11D-I

ENGINE ~

OVERHAUL
CONTENTS 11309000371

CRANKSHAFT AND CYLINDER BLOCK ... 50 PISTON AND CONNECTING ROD ......... 42
CYLINDER HEAD AND VALVES .......... 30 ROCKER ARMS AND CAMSHAFT ........ 24

FUEL AND EMISSION CONTROL SYSTEM SPECIAL TOOLS .. . . .. . .. . .. . .. .. ... . . . ... 7

.......................................... 17
SPECIFICATIONS .. . . . . ... . .. . . . . . . . .. . . ...3
GENERAL INFORMATION ...... ..... ..... .. 2 Rework Dimensions . . . . . .................4
General Specification . . . . . , . , . . . . , . . . . ... . . . . 2 Sealant . . . . . . . . . . . . . . . .

GENERATOR AND IGNITION SYSTEM Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3

.......................................... 10 Torque Specifications . . . . . . . . , . . , . . . . . . . .... 5
.P
INTAKE AND EXHAUST MANIFOLDS TIMING BELT ........ . .................. 12
.......................................... 19
WATER PUMP AND WATER HOSE ....... 21
OIL PUMP AND OIL PAN ................ 37
11D-2 ENGINE OVERHAUL el .8L> - General Information

GENERAL INFORMATION 11300010243

GENERAL SPECIFICATION
Descriptions Specifications

TY Pe In-line OHV, SOHC

Number of cylinders 4

Combustion chamber Pentroof type

Total displacement dm3 (cu.in.) 1,834 (111.9)

Cylinder bore mm (in.) 81 .O (3.19)

Piston stroke mm (in.) 89.0 (3.50)

Compression ratio 9.5

Exhaust 8

Valve timing Intake valve Opens (BTDC) 6"

Closes (ABDC) 54"

' Exhaust valve Opens (BBDC) 54"

Closes (ATDC) 6"

Lubrication system 1 Pressure feed, full-flow filtration

Cooling system Water-cooledforced circulation

Water pump type 1 Centrifugal impeller type

 ENGINE OVERHAUL <I .8L> - Specifications 11D-3

SPECIFICAT10NS I 1300030454

SERVICE SPECIFICATIONS
___________~

Items 1 Standard value I Limit

~~~ -~

Camshaft cam height mm (in.) Intake 37.11 (1.46) 36.61 (1.44)

Exhaust 37.15 (1.46) 36.65 (1.44)

Cylinder head flatness Less than 0.03 (.0012)

~~~~~

Cylinder head grinding

*Total resurfacing depth of both cylinder head and cylinder block
Cylinder head overall height mm (in.) I 119.9 - 120.1 (4.720 - 4.728) I -
Cylinder head bolt shank length mm (in.) I- 1 96.4 (17.23)
Valve stem O.D. mm (in.) 6.0 (.234)
-____
Valve stem-to-guide clearance mm (in.) ~ intake 0.02 - 0.05 (.0008 - .0020) 0.10 (.0039)
~ Exhaust 1 0.05 - 0.09 (.0020 - .0035) 1 0.15 (.0059)
Valve face angle 45" - 45.5" I-
Valve margin mm (in.) Intake 1.O (.039) ! 0.5 (.020)
I Exhaust 1 1.3 (.051) I 0.8 (.031)
Valve stem projection mm (in.) 1 Intake 1 49.30 (1.9409) i 49.80 (1.9606)
I Exhaust I 49.35 (1.9429) i 49.85 (1.9626)
Overall valve length mm (in.) I Intake I 109.65 (4.317)
1 113.20 (4.457)
Valve spring free height mm (in.) 1 50.9 (2.00) ~
1 49.9 (1.96) ~

Valve spring load/installedheight N/mm (ibs./in.) 216/44.2 (59/1.74) -

Valve spring squareness Max. 2" 4"
~~ -~

Valve seat contact width mm (in.) 0.9 - 1.3 (.035 - .051) -

Valve guide I.D. mm (in.) 6.0 (.234) -
Valve guide projection mm (in.) 14.0 (.551)

Oil pump tip clearance mm (in.) 0.06 - 0.18 (.0024 - .0071) -

Oil pump side clearance mm (in.) 0.04 - 0.10 (.0016 - .0039) -
Oil pump body clearance mm (in.) 0.10 - 0.18 (.0039 - .0071) 0.35 (.0138)

Piston O.D. mm (in.)

__
81 .O (3.19) -
Piston ring side clearance mm (in.) No.1 0.03 - 0.07 (.0012 - ,0028) 0.1 (.0039)
-

No.2 0.02 - 0.06 (.0008 - ,0024) 0.1 (.0039)

Piston ring end gap mm (in.) No.1 0.25 - 0.40 (.0098 - ,0157) 0.8 (.031)
No.2 0.40 - 0.55 (.0157 - .0217) 0.8 (.031)
Oil ring 0.20 - 0.60 (.0078 - .0236) 1.O (.039)
11D-4 ENGINE OVERHAUL c1.8L> - Specifications

Items 1 Standard value 1 Limit

Piston pin O.D. mm (in.) 1 19.0(.75) I-

Piston pin press-in load [at room temperature] N (Ibs.)

Crankshaft pin oil clearance mm (in.)

4900 - 14700
(1.lo20- 3.3070) l-
I 0.02- 0.05(.0008- .0020) 1 0.1 (.004)
.

