Engine Overhaul <2.4l> - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

REWORK DIMENSIONS

CYLINDER HEAD OVERSIZE VALVE REWORK SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE 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 tightening torque, further tighten 90° 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

SEALANTS SPECIFICATIONS

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 amount causes leakage while too much amount squeezes out to block or narrow water and oil passages. Therefore, it is absolutely essential to apply a correct amount of liquid sealant continuously without break to eliminate leakage from joints.

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 drive plate MB991398 Spark plug wrench - Removal and installation of spark plug MB992106 O-ring installer - Installation of O-ring on injector injection nozzle side MB991396 Oil filter wrench - 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 MD998780 Piston pin setting tool MIT216941 Extraction and press fit of piston pin MB991659 Guide D - MB991614 Angle gauge General service tool Installation of crankshaft bearing cap bolt and installation of balancer shaft module bolt MD998718 Rear oil seal installer MD998718-01 Press fit of rear oil seal

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Required Special Tool

1. MB991883: Flywheel Stopper
2. MB991398: Spark plug wrench

Scheme 677

1. Use special tool MB991883, to secure the drive plate.
2. Remove the crankshaft pulley center bolt.

<< B >> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

Scheme 678

>> A << SPARK PLUG INSTALLATION

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

Tightening torque: 25 ± 5 N.m (18 ± 3 ft-lb)

Scheme 679

Scheme 680

1. Use special tool MB991883, to secure the drive plate.
2. Wipe the dirt on the crankshaft pulley washer and on the thread hole of the crankshaft using a rag.
3. Wipe 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 the chamfered side on the inside of the crankshaft pulley washer facing the bolt top, install the crankshaft pulley washer to the crankshaft pulley center bolt.
7. Tighten the crankshaft pulley center bolt to the specified tightening torque. Tightening torque: 210 N.m (155 ft-lb)

Scheme 681

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 26 ± 3 N.m (19 ± 32 ft-lb) M10 44 ± 8 N.m (32 ± 5 ft-lb) Generator: 44 ± 10 N.m (32 ± 7 ft-lb)

Scheme 682

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

Scheme 683

Scheme 684

Scheme 685

1. Temporarily tighten each part so that the protrusion of each gasket is positioned as illustrated in the figure.
2. Tighten mounting bolts to the specified tightening torque in the order shown in the illustration. Tightening torque: 20 ± 2 N.m (15 ± 1 ft-lb)

>> C << EXHAUST GAS RECIRCULATION VALVE GASKET INSTALLATION

Install the Exhaust gas recirculation valve gasket with the diagonally shaded area used as the illustrated position in the figure so as not to confuse the front with the back.

Scheme 686

Scheme 687

1. Make sure that the throttle body gasket is placed before installing the throttle body.
2. Temporarily tighten throttle body and throttle body stay mounting bolts at A and B in the illustration.
3. Tighten the throttle body mounting bolt at illustrated position A in the figure to the specified torque. Tightening torque: 20 ± 2 N.m (15 ± 1 ft-lb)
4. Tighten the throttle body mounting bolts at illustrated position B in the figure to the specified tightening torque. Tightening torque: 9.5 ± 2.5 N.m (84 ± 22 in-lb)

Scheme 688

Required Special Tool

1. MB992106: O-ring installer

>> A << ENGINE OIL PRESSURE SWITCH INSTALLATION

Scheme 689

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

>> B << GENERATOR BRACKET INSTALLATION

Tighten the Generator bracket to the specified tightening torque.

Tightening torque: 44 ± 8 N.m (33 ± 5 ft-lb)

Note. Be careful to install mounting bolts because they are different in length.

Scheme 690

>> C << INTAKE MANIFOLD INSTALLATION

Tighten each inlet manifold bolt and nut to the temporarily torque of 3.5 ± 1.5 N.m (31 ± 13 in-lb).

