2. Place a plastigage in length equal to the bearing width on the pin shaft straight in alignment with the shaft center.
3. Carefully install the connecting rod cap and tighten bolts to the specified torque of 5.0 N.m (44 in-lb) --> 20 N.m (15 ft-lb) --> +90°.
4. Remove bolts and gently remove the connecting rod cap.
5. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag. Standard value: 0.038 - 0.069 mm (0.0015 - 0.0027 inch) Limit: 0.10 mm (0.004 inch)

Scheme 656

<< A >> CRANKSHAFT REMOVAL

After removing the crankshaft with the crankshaft sensing ring attached, temporarily place it on a V-block to prevent teeth of the sensing ring from deforming.

Note. If a tooth bends, be sure to replace the crankshaft sensing ring with a new one.

>> A << CRANKSHAFT SENSING RING INSTALLATION

Tighten crankshaft sensing ring bolts to the specified torque in the tightening order shown in the illustration.

Specified torque: 11 ± 1 N.m (98 ± 8 in-lb)

Scheme 657

Scheme 658

1. Install the thrust bearing on the No. 3 bearing on the cylinder block side. Application of engine oil makes the installation easier.
2. Install the thrust bearing so that the grooved side is on the crankshaft weight side.

Scheme 659

Scheme 660

1. When replacing the crankshaft bearing upper, select a bearing with the size corresponding to the crankshaft journal diameter in the table below.
2. The crankshaft bearing upper has an identification color at the illustrated position in the figure. CYLINDER BLOCK SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification color No. 1, 2, 4, 5 No. 3 No. 1, 2, 4, 5 No. 3 1 0 56.000 - 56.006 (2.2047 - 2.2050) Black Red 2 1 56.006 - 56.012 (2.2050 - 2.2052) None Black 3 2 56.012 - 56.018 (2.2052 - 2.2054) Green None
3. Install the selected crankshaft bearing upper.

Scheme 661

Scheme 662

1. When replacing the crankshaft bearing lower, select a bearing with the size corresponding to the crankshaft journal diameter in the table below.
2. The crankshaft bearing lower has an identification color at the illustrated position in the figure.
3. Install the selected crankshaft bearing lower. CYLINDER BLOCK SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification color No. 1, 2, 4, 5 No. 3 No. 1, 2, 4, 5 No. 3 0 8 51.985 - 51.988 (2.0467 - 2.0468) Red Brown 1 9 51.982 - 51.985 (2.0465 - 2.0467) Black Yellow 2 0 51.979 - 51.982 (2.0464 - 2.0465) None Red 3 1 51.976 - 51.979 (2.0463 - 2.0464) Green Black 4 2 51.973 - 51.976 (2.0462 - 2.0463) Blue None

Scheme 663

Scheme 664

Scheme 665

Scheme 666

1. Install the crankshaft bearing cap with reference to the identification mark as illustrated in the figure.
2. Before using the crankshaft bearing cap bolt again, carry out the check according to the following procedure: Measure the 2 points on the outside diameter of thread as shown in the illustration. When the difference between the measured outside diameters is beyond the limit value, replace the crankshaft bearing cap bolt. Limit value M10: 0.15 mm (0.006 inch) M8: 0.10 mm (0.004 inch)
3. Apply engine oil to the threaded portion and seat surface of the bolt.
4. Tighten crankshaft bearing cap bolts to the specified torque according to the tightening order shown in illustration. Specified torque M10: 37.2 ± 2.0 N.m (27 ± 1 ft-lb) M8: 9.0 ± 2.0 N.m (80 ± 17 in-lb)
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap 90° from the paint mark made on the bolt, in the direction of tightening the bolt. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
7. Turn each bolt 90° in the tightening sequence specified in step 1 and make sure that the paint marks on the bolt and cap are aligned.
8. Check end play of the crankshaft after installing the crankshaft bearing cap. If the end play exceeds the limit, replace the thrust bearing. Standard value: 0.05 - 0.25 mm (0.002 - 0.010 inch) Limit: 0.4 mm (0.02 inch)

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)

Oil clearance can be easily measured by using a "plastigage." When using a "plastigage," perform measurement in the following procedure.

Scheme 667

Scheme 668

1. Fully wipe oil off the outside diameter of the crankshaft and inside diameter of the bearing.
2. Assemble the crankshaft.
3. Place a plastigage in length equal to the bearing width on the journal shaft straight in alignment with the shaft center.
4. Carefully install the bearing cap and tighten the bolt according to the main point of installation >> B <<.
5. Remove the bolt, and then carefully remove the crankshaft bearing cap.
6. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag. Standard value: No. 1, 2, 4, 5: 0.039 - 0.065 mm (0.0015 - 0.0026 inch) No. 3: 0.051 - 0.077 mm (0.0020 - 0.0030 inch) Limit: 0.10 mm (0.004 inch)

Scheme 669

Scheme 670

1. Visually check the cylinder block for scratch, rust and corrosion. Use a flaw detecting agent to check for cracks. If it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block using a straight edge and thickness gauge. If distortion exceeds the limit, grind and repair it. A gasket or the like must not be adhered to the top surface of the cylinder block during measurement. Distortion on bottom Standard value: Within 0.05 mm (0.002 inch) Limit: 0.2 mm (0.01 inch) Grinding limit: 0.2 mm (0.01 inch)
3. Check the cylinder bore for scoring or seizure. If faulty replace.
4. Measure the bore and cylindricity of the cylinder using a cylinder gauge. If the cylinder is excessively worn, repair the cylinder and replace the piston and piston rings. Measuring points are as shown in the illustration. Standard value Cylinder bore: 86 mm (3.4 inches) Cylindricity: 0.010 mm or less (0.0004 inch)

See also:
• REMOVAL AND INSTALLATION