Connecting rod big end side clearance mm (in.) 0.10- 0.25(.0039- .0098) 0.4 (.016)

Crankshaft end play mm (in.) I 0.05- 0.25(.0020- .0098) 1 0.4(.016)

Crankshaft journal O.D. mm (in.) 1 50 (1.97) l-
Crankshaft journal oil clearance mm (in.) 0.02- 0.02(.0008- ,0016) 0.1 (.004)
Cylinder block gasket surface flatness mm (in.) j 0.05(.0020) I 0.1 (.004)
1 0.2(.008)
~~~

Cylinder block gasket surface grinding limit mm (in.) -

Cylinder block overall height mm (in.) I 263.5(10.374) l-
Cylinder bore I.D. mm (in.) 81 .O (3.19) -
Cylinder bore cylindricity mm (in.) 0.01 (.0004) or less -
Piston-to-cylinderclearance mm (in.) 1 0.02- 0.04(.0008- .0016) 1 -
Bearing cap bolt shank length mm (in.) I- 1 71.1 (2.799)
REWORK DIMENSIONS
Items Standard value

Oversize valve guide hole diameter mm (in.) 0.050.S. 1 11.05- 11.07(.4350- .4358) I
0.25O.S. 1 11.25- 11.27(.4429- ,4337) I
0.50O.S. ~

I
1 1 5 0 - 11.52(.4528- .4535)
Oversize intake valve seat hole diameter mm (in.) 0.30O.S. 1 31.80- 31.83(1.2520- 1.2531) I
0.60O.S. 1 32.10- 32.13(1.2638- 1.2650) I
Oversize exhaust valve seat hole diameter mm (in.) 0.30O.S. I 29.30- 29.32(1.1535- 1.1543) I
0.60O.S. 29.60- 29.62 (1.1654- 1.1661)
NOTE
O.S.: Oversize diameter
 ENGINE OVERHAUL <I .8L> - Specifications 11D-5
TORQUE SPECIFICATIONS

Ignition coil 10 7
Spark plug 25 18
Crankshaft bolt 181 131
~~

Generator brace (M10) 49 35

Generator brace (MB)

~~~
I 23 I 17
Lock bolt 23 17
Adjusting bolt 10 7
~~

Generator pivot nut 44 32

Ignition failure sensor 23 17

Cam position sensor I9 1 7

Cam position sensor support 13 9
Cam position sensing cylinder 21 15
Timing be1t
Camshaft SDrocket bolt I aa I 64
Crank angle sensor 9 6
Timing belt rear cover 11 a
Timing belt tensioner 1 23 I 17
Engine support bracket, right 49 I 35
Timing belt cover 11 18
_ _ ~ _ _ I

Fuel return pipe 9 7

Fuel rail 12 9
Fuel pressure regulator 9 7
~-

EGR Valve 22 16
Throttle body 19 14
Vacuum hose and pipe assembly 11 8

Manifold differential pressure sensor 5 4

Exhaust manifold (M10) 29 21
Exhaust manifold (M8)
I l3
Exhaust manifold bracket I19 I14
Engine hanger 18 9
Oil dipstick guide 14 10
Exhaust manifold cover I13 19

Intake manifold I 20 I 15
Intake manifold stay I 30 ~ 22
11D-6 ENGINE OVERHAUL <I .8L> - Specifications
Items Nm ft.lbs.

~~

Water pump 24 17
Water inlet pipe 14 10
Thermostat case 24 17
___ --

Water inlet fitting 18 14

~ _ _
Water outlet fitting 14 10
__
Engine coolant temperature gauge unit 10 7
Engine coolant temperature sensor 29 21

-~ -

Rocker arm shaft 31 22

Rocker cover 4 3

Cylinder head bolt [74 Nm (54 ft.lbs.) and then completely 20 + 90" + 90" 15 + 90" + 90"
loosen finally tighten]

Oil pump cover 10 7

Front case 14 10

Oil screen 19 14
Oil pan 7 5
Drain plug 39 28
Oil pressure switch 10 7

____
Connecting rod cap nut 20 + 90" to 100" 15 + 90" to 100"

Bearing cap bolt 25 + 90" to 100" 18 + 90" to 100"

