Overhaul - Lancer Evolution: Removal & Installation Mitsubishi Lancer X

<< B >> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

Scheme 101

>> A << SPARK PLUGS INSTALLATION

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

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

Scheme 102

Scheme 103

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

Scheme 104

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. Specified torque Power steering pump bracket: M8 23 ± 2 N.m (17 ± 1 ft-lb) M10 44 ± 8 N.m (33 ± 5 ft-lb) Generator: 44 ± 10 N.m (32 ± 7 ft-lb)

Scheme 105

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

>> B << THROTTLE BODY GASKET INSTALLATION

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

Scheme 106

Scheme 107

Required Special Tool

1. MB992106: O-ring Installer

>> A << ENGINE OIL PRESSURE SWITCH INSTALLATION

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

>> B << KNOCK SENSOR INSTALLATION

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

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

Scheme 108

>> C << INTAKE MANIFOLD STAY INSTALLATION

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

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

Scheme 109

>> D << O-RING INSTALLATION

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

Scheme 110

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

Scheme 111

Scheme 112

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

>> F << FUEL RAIL ASSEMBLY INSTALLATION

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

>> G << FUEL PRESSURE REGULATOR INSTALLATION

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

Scheme 113

Required Special Tool

1. MB991614: Angle Sensor

>> A << AIR INLET FITTING GASKET INSTALLATION

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

Scheme 114

>> B << AIR OUTLET FITTING GASKET INSTALLATION

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

Scheme 115

>> C << WATER PIPE B INSTALLATION

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

Note. Be sure to install the gasket.

Scheme 116

Scheme 117

Scheme 118

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

Scheme 119

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

>> F << OIL RETURN PIPE GASKET INSTALLATION

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

Scheme 120

Scheme 121

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

Scheme 122

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

Scheme 123

>> A << CRANKSHAFT POSITION SENSOR INSTALLATION

Tighten the crankshaft position sensor to the specified torque.

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

>> B << THERMOSTAT HOUSING / WATER PIPE ASSEMBLY / WATER PIPE GASKET INSTALLATION

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

>> C << THERMOSTAT INSTALLATION

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

Scheme 124

>> D << WATER OUTLET FITTING GASKET INSTALLATION

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

Scheme 125

>> E << ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

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

Scheme 126

Required Special Tools

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

<< A >> OIL FILTER REMOVAL

Use special tool MB991610 to remove the oil filter.

Scheme 127

Scheme 128

Scheme 129

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

<< C >> TIMING CHAIN CASE REMOVAL

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

Scheme 130

>> A << TIMING CHAIN CASE INSTALLATION

Scheme 131

Scheme 132

Scheme 133

1. Completely remove liquid gasket adhering to the timing chain case, cylinder block and cylinder head.
2. Using white gasoline and so on, degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and the cylinder head. CAUTION: Install the timing chain case within three minutes after applying liquid gasket.
3. Apply liquid gasket (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) in thickness to the timing chain case. For illustrated A locations, however, apply liquid gasket of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) in diameter or liquid gasket of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) by putting one on top of another as shown in the illustration.
4. Completely remove the sealant remaining on the gasket which is the three-plane mating surface between the cylinder head and the cylinder block. Use the white gasoline to degrease them.
5. The engine oil remaining at the cylinder gasket overflows from the three-plane mating surface described in step 4 above. Apply the liquid gasket (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) to this area as soon as grease is removed.
6. Install the timing chain case.
7. Tighten timing chain case mounting bolts to the specified torque. NOTE: Be careful when install mounting bolts as they are different in length. Specified torque 24 ± 4 N.m (18 ± 2 ft-lb) 10 ± 2 N.m (89 ± 17 in-lb) 10 ± 2 N.m (89 ± 17 in-lb) 13 ± 1 N.m (115 ± 8 in-lb)