>> D << INLET MANIFOLD STAY INSTALLATION

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

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

Scheme 691

Scheme 692

1. Apply gasoline to the O-ring.
2. 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.

>> F << INJECTOR AND INJECTOR SUPPORT INSTALLATION

Scheme 693

Scheme 694

1. Apply gasoline to the O-ring of the injector.
2. Insert the injector into the delivery pipe 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 delivery pipe 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 delivery pipe collar.

Scheme 695

1. Install the delivery pipe assembly, bracket and injector protector rear on the cylinder head.
2. Tighten mounting bolts together with temporarily tightened inlet manifold mounting bolts in the order shown in the illustration.
3. Tighten the delivery pipe assembly, bracket, injector protector rear and inlet manifold in the order shown in the illustration. Temporarily torque: 3.5 ± 1.5 N.m (31 ± 13 in-lb) Specified torque: 20 ± 2 N.m (15 ± 1 ft-lb)

Scheme 696

Scheme 697

>> A << CRANKSHAFT POSITION SENSOR/O-RING INSTALLATION

Tighten the crankshaft position sensor to the specified tightening torque of 11 ± 1 N.m (98 ± 8 in-lb).

>> B << EXHAUST MANIFOLD BRACKET INSTALLATION

Make sure that exhaust manifold bracket A is in intimate contact with the exhaust manifold and cylinder block, and then tighten it to the specified tightening torque.

Tightening torque

M10 x 30: 41 ± 10 N.m (30 ± 7 ft-lb)

M8 x 20: 20 ± 5 N.m (15 ± 3 ft-lb)

Scheme 698

Scheme 699

Scheme 700

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)

>> B << THERMOSTAT INSTALLATION

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

Scheme 701

>> C << WATER OUTLET FITTING GASKET INSTALLATION

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

Scheme 702

>> D << ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

Scheme 703

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

Scheme 704

Required Special Tool

1. MB991396: Oil filter wrench
2. MD998727: Oil pan FIPG cutter
3. MB991448: Bushing remover and installer base

<< A >> OIL FILTER REMOVAL

Use special tool MB991396 to remove the oil filter.

Scheme 705

Scheme 706

Scheme 707

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 oil pan FIPG cutter (MD998727) to drive in the illustrated groove of the oil pan and ladder frame in the figure.
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 708

>> A << TIMING CHAIN CASE INSTALLATION

Scheme 709

Scheme 710

Scheme 711

1. Completely remove the liquid gasket adhering to the timing chain case, the cylinder block and the cylinder head.
2. Completely remove the sealant remaining on the 3-plane contact surface among the cylinder head, the cylinder block and the gasket. Carry out the degreasing CAUTION: Install the timing chain case within three minutes after applying the liquid gasket.
3. Apply liquid gasket 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. Specified sealant: Three bond 1217G or exact equivalent
4. The engine oil staying at the cylinder gasket oozes to the 3-plane contact surface described in Step 2 and 3. Swiftly apply the liquid gasket to this area after degreasing. Specified sealant: Three bond 1217G or exact equivalent
5. Tighten timing chain case mounting bolts to the specified tightening torque. Tightening torque A: 24 ± 4 N.m (18 ± 2 ft-lb) B: 10 ± 2 N.m (89 ± 17 in-lb) C: 10 ± 2 N.m (89 ± 17 in-lb) D: 13 ± 1 N.m (115 ± 8 in-lb)

Scheme 712

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 713

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 of ø2.5 ± 0.5 mm (0.10 ± 0.02 inch) of thickness in diameter to the illustrated area of the oil pan shown in the figure. Specified sealant: Three bond 1217G or exact equivalent
4. Tighten the oil pan to the specified tightening torque. Tightening torque: M6:10 ± 2 N.m (89 ± 17 in-lb) M8: 29 ± 2 N.m (21 ± 1 ft-lb)