Oil seal case 11 8
-

Bell housing cover 9 7

~~~

Rear plate 11 8
Drive plate bolt 98 71
Flywheel bolt 98 71
 ENGINE OVERHAUL <I .8L> - Specifications/Special Tools 11D-7
SEALANT 11300050177

Items ~ Specified sealant Quantity

Water pump Mitsubishi Genuine Part No.MD970389 or equivalent As required
Thermostat case Mitsubishi Genuine Part No.MD970389 or equivalent As required
Engine coolant tempera- 3M Nut Locking Part No.4171 or equivalent As required
ture sensor
Engine coolant tempera- 3M ATD Part No.8660 or equivalent As required
ture gauge unit
Oil pressure switch 3M ATD Part No.8660 or equivalent As required
Water outlet fitting Mitsubishi Genuine Part No.MD970389 or equivalent As required
Front case Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil pan Mitsubishi Genuine Part No.MD970389 or equivalent As required
Oil seal case Mitsubishi Genuine Part No.MD970389 or equivalent As required
__________~ ~~~~~~ ~

Drive plate bolt 3M Nut Locking Part No.4171 or equivalent As required

~ -

Flywheel bolt 3M Nut Locking Part No.4171 or equivalent As required

Cam position sensor Mitsubishi Genuine Part No.MD970389 or equivalent As required
support

SPECIAL TOOLS 113OOO60361

Tool Tool number and name Supersession Application

MB990767 MB990767-01 Holdingcamshaft sprocket when
End yoke holder Use with MIT308239 loosening or torquing bolt
Use with MD998719

MB990938 MB990938-01 Installation of crankshaft rear oil

Handle seal

MD998713 MD998713-01 Installation of camshaft oil seal

Camshaft oil seal in-
staller

MD998716 MD998716-01 Turning crankshaft

Crankshaft wrench

MD998717 MD998717-01 Installation of crankshaft front oil

Crankshaft front oil seal seal
installer
11D-8 ENGINE OVERHAUL <1.8L> - Special Tools
rooI roo1 number and name Supersession Jpplication
___
AD998719 MIT308239 iolding camshaft sprocket wht
'ulley holding pins (2) oosening or torquing bolt

vlD998727 qemoval of oil pan

T 31 pan remover

Vl D998772
ilalve spring compres-
General service tool zompressing valve spring

sor

blD998774 Installation of valve stem seal

dalve stem seal installer

MD998776 Use with Installationof crankshaft rear

Q :rankshaft rear oil seal

nstaller
Use with MB990938
MB990938-01 seal

MD998780 MIT216941 Removal and installation

Piston pin setting tool piston pin

MD998781 Holdingflywheel
Flywheel stopper

MD998735 MD998735-01 Compression of valve spring

Valve spring compres-
sor

M699 1653 Loosening and torquing of cylin-

Cylinder head bolt der head bolt
wrench
 ENGINE OVERHAUL c1.8L> - Special Tools 11D-9

Tool Tool number and name Supersession Application

MB991659 Removal of piston pin (Use with
Guide D MD998780)

MD998440 Leak down test of lash adjuster

Leak down tester

MD998441 Air bleeding of lash adjuster

06 Lash adjuster retainer

MD998442 Air bleeding of lash adjuster

Air bleed wire

MD998443 MD998443-01 Supporting lash adjuster to pre-

Lash adjuster holder (8) vent it from falling when rocker
arm shaft assembly is removed
or installed.
11D-10 ENGINE OVERHAUL c1.8L> - Generator and Ignition System
GENERATOR AND IGNITION SYSTEM 11300100124

REMOVAL AND INSTALLATION

23
17

9EN0709
131 ft.lbs.

Removal steps
1. Drive belt 7. Spark plug cable
2. Generator 8. Ignition coil
3. Generator brace 9. Spark plug
+AF F B q 4. Crankshaft bolt 10. Cam position sensor
5. Crankshaft pulley F A + 11. Cam position sensor support
6. Front flange 12. Cam position sensing cylinder
 ENGINE OVERHAUL <1.8L> - Generator and Ignition System 11D-11
REMOVAL SERVICE POINT
+ A b CRANKSHAFT BOLT REMOVAL
(1) Lock the flywheel or drive plate in positionusingthe special
tool shown in the illustration, then loosen the crankshaft
bolt.

Z9EN0268

INSTALLATION SERVICE POINTS

A
.( CAM POSITION SENSOR SUPPORT
INSTALLATION
(1) Clean the sealant application surfaces of cam position
sensor support and cylinder head.
(2) Apply a 3 mm (.I2in.) diameter bead of sealant to the
area shown in the illustration.Be sure to install the sensor
support with in 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent .
(3) After installation, wait at least one hour. Never start the
engine or let engine oil touch the adhesion surface during
that time.

b B + CRANKSHAFT BOLT INSTALLATION

I
6 Z9EN0268

I
(1) Lockthe flywheel or drive plate in positionusingthe special
tool shown in the illustration, then tighten the crankshaft
bolt.
11D-12 ENGINE OVERHAUL <1.8L> - Timina Belt
TIMING BELT 11 300190183

REMOVAL AND INSTALLATION

Removal steps
1. Timing belt front upper cover 8. Crankshaftangle sensor
2. Timing belt front lower cover 9. Crankshaftsprocket
3. Engine support bracket, right 10. Crankshaftspacer
+Ah .D+ 4. Timing belt 11. Crankshaftsensing plate
FC+ 5. Tensioner spring 12. Crankshaftkey
FB4 6. Timing belt tensioner 4Bb F A 4 13. Camshaft sprocket bolt
7. Timing belt rear cover 14. Camshaft sprocket
ENGINE OVERHAUL <1.8L> - Timing Belt 11D-13
REMOVAL SERVICE POINTS
+ A F TIMING BELT REMOVAL
(1) Mark the belt running direction for reference in
reinstallation.
(2) Loosen the tensioner mounting bolt.
(3) Insert a cross-tipscrewdriver into the hole of the tensioner
arm as shown illustration.
(4) Move the screwdriver all the way in the direction of the