Scheme 134

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 135

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

Scheme 136

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

Scheme 137

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

Scheme 138

Scheme 139

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

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

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

Scheme 140

<< 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 141

Scheme 142

Scheme 143

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

Scheme 144

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

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

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

>> D << TIMING CHAIN TENSIONER INSTALLATION

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

<< 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 150

<< 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 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. When replacing a camshaft bearing, select a bearing with the size corresponding to the identification mark in the table below.
2. Install camshaft bearings on the cylinder head. FRONT CAMSHAFT BEARING CAP SPECIFICATIONS Front camshaft bearing cap Camshaft bearing Identification mark Inner diameter mm (in) Identification mark 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3
3. The identification mark of the camshaft bearing is stamped at the illustrated position.
4. Set the dowel pins of the camshaft at the illustrated positions.
5. Install them upon checking the identification mark so as not to misidentify cap No. and to confuse the intake side with the exhaust side. Identification mark I: Intake side E: Exhaust side
6. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps. Specified torque: 12 ± 1 N.m (106 ± 8 in-lb)
7. Tighten each front camshaft bearing cap mounting bolt to the temporarily torque of 17 ± 3 N.m (14 ± 2 ft-lb) in the order shown (1).
8. Tighten each front camshaft bearing cap mounting bolt to the specified torque in the order shown (2). Specified torque: 30 ± 2 N.m (22 ± 1 ft-lb)

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

Scheme 156

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

<< A >> RETAINER LOCK REMOVAL

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

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

Scheme 157

<< 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 158

>> A << VALVE STEM SEAL INSTALLATION

Scheme 159

Scheme 160

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

>> B << VALVE SPRING INSTALLATION

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

Scheme 161

>> C << RETAINER LOCK INSTALLATION

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

Scheme 162

Scheme 163

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. Using white gasoline and so on, degrease the place specified in the illustration.
3. As shown in the illustration, apply a 2.0 to 3.0 mm (0.08 to 0.12 inch) of sealant (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) to the top face of cylinder block.
4. Install the cylinder head gasket. NOTE: Check that the center of the liquid gasket is located toward the cylinder gasket in the position specified in the illustration.
5. As shown in the illustration, apply a 2.0 to 3.0 mm (0.08 to 0.12 inch) of sealant (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) to the top face of cylinder head gasket.
6. Install the cylinder head assembly.

Scheme 164

Scheme 165

Scheme 166

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

Scheme 167

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

Scheme 168

Scheme 169

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

Scheme 170

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

<< A >> DRIVE PLATE BOLT / FLYWHEEL BOLT REMOVAL

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

<< B >> OIL PUMP SPROCKET REMOVAL

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

Scheme 171

Scheme 172

Scheme 173

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

>> A << LADDER FRAME INSTALLATION

Scheme 174

Scheme 175

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. Using white gasoline and so on, degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.
3. Squeeze liquid gasket (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) of f2.0 to 3.0 mm (0.08 to 0.12 inch) in thickness and apply it to the illustrated position of the ladder frame.
4. Tighten the ladder frame to the specified torque in the order shown in the illustration. Specified torque: 26 ± 1 N.m (19 ± 1 ft-lb)

Scheme 176

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

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

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

>> D << REAR OIL SEAL CASE INSTALLATION

Scheme 177

Scheme 178

1. Completely remove liquid gasket adhering to the cylinder block, ladder frame and rear oil seal case. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Using white gasoline and so on, degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.
3. Apply a small amount of engine oil to the oil seal lip. Install the timing chain case within three minutes after applying liquid gasket.
4. Squeeze liquid gasket (Three bond 1217G [Mitsubishi Genuine Part No.1000A923] or equivalent) of f2.0 to 3.0 mm (0.08 to 0.12 inch) in thickness and apply it to the illustrated position of the cylinder block and ladder frame.
5. Install the rear oil seal case aligned with the locating pin and tighten it to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 ft-lb)

Scheme 179

Scheme 180

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

Scheme 181

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

Scheme 182

1. Make sure that valve moves smoothly.
2. Ensure that the dimension L measures the standard value under normal temperature and humidity. Standard value: 34.5 mm (1.358 inches)
3. The dimension must be the standard value when measured after the valve has been dipped in 97 to 103°C (207 to 217°F) oil. Standard value: 40.0 mm (1.575 inches)