Scheme 714

Scheme 715

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. Besides, be careful not to allow sealant to squeeze out from the application area. Apply liquid gasket of 4 mm (0.15 inch) of thickness in diameter. Specified sealant: Three bond 1217G or exact equivalent
4. Tighten the cylinder head cover to the tightening torque in the order shown in the illustration. Tightening torque: 3.0 ± 1.0 N.m (27 ± 8 in-lb)
5. Then, tighten it to the specified tightening torque in the same order. Tightening torque: 5.5 ± 0.5 N.m (49 ± 4 in-lb)

Scheme 716

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 MB991396 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. Tightening torque 3/4 turns (14 ± 2 N.m [124 ± 17 in-lb])

Scheme 717

Scheme 718

1. Insert a flat-blade 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 [0.06 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 719

<< 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 720

Scheme 721

Scheme 722

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 tightening torque. Tightening torque: 59 ± 5 N.m (44 ± 3 ft-lb)

Scheme 723

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 tightening torque. Tightening torque: 59 ± 5 N.m (44 ± 3 ft-lb)

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

1. Align the timing mark of the V.V.T. sprocket.
2. Align the crankshaft sprocket keys 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 the timing chain slacks, hold it to prevent the timing mark from coming off the link plate.
6. Make sure that the timing mark of each sprocket is aligned with the link plate of the timing chain at all of three locations.
7. Install the timing chain guide and tensioner lever.

Scheme 729

1. Install the timing chain tensioner on the cylinder block and tighten it to the specified torque. Tightening 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 730

Scheme 731

Scheme 732

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 20°) 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 733

Scheme 734

Scheme 735

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 10°) 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 in the following procedure.

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

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 Number 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 free 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 Number 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 mm (0.1181 inch) and 3.690 mm (0.145 inch).
9. Select a valve tappet in the following procedure. Measure thickness of a removed valve tappet. Calculate thickness of a valve tappet so that valve clearance meets the standard value. A: Thickness of valve tappet to be selected B: Thickness of removed valve tappet C: Measured valve clearance Formula Intake side: A = B + (C - 0.20 mm [0.08 inch]) Exhaust side: A = B + (C - 0.30 mm [0.012 inch]) Refer to " «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-24l-except-lancer-evolution) " for removal, installation and inspection procedure of valve tappets.

Scheme 742

<< 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 743

<< 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 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

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. CAMSHAFT BEARING IDENTIFICATION MARKS Camshaft Camshaft bearing Identification mark Journal 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 painted at the illustrated position in the figure.
4. Set the dowel pins of the camshaft at the illustrated positions in the figure.
5. Camshaft bearing caps Number 1 to Number 4 are of the same shape. Install them upon checking the identification mark so as not to misidentify cap Number and to confuse the intake side with the exhaust side. Identification mark (stamped on front and Number 1 to Number 4 bearing caps) I: Intake side E: Exhaust side
6. Tighten each camshaft bearing cap mounting bolt to the specified tightening torque of 12 ± 1 N.m (107 ± 1 in-lb) in the order of number shown in the figure in two or three steps.
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 of number shown (1) in the illustration.
8. Tighten each front camshaft bearing cap mounting bolt to the specified tightening torque of 30 ± 2 N.m (22 ± 1 ft-lb) in the order of number shown (2) in the illustration.

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

Scheme 749

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

CAMSHAFT

Measure camshaft height (camshaft major axis). If the height exceeds the limit, replace the camshaft.

Standard value

Intake: 44.1 mm (1.736 inch)

Exhaust: 45.0 mm (1.772 inch)

Limit

Intake: 43.6 mm (1.717 inch)

Exhaust: 44.5 mm (1.752 inch)

Scheme 750

Scheme 751

Scheme 752

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 - 0.032 mm (0.0013 inch) CAUTION: When the bearing is used again, be careful not to reverse the cylinder head side and the camshaft side at the installation.