arrow, and tighten the tensioner mounting bolt to hold
this position.
(5) Remove the timing belt.
NOTE
(1) Water oil on the belt shortens its life drastically, so
the removedtiming belt, sprocket, and tensioner must
be kept free from oil and water. Do not immerse parts
in cleaning solvent.
(2) If there is oil or water on any part, check the front
case oil seal, camshaft oil seal and water pump for
leaks.

+ B F CAMSHAFT SPROCKET BOLT LOOSENING

INSTALLATION SERVICE POINTS

F A + CAMSHAFT SPROCKET BOLT TIGHTENING

F B d TIMING BELT TENSIONER INSTALLATION

(1) Install the timing belt tensioner in the illustrated position,
and then tighten the tensioner mounting bolt.
11D-14 ENGINE OVERHAUL <1.8L> - Timing belt
F C q TENSIONER SPRING INSTALLATION
(1) Install the tensioner spring onto the boss of the front
case, and then hook the spring end “A” (shorter one)
to the front case rib.
(2) Grip the spring end “6” (longer one), and then hook it
onto the tensioner arm.

D
.( TIMING BELT INSTALLATION
(1) Align the crankshaft sprocket timing mark with the timing
mark on the front case, and then rotate the crankshaft
sprocket three teeth counterclockwise.
Caution
Aligning the timing marks positions the piston to the
top dead center. Then, if the camshaftturns, the valves
might interfere and damage the pistons.

b l - 9EN0568 I
(2) Align the camshaft sprocket timing mark with the timing
mark on the cylinder head.

. . .
7
569 I

(3) Rotate the crankshaft sprocket three teeth

counterclockwise,and alignthe crankshaftsprockettiming
mark with the timing mark on the front case.
(4) Keeping the tension side of the timing belt tight, fit the
timing belt onto the crankshaft sprocket, water pump
sprocket, camshaft sprocket and tensioner puller in that
order.

-B-w 9EN0570

(5) Slightly loosen the timing belt tensioner bolt to tension

the belt by a force of the tensioner spring.
 ENGINE OVERHAUL <1.8L> - Timing Belt 11D-15
(6) Turn the crankshaft twice in the clockwise direction.
Caution
This procedure utilizes the camshaft’s driving torque
to apply tension evenly to the timing belt. Be sure
to turn the crankshaft as described above. Do not
turn the crankshaft counterclockwise.
(7) Check that the timing marks are correctly aligned.
(8) Tighten the timing belt tensioner locking bolt to the
specified torque.

INSPECTION 11300200152

TIMING BELT
Check the timing belt closely. Replace the belt with a new
one if any of the following defects are evident:
(1) Hardened backing rubber (the backing rubber is glossy,
non-elastic, and so hard that scratching with fingernails
leaves no mark.)

Z8EN0066

(2) Surface cracks on the backing rubber.

d
Cracks (3) Cracks or peeling of the canvas.
(4) Cracks on the tooth bottom.
(5) Cracks on the belt sides.
Peeling

Cracks
Z1 EN0249

(6) Abnormal wear on the belt sides.

NOTE
, Rounded edge The sides of the belt are normal if they are sharp as
if cut by a knife.

Abnormal wear
(exposed core wire)
28EN0067

(7) Abnormal wear on teeth.

Initial stage: Canvas worn (fluffy canvas fibers, rubbery
texture gone, white discoloration,canvas texture indistinct)
Final stage: Canvas worn, exposing rubber (tooth width
reduced)
(8) Missing teeth.

Z8EN0068
11D-16 ENGINE OVERHAUL <1.8L> - Timing Belt
TENSIONER PULLER
(1) Check the pulley for smooth rotation, without play and
are not noisy.

lEN0538
 ENGINE OVERHAUL <1.8L> - Fuel and Emission Control System 11D-17
FUEL AND EMISSION CONTROL SYSTEM 11300220103

REMOVAL AND INSTALLATION

vF4rsm

Removal steps
1. Vacuum hose and pipe assembly 10. O-ring
2. Solenoid valve assembly 11. Fuel rail and injector
3. Throttle body 12. Insulator
b C 4 4. Gasket 13. Insulator
5. EGR valve F A 4 14. Injector
6. EGR valve gasket 15. O-ring
7. Vacuum hose 16. Grommet
8. Fuel hose 17. Fuel rail
b B 1 9.Fuel pressure regulator 18. Fuel return pipe
11D-18 ENGINE OVERHAUL <1.8L> - Fuel and Emission Control System
INSTALLATION SERVICE POINTS
F A + INJECTORS INSTALLATION
(1) Fit a new O-ring and grommet onto the injector.

I Injector connector I (2) Apply clean engine oil or gasoline to the injector O-ring.
(3) Fit the injector onto the fuel rail, turning it to the left and
right as it goes in.
(4) Check that the injector rotates smoothly.
(5) Check that the clearance between the injector connector
and the fuel rail is uniform (A = B).

Fuel rail

I FBd FUEL PRESSURE REGULATOR INSTALLATION

(1) Apply a drop of clean engine oil to the O-ring, then insert
the fuel pressure regulator into the fuel rail, being careful
not to damage the O-ring.
Caution
Do not let engine oil get into the fuel rail.
I (2) Check that the fuel pressure regulator rotates smoothly.
." If it does not rotate smoothly, the O-ring may be binding.
If this occurs, remove the fuel pressure regulator, check
the O-ring for damage, then re-insert the regulator Mito
the fuel rail.

F C d GASKET INSTALLATION
(1) Position the projection as shown in the illustration.

9EN0500 I
 ENGINE OVERHAUL c1.8L> - Intake and Exhaust Manifolds 11D-19
INTAKE AND EXHAUST MANIFOLDS 11301750113

REMOVAL AND INSTALLATION

20
15

Removal steps
1. Manifold differential pressure sen- 9. Oil dipstick guide
sor 10. O-ring