Scheme 183

Required Special Tools

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

<< A >> CONNECTING ROD REMOVAL

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

Scheme 184

<< B >> SNAP RING REMOVAL

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

Scheme 185

<< C >> PISTON PIN REMOVAL

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

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1. When replacing a piston, check the cylinder bore size mark stamped on the illustrated position of the cylinder block and select a corresponding piston from the table below. CYLINDER BORE SIZE MARK Cylinder bore size mark Piston size mark A A B B or none C C NOTE: The piston size mark is indicated on the piston top face. CAUTION: The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure the heat the piston before pulling out the piston pin. Use care sine the piston is hot after heating.
2. Into each container, pour enough engine oil to completely cover a piston.
3. Heat the engine oil to warm the piston to approximately 70°C (158°F), and then remove the piston pin.
4. Sufficiently apply the engine oil to the outer circumference of piston pin and the small end hole of connecting rod.
5. Put the front mark of connecting rod and the front mark of piston toward the same side, and then insert the piston pin.
6. Install the circlip to the piston according to the following procedure: With the open side facing upward, install the new circlip to the special tool MB992236. Align the open side of circlip with the piston groove, and then set the circlip together with the special tool MB992236. Install the guide A (f21.9 mm [0.88 inch]), to the push rod of special tool MD998780. Push the opposite side of open side with the special tool MD998780, and install the circlip to the piston groove. Make sure the circlip is seated into the groove. Unless seated into the groove, the circlip must be pushed with the special tool MD998780 again to be seated into the groove.
7. Check that the piston moves smoothly.

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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. NOTE: New spacers and side rails are an identified by color marks as follows: OIL RING SPECIFICATIONS Size Color mark Standard Non mark 0.25 mm (0.010 inch) oversize Two blue CAUTION: The side rail may be broken if its end gap is widened by a ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, after fitting one end of the side rail into the piston groove, for easy assembly.
3. After assembling the oil ring into the piston, make sure that the side rail turns smoothly to either direction.

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

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

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Identification mark

No. 1 ring: 1R

No. 2 ring: 2R

Note. Each of the available piston rings has a size mark as follows

PISTON RING SPECIFICATIONS

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

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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 51.966 - 51.972 (2.0459 - 2.0461) 1 2 51.960 - 51.966 (2.0457 - 2.0459) 2 3 51.954 - 51.960 (2.0454 - 2.0457) 3
2. An identification mark of a crankshaft is stamped at the illustrated position by No.
3. A connecting rod bearings an identification mark at the illustrated position.

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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.
2. Make sure that clearance of the thrust of the connecting rod big end is appropriate. Standard value: 0.10 - 0.25 mm (0.004 - 0.010 inch) Limit: 0.4 mm (0.02 inch)

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1. Check in the following procedure before reusing the connecting rod bolt. Measure the outside diameter "A". Measure the smallest outside diameter "B" within the range "X" shown in the illustration. If the difference of outside diameter of thread exceeds the limit, replace the connecting rod bolt. Limit: 0.10 mm (0.004 inch)
2. Apply engine oil to the threaded portion and seat surface of the bolt before installing it.
3. After installing each bolt and tightening it by fingers, tighten bolts alternately to properly assemble the cap.
4. Tighten the bolt in several steps until the torque reaches 5.0 N.m (44 in-lb).
5. Tighten the bolt in several steps until the torque reaches 20 N.m (15 ft-lb).
6. Put a paint mark on the bolt head as illustrated.
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.

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

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

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<< A >> CRANKSHAFT REMOVAL

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

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

>> A << CRANKSHAFT SENSING RING INSTALLATION

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

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

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

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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. CYLINDER BLOCK SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark No. 1, 2, 4, 5 No. 3 No. 1, 2, 4, 5 No. 3 1 0 56.000 - 56.006 (2.2047 - 2.2050) 1 0 2 1 56.006 - 56.012 (2.2050 - 2.2052) 2 1 3 2 56.012 - 56.018 (2.2052 - 2.2054) 3 2
3. Install the selected crankshaft bearing upper.

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1. When replacing the crankshaft bearing lower, select a bearing with the size corresponding to the crankshaft journal diameter in the table below.
2. The crankshaft bearing lower has an identification color or identification mark at the illustrated position.
3. Install the selected crankshaft bearing lower. CYLINDER BLOCK SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark No. 1, 2, 4, 5 No. 3 No. 1, 2, 4, 5 No. 3 0 8 51.985 - 51.988 (2.0467 - 2.0468) 0 8 1 9 51.982 - 51.985 (2.0465 - 2.0467) 1 9 2 0 51.979 - 51.982 (2.0464 - 2.0465) 2 0 3 1 51.976 - 51.979 (2.0463 - 2.0464) 3 1 4 2 51.973 - 51.976 (2.0462 - 2.0463) 4 2

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