Scheme 753

Scheme 754

1. Check the thickness stamp.
2. If the measured value in the table value is not in agreement with the value in the table to the thickness stamp, replace the valve tappet. 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). VALVE TAPPET THICKNESS SPECIFICATIONS Thickness mm (in) Thickness stamp 3.000 (0.1181) 3.000 3.015 (0.1187) 3.015 3.030 (0.1193) 3.030 3.045 (0.1199) 3.045 3.060 (0.1205) 3.060 3.075 (0.1211) 3.075 3.090 (0.1217) 3.090 3.105 (0.1222) 3.105 3.120 (0.1228) 3.120 3.135 (0.1234) 3.135 3.150 (0.1240) 3.150 3.165 (0.1246) 3.165 3.180 (0.1252) 3.180 3.195 (0.1258) 3.195 3.210 (0.1264) 3.210 3.225 (0.1270) 3.225 3.240 (0.1276) 3.240 3.255 (0.1281) 3.255 3.270 (0.1287) 3.270 3.285 (0.1293) 3.285 3.300 (0.1299) 3.300 3.315 (0.1305) 3.315 3.330 (0.1311) 3.330 3.345 (0.1317) 3.345 3.360 (0.1323) 3.360 3.375 (0.1329) 3.375 3.390 (0.1335) 3.390 3.405 (0.1341) 3.405 3.420 (0.1346) 3.420 3.435 (0.1352) 3.435 3.450 (0.1358) 3.450 3.465 (0.1364) 3.465 3.480 (0.1370) 3.480 3.495 (0.1376) 3.495 3.510 (0.1382) 3.510 3.525 (0.1388) 3.525 3.540 (0.1394) 3.540 3.555 (0.1400) 3.555 3.570 (0.1406) 3.570 3.585 (0.1411) 3.585 3.600 (0.1417) 3.600 3.615 (0.1423) 3.615 3.630 (0.1429) 3.630 3.645 (0.1435) 3.645 3.660 (0.1441) 3.660 3.675 (0.1447) 3.675 3.690 (0.1453) 3.690

Scheme 755

Required Special Tool

1. MD998735: Valve spring compressor
2. MB992089: Retainer holder C
3. MB992085: Valve stem seal pliers

<< 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 Number and installed position attached for reassembly.

Scheme 756

<< 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 757

>> A << VALVE STEM SEAL INSTALLATION

Scheme 758

Scheme 759

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 << RETAINER LOCK INSTALLATION

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

Scheme 760

Scheme 761

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 2.5 ± 0.5 mm (0.1 ± 0.02 inch) of sealant to the top face of cylinder block. Specified sealant: Three bond 1217G or exact equivalent
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 2.5 ± 0.5 mm (0.1 ± 0.02 inch) of sealant to the top face of cylinder head gasket. Specified sealant: Three bond 1217G or exact equivalent
6. Install the cylinder head assembly.

Scheme 762

Scheme 763

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 tightening torque of 35 ± 2 N.m (26 ± 1 ft-lb) according to the assembly order.
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 764

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 (0.008 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 free 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 (0.008 inch) Grinding limit: 0.2 mm (0.008 inch) Cylinder head height Standard value: 128.5 mm (5.06 inch)

Scheme 765

Scheme 766

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 inch) Exhaust 105.89 mm (4.169 inch) Limit: Intake 112.68 mm (4.436 inch) Exhaust 105.39 mm (4.149 inch)

Scheme 767

1. Measure free height of the spring. If the limit is exceeded, replace the spring. Standard value: 47.2 mm (1.858 inch) Limit: 46.2 mm (1.819 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 - 0.054 mm (0.0012 - 0.0021 inch)

Limit

Intake 0.10 mm (0.0039 inch)

Exhaust 0.11 mm (0.0043 inch)

Scheme 768

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 769

Scheme 770

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 771

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 Over size: 36.22 - 36.24 mm (1.426 - 1.427 inch) Exhaust valve seat bore diameter: 0.3 Over size: 30.22 - 30.24 mm (1.190 - 1.191 inch)
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-24l-except-lancer-evolution) ."

