Overhaul - Evolution: Removal & Installation Mitsubishi Lancer IX

<< E >> TIMING BELT "B" REMOVAL

Scheme 146

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

Scheme 147

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

Scheme 148

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

<< H >> CAMSHAFT SPROCKET REMOVAL

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

Scheme 149

>> A << CAMSHAFT SPROCKET INSTALLATION

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

Scheme 150

Scheme 151

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

>> B << ENGINE SUPPORT BRACKET INSTALLATION

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

Scheme 152

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

Scheme 153

Scheme 154

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

Scheme 155

Scheme 156

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

>> E << CRANKSHAFT SPROCKET "B" INSTALLATION

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

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

Scheme 157

Scheme 158

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

Scheme 159

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

Scheme 160

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Scheme 163

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

Scheme 164

Scheme 165

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

Scheme 166

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

Scheme 167

Scheme 168

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

>> L << TENSIONER PULLEY INSTALLATION

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

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Scheme 184

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

>> A << INJECTOR INSTALLATION

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

>> B << FUEL PRESSURE REGULATOR INSTALLATION

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

>> c << THROTTLE BODY GASKET INSTALLATION

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

Scheme 185

Scheme 186

>> A << INTAKE MANIFOLD STAY INSTALLATION

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

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

Scheme 187

>> B << MDP SENSOR INSTALLATION

Scheme 188

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

Scheme 189

Scheme 190

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

>> B << OIL RETURN PIPE GASKET INSTALLATION

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

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

Scheme 191

>> C << OUTLET FITTING GASKET INSTALLATION

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

Scheme 192

Scheme 193

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

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

Scheme 194

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

Scheme 195

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

Scheme 196

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

Scheme 197

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

Scheme 198

Required Special Tools

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

<< A >> LASH ADJUSTER REMOVAL

>> A << LASH ADJUSTER INSTALLATION

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

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Scheme 202

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

>> D << CAMSHAFT OIL SEAL INSTALLATION

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

Scheme 203

Scheme 204

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

>> F << CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION

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

Scheme 205

<< A >> CYLINDER HEAD BOLT REMOVAL

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

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Scheme 208

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

<< C >> VALVE STEM SEAL REMOVAL

Do not reuse removed valve stem seal.

Scheme 209

>> B << VALVE SPRING INSTALLATION

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

Scheme 210

>> C << RETAINER LOCK INSTALLATION

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

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

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Scheme 215

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

Scheme 216

1. Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage.
2. Remove all oil, water scale, sealant, and carbon. After cleaning the oil passages, blow air through them to verify that they are not blocked.
3. Check the cylinder head gasket surface for flatness by using a straight edge and feeler gauge. Standard value: 0.05 mm (0.0020 inch) Limit: 0.2 mm (0.008 inch)
4. If flatness exceeds the specified limit, grind the gasket surface to specification. Grinding limit: *0.2 mm (0.008 inch) *Includes/combined with cylinder block grinding> Cylinder head height (Specification when new): 131.9 - 132.1 mm (5.193 - 5.201 inches)

Scheme 217

1. Check the valve face for correct contact. If contact is uneven or incomplete, reface the valve seat.
2. If the margin is less than specified, replace the valve. Standard value: Intake: 1.0 mm (0.039 inch) Exhaust: 1.5 mm (0.059 inch) Limit: Intake: 0.5 mm (0.020 inch) Exhaust: 1.0 mm (0.039 inch)
3. Measure the valve length. If the measurement is less than specified, replace the valve. Standard value: Intake: 109.50 mm (4.311 inches) Exhaust: 109.70 mm (4.319 inches) Limit: Intake: 109.00 mm (4.291 inches) Exhaust: 109.20 mm (4.299 inches)

Scheme 218

1. Measure the valve spring free height. If the measurement is less than specified, replace spring. Standard value: 50.4 mm (1.98 inches) Limit: 49.4 mm (1.94 inches)
2. Measure the squareness of the spring. If the measurement is less than specified, replace the spring. Standard value: 2° or less Limit: 4°

<< D >> COUNTERBALANCE SHAFT FRONT BEARING REMOVAL

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

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

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Scheme 220

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

Scheme 221

Scheme 222

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

Scheme 223

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

Scheme 224

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

>> D << COUNTERBALANCE SHAFT OIL SEAL INSTALLATION

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

Scheme 225

>> E << OIL PUMP OIL SEAL INSTALLATION

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

Scheme 226

>> F << CRANKSHAFT FRONT OIL SEAL INSTALLATION

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

Scheme 227

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

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

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Scheme 230

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

Scheme 231

Scheme 232

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

Scheme 233

1. Install a new O-ring to the groove of the front case.
2. Install the plug cap to the front case.
3. Fit special tool MD998162 on the plug cap, and then hold it in position with special tool MD998783.
4. Tighten the plug cap to the specified torque. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
5. Remove special tools MD998783 and MD998162. CAUTION: Be careful not to block the oil passage with sealant.