2. O-ring 11. Exhaust manifold cover
3. Engine hanger 12. Engine hanger
4. Intake manifold stay F A + 13. Exhaust manifold bracket A
5. Intake manifold .A+ 14. Exhaust manifold bracket 8
6. Intake manifold gasket 15. Exhaust manifold
7. Oil dipstick 16. Exhaust manifold gasket
8. O-ring
11D-20 ENGINE OVERHAUL c1.8L> - Intake and Exhaust Manifolds

INSTALLATION SERVICE POINT

.A+ EXHAUST MANIFOLD/BRACKET INSTALLATION
(1) Installthe exhaust manifold brackets“ Aand “6”
as shown
in the illustration, and finger tighten each bolt.
(2) Tighten the all bolts to the specified torque.
 ENGINE OVERHAUL <1.8L> - Water Pump and Water Hose 11D-21
WATER PUMP AND WATER HOSE 11301790030

REMOVAL AND INSTALLATION

I 10Nm
29 Nm 7 ft.lbs.
11D-22 ENGINE OVERHAUL <I .8L> - Water Pump and Water Hose
INSTALLATION SERVICE POINTS
a A
.( WATER PUMP INSTALLATION
$3 rnm (.I 2 in )
(1) Clean the sealant application surfaces of the water pump
case and cylinder block.
(2) Apply a 3 mm (.12 in.) diameter bead of sealant to the
area shown in the illustration. Be sure to install the water
pump within 15 minutes after applying sealant.

w 9EN0505
Specified sealant:
Mitsubishi Genuine
equivalent
Part No.Mb970389 or

(3) After installation, wait at least one hour. Never start the
engine or let coolant touch the adhesion surface during
that time.

.B( WATER INLET PIPE/O-RING INSTALLATION

(1) Replace the water inlet pipe O-ring with new ones, then
apply water to the O-rings so that they can be inserted
easily into the cylinder block and the thermostat case.
Caution
1. Never apply any oil or grease to the O-ring.
2. Secure the water pipe after the thermostat case
has been installed.
P

p@+
THERMOSTAT CASE INSTALLATION
(1) Clean the sealant application surfaces of the thermostat
case and cylinder head.
(2) Apply a 3 mm (.12 in.) diameter bead of sealant to the
area shown in the illustration. Be sure to install the
thermostat case within 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
(3) After installation, wait at least one hour. Never start the
engine or let coolant touch the adhesion surface during
that time.
 ENGINE OVERHAUL c1.8L> - Water Pump and Water Hose ' 11D-23
F D I THERMOSTAT INSTALLATION
(1) Install the thermostat so that the jiggle valve is at the
top.

.Ed OUTLET FllTlNG INSTALLATION

(1) Clean the sealant application surfaces of the fittings and
cylinder head.
(2) Apply a 3 mm (.12 in.) diameter bead of sealant to the
area shown in the illustration. Be sure to install the fitting
within 15 minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
+3 mm (. 12 in.) 9EN0579 (3) After installation, wait at least one hour. Never start the
engine or let coolant touch the adhesion surface during
that time.

,F+ ENGINE COOLANT TEMPERATURE GAUGE UNIT

INSTALLATION
(1) When reusing the gauge unit, clean its thread.
(2) Apply the specified sealant to the threads.
Specified sealant:
3M Nut Locking Part No.4171 or equivalent

6AE0077

,G+ENGINE COOLANT TEMPERATURE SENSOR

INSTALLATION
(1) When reusing the sensor, clean its thread.
(2) Apply the specified sealant to the threads.
Specified sealant:
3M ATD Part No.8660 or equivalent

6AE0070
11D-24 ENGINE OVERHAUL <1.8L> - Rocker Arms and Camshaft
ROCKER ARMS AND CAMSHAFT I1 300540421

REMOVAL AND INSTALLATION

4
3

Removal steps
1. Breather hose 4AF 10. Rocker arms and rocker arm shaft
2. P.C.V. hose (Exhaust)
3. Oil filler cap 11. Rocker arm B
4. Rocker cover 12. Rocker arm A
5. Rocker cover gasket FB4 13. Rocker arm shaft
6. Oil seal F A 4 14. Lash adjuster
.El 7. Oil seal 15. Rocker arm C
FDA 8. Rocker arm spring FB4 16. Rocker arm shaft
4 A F b C 4 9. Rocker arms and rocker arm shaf-t F A 4 17. Lash adjuster
(Intake) 18. Camshaft
 ENGINE OVERHAUL <1.8L> - Rocker Arms and Camshaft 11D-25
REMOVAL SERVICE POINT
+A,ROCKER ARM AND ROCKER ARM SHAFT
REMOVAL
Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11D-26.)
(1) Set special tool MD998443 to prevent the lash adjuster
coming free and falling to the floor.

INSTALLATION SERVICE POINTS

F A + LASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
(Refer to 11D-26.)
(1) Fit the lash adjuster onto the rocker arm without allowing
diesel fuel to spill out. Fit specialtool MD998443to prevent
the lash adjuster coming free and falling to the floor.

NotchI For intake side F B + ROCKER ARM SHAFT INSTALLATION

v-
d I
(1) Install the rocker arm shafts, place the end with notched
side toward the timing belt side as shown.
U
g n g belt side

1I 0 - 0
Notchf"l For exhaust side
9ENO857

FCdROCKER ARMS AND ROCKER ARM SHAFT

INSTALLATION
(1) Move the rocker arms in the directions shown in the
illustration before tightening the rocker arm shaft bolts.
NOTE
Move the rocker arms until they touch the rocker arm
shaft mounting bosses on the cylinder head.

F D + ROCKER ARM SPRING INSTALLATION

(1) Insert the rocker arm spring at an angle to the spark
plug guide and then install it so that it is at a right angle
to the guide.
(2) Remove the special tools from rocker arms.
11D-26 ENGINE OVERHAUL <1.8L> - Rocker A r m s and Camshaft
FE( OIL SEAL INSTALLATION

INSPECTION 11300550400

CAMSHAFT
(1) Measurethe cam height and replace the camshaft if any