Scheme 772

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 Over size: 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 773

Required Special Tool

1. MB991883: Flywheel stopper
2. MB991614: Angle gauge
3. MD998718: Rear oil seal installer

Scheme 774

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

<< B >> BALANCER SHAFT CHAIN TENSIONER/CRANKSHAFT SPROCKET/BALANCER CHAIN/BALANCER SHAFT MODULE REMOVAL

Scheme 775

Scheme 776

1. Push in the balancer shaft tensioner lever by hand and push in the plunger of the chain tensioner until it contacts the bottom. Then, insert hard wire (piano wire, etc.) of f1.5 or hexagonal bar wrench (1.5 mm [0.06 inch]) into the plunger fixing hole to secure.
2. Remove the balancer shaft chain tensioner. CAUTION: The balancer shaft module must not be disassembled because of assembly warranty.
3. Remove the crankshaft sprocket, balancer chain and balancer shaft module as a unit.

Scheme 777

Scheme 778

1. Pry the illustrated position in the figure with a screwdriver or tap the boss with a hammer.
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 779

Scheme 780

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 of f2.5 ± 0.5 mm (0.10 ± 0.02 inch) in thickness and apply it to the illustrated position of the ladder frame in the figure. Specified sealant: Three bond 1217G or exact equivalent
4. Tighten the ladder frame to the specified tightening torque in the order shown in the illustration. Tightening torque: 26 ± 1 N.m (19 ± 1 ft-lb)

>> B << CRANKSHAFT SPROCKET/BALANCER CHAIN/BALANCER SHAFT MODULE INSTALLATION

When the new balancer shaft module is installed, supply oil to the oil pump and the balancer shaft bearing in the balancer shaft module using the following procedures.

Scheme 781

1. Clean the inside of the removed oil pan. Put the balancer shaft module carefully into the oil pan so that the oil inlet can be upward.
2. Pour the engine oil so that the two-third of the balancer module can be immersed.
3. Also, pour approximate 50 cc of engine oil from the oil inlet.
4. By giving four clockwise rotations or more to the balancer shaft sprocket, the oil is supplied to the oil pump and the balancer shaft bearing.

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

1. Wipe 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. Align the timing mark of the balancer shaft module sprocket with that of the balancer shaft module.
3. Insert a hexagonal bar wrench (3 mm [0.12 inch]) as illustrated in the figure to prevent the balancer shaft module sprocket from moving.
4. Loop the balancer chain, aligning its link plate with the timing mark.
5. Install the crankshaft sprocket on the crankshaft. NOTE: Do not push in the crankshaft sprocket to the normal position. Push it in only up to the tip of the crankshaft.
6. While slanting the balancer shaft module, align the link plate of another balancer chain with the timing mark of the crankshaft sprocket to loop. Gradually push in the crankshaft sprocket and fit it into the key groove of the crankshaft. Then, install the balancer shaft module on the ladder frame. NOTE: Make sure that the balancer shaft module is completely intimate contact with the ladder frame. NOTE: Make sure that the key groove of the crankshaft is aligned with the contact surface of the cylinder block and ladder frame as shown in the illustration.
7. Apply an appropriate and minimum amount of engine oil to the screw thread of the balancer shaft module bolt.
8. Tighten bolts to the specified tightening torque of 20 N.m (14 ft-lb) according to the assembly order in the illustration, retighten them to 44 N.m (32 ft-lb), and then completely loosen them.
9. After tightening them to the specified tightening torque of 20 N.m again, use special tool MB991614 to tighten them up to 135°.
10. Pull out the hexagonal bar wrench from the balancer module sprocket.
11. Make sure that the respective timing mark is aligned with each other as illustrated in the figure.
12. Install the balancer chain tensioner lever and balancer chain guide.

>> C << BALANCER SHAFT CHAIN TENSIONER INSTALLATION

1. Attach the chain tensioner to the ladder frame. CAUTION: Install the chain tensioner precisely in place after installing the tensioner lever and chain guide to prevent the plunger of the chain tensioner from jumping out.
2. Remove the hard wire (piano wire, etc.) of f1.5 or hexagonal bar wrench (1.5 mm [0.06 inch]) from the tensioner. This enables the plunger of the chain tensioner to push the balancer shaft tensioner lever to keep the balancer shaft chain tight.