Scheme 234

Scheme 235

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

Scheme 236

Scheme 237

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

>> N << DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction shown.

Scheme 238

Scheme 239

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

Scheme 240

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

Scheme 241

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

Scheme 242

Required special tool

1. MIT216941: Piston Pin Setting Tool

Scheme 243

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

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

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1. When replacing the piston, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the flowing table. NOTE: The piston size mark shows on the top of the piston.
2. Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw.
3. Using the markings on the press pin, adjust the stop screw to the depth shown on the instruction for special tool MIT216941.
4. Place the base on press support blocks.
5. Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it.
6. Coat the piston pin with engine oil. With the connecting rod held in position, slide the guide pin through the piston and connecting rod.
7. Press the piston pin through the connecting rod until the guide pin contacts the stop screw. CAUTION: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.
8. Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly.
9. Check that the piston moves smoothly.

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Scheme 254

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

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

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Scheme 260

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

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Scheme 262

1. Apply engine oil on the circumference of the piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3. Rotate the crankshaft so that crank pin is on the center of the cylinder bore.
4. Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin.
5. Insert the piston and connecting rod assembly into the cylinder with front mark on the piston crown pointing to the timing belt side. CAUTION: >Must be careful the piston and connecting rod shall not touch to the oil jet at the installation.
6. Using a suitable piston ring compressor tool,0 install the piston and connecting rod assembly into the cylinder block.

Scheme 263

Scheme 264

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

Scheme 265

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

Scheme 266

Scheme 267

1. Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. Standard value: NO.1: 0.03 - 0.07 mm (0.0012 - 0.0028 inch) NO.2: 0.02 - 0.06 mm (0.0008 - 0.0024 inch) Limit: NO.1: 0.1 mm (0.0039 inch) NO.2: 0.1 mm (0.0039 inch)
2. Install the piston ring into the cylinder bore. Force the ring down with a piston, the piston crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the end gap is excessive, replace the piston ring. Standard value: NO.1 ring: 0.20 - 0.30 mm (0.0079 - 0.0118 inch) NO.2 ring: 0.35 - 0.50 mm (0.0128 - 0.0197 inch) Oil ring: 0.10 - 0.40 mm (0.0039 - 0.0157 inch) Limit: NO.1, No.2 ring: 0.8 mm (0.031 inch) Oil ring: 1.0 mm (0.039 inch)

Scheme 268

1. Remove oil from the crankshaft pin and connecting rod bearing.
2. Cut the plastic gauging material to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified torque. (See "Connecting rod cap nut tightening" procedure.)
4. Carefully remove the connecting rod cap.
5. Measure the width of the plastic gauging material at its widest part by using a scale printed on its package. Standard value: 0.03 - 0.05 mm (0.0012 - 0.0020 inch) Limit: 0.1 mm (0.004 inch)

Scheme 269

Required Special Tools

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

Scheme 270

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

>> B << CRANKSHAFT BEARING INSTALLATION

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

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

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

Scheme 276

Scheme 277

Scheme 278

Scheme 279

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

>> D << OIL SEAL INSTALLATION

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

Scheme 280

Scheme 281

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

Scheme 282

Scheme 283

1. Remove oil from the crankshaft journal and crankshaft bearing.
2. Install the crankshaft.
3. Cut the plastic gauging material to the same length as the width of bearing and place it on journal in parallel with its axis.
4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified torque.
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the plastic gauging material at its widest part by using a scale printed on the plastic gauging material package. Standard value: 0.02 - 0.04 mm (0.0008 - 0.0015 inch) Limit: 0.1 mm (0.003 inch)

Scheme 284

Scheme 285

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

Scheme 286

Scheme 287

1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter (OD) of the piston to be used. Measure it in thrust direction as shown.
3. Based on the measured piston OD, calculate the boring finish dimension. Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin) CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from number 2 to number 4 to number 1 to number 3.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
6. Check the clearance between the piston and cylinder. Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0015 inch) NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.