height exceeds the specified limit.
Standard value:
Intake: 37.11 mm (1.46 in.)
Exhaust: 37.15 mm (1.46 in.)
Limit:
Intake: 36.61 mm (1.44 in.)
Exhaust: 36.65 mm (1.44 in.)
I I LASH ADJUSTERS
Outside
cleaning
Inside
cleaning
Fulling
diesel fuel 1 Caution
1. The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
2. Do not attempt to disassemble the lash adjusters.
3. Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters
B C
I of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjusterwhen it is standing
upright. Then, perform the following steps with each lash
adjuster.

(2) Place the lash adjuster in containerA and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
 ENGINE OVERHAUL <1.8L> - Rocker Arms and Camshaft ’ 11D-27
M D998441 (3) Fit special tool MD998441 onto the lash adjuster.
M (4) While gently pushing down the internal steel ball using
special tool MD998442, move the plunger through 5 to
10 strokes until it slides smoothly. In additionto eliminating
stiffness in the plunger, this operation will removed dirty
oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
6EN1700
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.

Removethe lash adjuster from the container. Then, push

down the steel ball gently and pushthe plungerto eliminate
diesel fuel from the pressure chamber.

MD998442
-
-
Diesel fuel 6EN1701

MD998441 (6) Fit special tool MD998441 onto the lash adjuster.
M (7) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using special tool MD998442
and move the plunger through 5 to 10 strokes until it
slides smoothly. This operation will clean the lash
adjuster’s pressure chamber.
Caution
The steel ball spring is extremely weak, so the lash
/
MD998442 Diesel fuel adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
6EN1700

(8) Removethe lash adjuster from the container.Then, push

down the steel ball gently and pushthe plungertoeliminate
diesel fuel from the pressure chamber.

MD998442
-
-
Diesel fuel 6EN1701
11D-28 ENGINE OVERHAUL <1.8L> - Rocker Arms and Camshaft
(9) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using special tool MD998442.
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when the chamber is filled with
diesel fuel.

7n3

(10)Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then releasethe steel ball and allow the pressurechamber
to fill with diesel fuel.
(11) Remove special tool MD998441.

(12)Removethe lash adjuster from the container, then stand

the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster's height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (9)
through (12) again to fill it with diesel fuel completely.
Replacethe lash adjuster if it still contracts after performing
these steps.
6ENl7041

(13)Set the ash adjuster on the special tool MD998440 (leak

Division = I m m (.04 in.)
down tester).
MD998440 / (14)After the plunger has moved downward slightly [0.2to
0.5 mm (.008 - .019 in.)], measure the time taken for
it to move downward by a further 1 mm (.04 in.).
Standard value:
adjuster -
3 20 seconddl mm (.04 in.)
[with diesel fuel at 15 to 20°C (59 - SSOF)]
NOTE
6EN1705 Replace the lash adjuster if the time measurement is
out of specification.
(15)Fit special tool MD998441 onto the lash adjuster.
(16)Place the lash adjuster in container C again, then gently
push down the internal steel ball using special tool
MD998442.
(17)Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then releasethe steel ball and allow the pressurechamber
to fill with diesel fuel.
(18) Remove special tool MD998441.
6 F N l 7nt3
ENGINE OVERHAUL c1.8L> - Rocker Arms and Camshaft 11D-29
(19)Removethe lash adjuster from the container, then stand
\ I the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (15)
through (19) again to fill it with diesel fuel completely.
Replacethe lash adjuster if it still contractsafter performing
u these steps.
6EN1704
(20)Stand the lash adjuster upright to prevent diesel fuel
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.
11D-30 ENGINE OVERHAUL <1.8L> - Cylinder Head and Valves
CYLINDER HEAD AND VALVES 11300690171

REMOVAL AND INSTALLATION

during reassembly.

9EN0727

Removal steps
++ (D. 1. Cylinder head bolt 11. Intake valve
2. Cylinder head assembly +Cb .A+ 12. Valve stem seal
3. Cylinder head gasket 13. Valve spring seat
+Bb b C + 4. Retainer lock +Cb F A 4 14. Valve stem seal
5. Valve spring retainer 15. Valve spring seat
b B + 6. Valve spring 16. Exhaust valve guide
7. Exhaust valve 17. Intake valve guide
+Bb .C( 8. Retainer lock 18. Exhaust valve seat
9. Valve spring retainer 19. Intake valve seat
b B + 10. Valve spring 20. Cylinder head
 *
ENGINE OVERHAUL <1.8L> - Cylinder Head and Valves 11D-31
REMOVAL SERVICE POINTS
+ A b CYLINDER HEAD BOLT REMOVAL
(1) Loosen the cylinder head bolts using the special tool.

4 B b RETAINER LOCK REMOVAL

(1) Tag removed valves, springs and other components,
noting their cylinder numbers and locations to facilitate
reassembly. Store these components safely.

MD998735
T

U 6EN1068

+CbVALVE STEM SEAL REMOVAL

11D-32 ENGINE OVERHAUL c1.8L> - Cylinder Head and Valves
INSTALLATION SERVICE POINTS
F A + VALVE STEM SEAL INSTALLATION
(1) Install the valve spring seat.