>> D << REAR OIL SEAL INSTALLATION

After applying a small amount of engine oil to the oil seal lip, use special tool MD998718 to press fit the oil seal.

Scheme 789

Scheme 790

Scheme 791

1. Clean off sealant and oil of thread of crankshaft and drive plate bolt or flywheel bolt.
2. Use special tool MB991883 to secure the drive plate or flywheel.
3. Apply engine oil to thread of crankshaft and bolt seat area of drive plate or flywheel.
4. Apply the sealant to the thread of drive plate bolt or flywheel bolt. Specified sealant: Three bond 1324 or equivalent
5. Tighten drive plate bolt or flywheel bolt to temporary torque of 40 N.m (32 ft-lb) in the order shown to illustration.
6. Tighten drive plate bolt or flywheel bolt to specified tightening torque of 130 N.m (95 ft-lb) in the order shown in the illustration.

Scheme 792

Required Special Tool

1. MD998780: Piston pin setting tool
2. MB991659: Guide D
3. MD998718: Rear oil seal installer

<< A >> CONNECTING ROD REMOVAL

Enter cylinder Number for reassembly on the side of the connecting rod big end.

Scheme 793

<< B >> PISTON PIN REMOVAL

Special tool MD998780 consists of parts shown in the illustration. Use also special tool MB991659 to remove the piston pin.

Scheme 794

Scheme 795

1. Insert the push rod into the piston pin from the front mark side of the piston top surface, and attach special tool MB991659.
2. Set the piston and connecting rod assembly on the base so that the front mark of the piston faces upward.
3. Use a press to push the push rod and pull out the piston pin. NOTE: After pulling out the piston pin, organize pistons, piston pins and connecting rods by cylinder Number

Scheme 796

Scheme 797

Scheme 798

1. When replacing a piston, check the cylinder bore size mark stamped on the illustrated position of the cylinder block in the figure and select a corresponding piston from the table below. CYLINDER BORE SIZE MARK SPECIFICATIONS Cylinder bore size mark Piston size mark A A B None C C NOTE: The piston size mark is indicated on the piston top face.
2. Insert the push rod into the piston pin and attach guide A.
3. Align the front mark of the piston with that of the connecting rod to assemble.
4. Apply engine oil to the circumference of the piston pin.
5. Insert the guide A side of the piston pin assembled in section 1 into the pin hole from the front mark side of the piston.
6. Screw guide B into guide A and open clearance between guide A and guide B by 3 mm (0.11 inch) (make the base in line with flushed surface) to assemble.
7. Set the piston on special tool piston setting base so that its front mark faces upward.
8. Use a press to press fit the piston pin. If the press fit load is below the standard value, replace the piston pin (piston assembly) or connecting rod, or both. Standard value: 7,500 - 17,500 N (1.686 - 3.934 lbf)

Scheme 799

Scheme 800

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 NUMBER. 2/PISTON RING NUMBER. 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 801

Identification mark

Number 1 ring: 1T

Number 2 ring: 2T

Scheme 802

Scheme 803

Scheme 804

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 belt 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 805

Scheme 806

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 mark 1 47.966 - 47.972 (1.8884 - 1.8886) 1 2 47.960 - 47.966 (1.8882 - 1.8884) 2 3 47.954 - 47.960 (1.8880 - 1.8881) 3
2. An identification mark of a crankshaft is stamped at the illustrated position in the figure by Number.
3. A connecting rod bearing has an identification mark at the illustrated position in the figure.

>> F << CONNECTING ROD CAP INSTALLATION

Note. The connecting rod resulting from the breaking process has the high insertion force. The new connecting rod assembly may possibly be difficult to remove the connecting rod. If difficult to remove it, alternately strike the two bolt heads with a plastic hammer while the connecting rod bolt is slightly loosened, or strike the center of the cap shaft's inside diameter slightly and outward. If the outside of the cap is directly struck, the lateral force is added to the broken-out section. Thus, pay attention to the broken-out section that might be difficult to be separated or might fall. Clean the broken-out section before the installation to the engine, using compression air.