(2) Install a new valve stem seal using the special tool shown
in the illustration.
Caution
1. Do not reuse removed valve stem seals.
2. The valve stem seal must be installed using the
correct special tool. Incorrect installation could
result in oil leaking past the valve guide.
I I FBA VALVE SPRING INSTALLATION
(1) Install the valve spring so that the painted end is on
Painted the rocker arm side.
end

I I
6EN0437 I
F C + RETAINER LOCK INSTALLATION
(1) The valve spring, if excessively compressed, causes the
bottom end of retainer to be in contact with the stem
seal, and damage it.

MD99

6EN1068

FD( CYLINDER HEAD BOLT INSTALLATION

(1) Before reusing the cylinder head bolt, measure that its
shank length does not exceed the specified limit. Replace
the bolt if this measurement exceeds the limit.
Limit: Max. 96.4 mm (17.23 in.)
(2) Fit the washer as shown.
(3) Apply engine oil to the bolt thread and washer.
Shank length
29EN0251
 ENGINE OVERHAUL <1.8L> - Cylinder Head and Valves 11D-33
(4) Tighten the bolts in the sequence shown until each is
Timing belt side
torqued to 74 Nm (54 ft.lbs.) using the special tool
(MB991653).
(5) Loosen all bolts fully.
(6) Retighten the bolts in the sequence shown until each
is torqued to 20 Nm (15 ft.lbs.).
(7) Make paint marks on the cylinder head bolt heads and
cylinder head as shown.
(8) In accordancewith the tightening sequence, tighten each
bolt by 90" (1/4 turn).
9EN0518 (9) Tighten each bolt by further 90" (1/4 turn) and check
that the paint marks on the bolt head and cylinder head
are aligned.

Caution
If the bolts are tightened by an angle of less than 90"
(1/4 turn), they may not hold the cylinder head with
sufficient strength.
If the bolts are tightened by an angle exceeding go",
completely remove them and repeat the installation
procedure.

INSPECTION 113OO7OO195

CYLINDER HEAD
(1) Before cleaningthe 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: 0.03 mm (.0012 in.)
Limit: 0.2 mm (.008 in.)
(4) If flatness exceeds the specified limit, grind the gasket
surface to specification.
Grinding limit: *0.2 mm (.008 in.)
*Includes/combined with cylinder block grinding
Cylinder head height (Specification when new):
119.9 - -
120.1 mm (4.720 4.728 in.)
11D-34 ENGINE OVERHAUL c1.8L> = Cylinder Head and Valves

VALVE
(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.
Valve seat contact Standard value:
Intake: 1.0 mm (.039 in.)
Exhaust: 1.3 mm (.051 in.)
I
I Limit:
6EN0542
Intake: 0.5 mm (.020 in.)
Exhaust: 0.8 mm (.031 in.)
(3) Measure the valve length. If the measurement is less
than specified, replace the valve.
Standard value:
Intake: 110.15 mm (4.337 in.)
Exhaust: 113.70 mm (4.476 in.)
Limit:
Intake: 109.65 rnrn (4.317 in.)
Exhaust: 113.20 mm (4.457 in.)

VALVE SPRING
It Out Of square
(1) Measurethe valve spring free height. If the measurement
is less than specified, replace spring.
Standard value: 50.9 mm (2.00 in.)
height Limit: 49.9 mm (1.96 in.)
(2) Measurethe squarenessof the spring. If the measurement
is less than specified, replace the spring.
Standard value: 2" or less
1ENP264
Limit: 4"
VALVE GUIDE
(1) Measurethe clearance betweenthe valve guide and valve
stem. If the clearance exceeds the specified limit, replace
valve guide or valve, or both.
Valv
Standard value:
guid
Intake: 0.02 - -
0.05 mm (.0008 .0020 in.)
-
Exhaust: 0.05 0.09 mm (.0020 .0035 in.)-
Limit:
21EN0279 Intake: 0.10 mm (.0039 in.)
.D. Exhaust: 0.15 mm (.0059 in.)
 ’
ENGINE OVERHAUL <1.8L> - Cylinder Head and Valves 11D-35
Valve stem end VALVE SEAT
(1) Assemble the valve, then measure the valve stem
projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds the
specified limit, replace the valve seat.
Standard value:
Intake: 49.30 mm (1.9409 in.)
Exhaust: 49.35 mm (1.9429 in.)
Limit
DEN0212 Intake: 49.80 mm (1.9606 in.)
Exhaust: 49.85 mm (1.9626 in.)

0.9 - 1.3 mm 0.9 - 1.3 mm VALVE SEAT RECONDITIONING PROCEDURE

(.035 - ,051 in.) (.035 - .051 in.) (1) Before correcting the valve seat, check the clearance
- . / between the valve guide and valve. If necessary, replace
the valve guide.
(2) Using the appropriate special tool or
the valve seat to achieve the spec
angle.
(3) After correcting the valve seat, lap
Exhaust Intake seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).
T

VALVE SEAT REPLACEMENT PROCEDURE

I 0.5 - 1.O mm (.020- ,039 in.) I (1) Cut the valve seat to be replacedfromthe inside to reduce
the wall thickness. Then, remove the valve seat.
(2) Rebore the valve seat hole in the cylinder head to match
the selected oversize valve seat diameter.
Intake valve seat hole diameter
- -
0.3 O.S.: 31.80 31.83 mm (1.2520 - 1.2531 in.)
0.5 1.0 mm
(.020- .039 in.) -
0.6 O.S.: 32.10 31.13 mm (1.2638 - 1.2650 in.)
Exhaust valve seat hole diameter
1EN0274 I 0.3 O.S.: 29.30 - 29.32 mm (1.1535 - 1.1543 in.)
0.6 O.S.: 29.60 - 29.62 mm (1.1654 - 1.1661 in.)
(3) Prevent galling of the cylinder head bore by cooling the
valve seat with liquid nitrogen before press-fitting it.
(4) Correct the valve seat to achieve the specified width and
angle (refer to VALVE SEAT RECONDITIONING
PROCEDURE).

275
11D-36 ENGINE OVERHAUL <1.8L> - Cylinder Head and Valves
VALVE GUIDE REPLACEMENT PRCEDURE