Scheme 807

Scheme 808

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 (0.016 inch)

Scheme 809

Scheme 810

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: 0.1 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 (14 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 811

Scheme 812

1. Check clearance between piston rings and ring grooves. If the limit is exceeded, replace piston rings or piston, or both. Standard value: Number 1 ring: 0.03 - 0.07 mm (0.001 - 0.003 inch) Number 2 ring: 0.03 - 0.07 mm (0.001 - 0.003 inch) Limit: 0.1 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 free gauge. If the end gap is excessive, replace piston rings. Standard value: Number 1 ring: 0.15 - 0.25 mm (0.006 - 0.011 inch) Number 2 ring: 0.25 - 0.40 mm (0.010 - 0.016 inch) Oil ring: 0.10 - 0.35 mm (0.004 - 0.014 inch) Limit: Number 1 ring: 0.8 mm (0.03 inch) Number 2 ring: 0.8 mm (0.03 inch) Oil ring: 1.0 mm (0.04 inch)

Scheme 813

Scheme 814

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 tightening 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: 0.018 - 0.045 mm (0.0007 - 0.0018 inch) Limit: 0.1 mm (0.04 inch)

Scheme 815

<< A >> CRANKSHAFT REMOVAL

When temporarily placing 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 torque of 11 ± 1 N.m (98 ± 8 in-lb) in the tightening order shown in the illustration.

Scheme 816

Scheme 817

1. Install the thrust bearing on the Number 3 bearing on the cylinder block side. Application of engine oil makes the installation easy.
2. Install the thrust bearing so that the grooved side is on the crankshaft weight side.

Scheme 818

Scheme 819

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 mark at the illustrated position in the figure. CYLINDER BLOCK SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark 1 56.000 - 56.006 (2.2047 - 202049) 1 2 56.006 - 56.012 (2.2050 - 2.2051) 2 3 56.012 - 56.018 (2.2050 - 2.2054) 3
3. Install the selected crankshaft bearing upper.

Scheme 820

Scheme 821

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 mark at the illustrated position in the figure. CRANKSHAFT SPECIFICATIONS Crankshaft Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark 0 51.985 - 51.988 (2.04665 - 2.04677) 0 1 51.982 - 51.985 (2.04653 - 2.04665) 1 2 51.979 - 51.982 (2.04641 - 2.04653) 2 3 51.976 - 51.979 (2.04629 - 2.04641) 3 4 51.973 - 51.976 (2.04618 - 2.04629) 4
3. Install the selected crankshaft bearing lower.

Scheme 822

Scheme 823

Scheme 824

Scheme 825

1. Install the crankshaft bearing cap with reference to the identification mark as illustrated in the figure.
2. Make sure that the underhead length of the bolt is at or below the limit before installing the crankshaft bearing cap bolt. If the length exceeds the limit, replace the bolt with a new one. Limit: 75.5 - 76.5 mm (2.972 - 3.012 inch)
3. Apply engine oil to the threaded portion and seat surface of the bolt.
4. Tighten crankshaft bearing cap bolts to the torque of 26.5 ± 2.0 N.m (20 ± 1 ft-lb) according to the tightening order. 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.
5. Use special tool Angle gauge (MB991614) to tighten bolts 45° according to the tightening order.
6. 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 (0.016 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 826

Scheme 827

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: 0.012 - 0.030 mm (0.0005 - 0.0012 inch) Limit: 0.08 mm (0.0031 inch)

Scheme 828

Scheme 829

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 free 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 (0.0020 inch) Limit: 0.2 mm (0.008 inch) Grinding limit: 0.2 mm (0.008 inch)
3. Check the cylinder wall for scratch or seizure. If there is any defect, replace the cylinder block.
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: 88 mm (3.4 inch) Cylindricity: 0.0076 mm (0.0003 inch)

See also:
• REMOVAL AND INSTALLATION