(1) Using a press, pushthe valve guide out toward the cylinder
block side.
(2) Reborethe valve guide hole in the cylinder head to match
the oversize valve guide that is to be fitted.
Caution
Do not install a valve guide of the same size again.
Valve guide hole diameters in cylinder head
0.05 O.S.: 11.05 -
11.07 -
mm (.4350 .4358 in.)
0.25 O.S.: 11.25 - -
mm (.4429 .4337 in.)
11.27
-
0.50 O.S.: 11.50 11.52 -
mm (.4528 .4535 in.)

(3) Press-fit the valve guide until it projects by the specified

amount.
Caution
1. The valve guide must be installed from the upper
side of the cylinder head.
2. The valve guides differ in length on the intake
and exhaust sides.
VALVE GUIDE LENGTH
INTAKE: 45.5 mm (1.791 in.)
EXHAUST: 50.5 mm (1.988 in.)
(4) After press-fitting the valve guide, insert a new valve and
check that it slides smoothly.
 ENGINE OVERHAUL <1.8L> - Oil Pump and Oil Pan 11D-37

OIL PUMP AND OIL PAN 11300810232

REMOVAL AND INSTALLATION

9EN0728

Removal steps
1. Oil pressure switch 9. Relief spring
2. Oil filter 10. Relief plunger
3. Drain plug F C + 11. Oil seal
4. Gasket F B I 12. Front case
5. Oil pan 13. O-ring
6. Oil screen 14. Oil pump case cover
7. Oil screen gasket + B F F A + 15. Outer rotor
8. Relief plug 4 B F .A+ 16. Inner rotor
11D-38 ENGINE OVERHAUL <1.8L> - Oil Pump and Oil Pan
~ MD998727 REMOVAL SERVICE POINTS
+A,OIL PAN REMOVAL
(1) Remove the oil pan mounting bolts.
(2) Knock the special tool between the oil pan and cylinder
block as shown in the illustration.
(3) Tapping the side of the special tool, slide the tool along
the oil pankylinder block seal and thus remove the oil
pan.

+ B F OUTER ROTOR/INNER ROTOR REMOVAL

(1) Make alignment dots on the outer and inner rotors for
reference in reassembly.

INSTALLATION SERVICE POINTS

.A+ INNER ROTOR/OUTER ROTOR INSTALLATION
(1) Apply engine oil to the rotors. Then, install the rotors
ensuring that the alignment dots made at disassembly
are properly aligned.

b B + FRONT CASE INSTALLATION

(1) Clean the sealant application surfaces on the cylinder
block and front case.
(2) Apply a 3 mm (.I2in) diameter bead of sealant to the
area shown. Be sure to install the front case within 15
minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
(3) Tighten the front case bolts to the specified torque.
(4) After installation, wait at least one hour. Never start the
engine or let engine oil touch the adhesion surface during
that time.
 ENGINE OVERHAUL <1.8L> - Oil Pump and Oil Pan 11D-39
F C d FRONT OIL SEAL INSTALLATION
(1) Place the special tool on the crankshaft front end and
apply engine oil to the its outer diameter.
(2) Apply engine oil to the oil seal lip, then push the oil seal
along the guide by hand until it touches the front case.
Tap the oil seal into place using the special tool.

F D d OIL PAN INSTALLATION

(1) Clean the mating surfaces of the oil pan and cylinder
block.
(2) Apply a 4 mm (.16 in.) diameter bead of sealant to the
oil pan flange. Be sure to install the oil pan within 15
minutes after applying sealant.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
Groove portion gEN05841 (3) Tighten the oil pan bolts to the specified torque.
(4) After installation, wait at least one hour. Never start the
engine or let engine oil touch the adhesion surface during
that time.

.Ed DRAIN PLUG GASKET INSTALLATION

(1) Replace the drain plug gasket with a new one. Fit the
new gasket as shown.
11D-40 ENGINE OVERHAUL <1.8L> - Oil Pump and Oil Pan

+F. OIL FILTER INSTALLAION

(1) Clean the filter mounting surfaces on the front case.
(2) Apply clean engine oil to the O-ring of the oil filter.
(3) Screw on the oil filter until its O-ring is seated on the
mounting surface. Then, give the oil filter one further
turn.
Caution
The oil filter must be tightened using a commercially
available filter wrench. If the filter is tightened by hand
only, it will be insufficiently torqued, resulting in oil
leaks.
.G+OIL PRESSURE SWITCH INSTALLATION
(1) Apply the specified sealant to the threads of the switch.
Specified sealant:
3M ATD Part No.8660 or equivalent
Caution
Use care not to allow the sealant to plug the oil
passage.
(2) Install and tighten the switch to the specified torque by
I Z9EN0094 using a socket wrench and torque wrench.
Caution
If the switch is tightened with a spanner or offset
wrench, an over-torque may be applied and the switch
to be damaged.
ENGINE OVERHAUL <1.8L> - Oil Pump and Oil Pan ' 11D-41
INSPECTION 11300820099

OIL PUMP
(1) Fit the rotors into the front case.
(2) Check the tip clearance, using a feeler gauge.
Standard value: 0.06 - 0.18 mm (.0024- .0071 in.)

(3) Check the side clearance, using a straight and feeler

gauge.
Standard value: 0.04 -0.10 mm (.0016 - .0039 in.)

(4) Check the body clearance, using a feeler gauge.

Standard value: 0.10 - 0.18 mm (.0039- .0071 in.)
Limit: 0.35 mm (.0138 in.)
11D-42 ENGINE OVERHAUL <1.8L> - Piston and Connecting Rod
PISTON AND CONNECTING ROD 11300840170

REMOVAL AND INSTALLATION

I I
I 1
Lubricate all in-
*ternal parts with
engine oil during

B
11 -
/ @- -
10

12
4

Removal steps
2 FGd 1. Nut FC+ 7. Piston ring No.2
+AF FF+ 2. Connecting rod cap FB+ 8. Oil ring
FE+ 3. Connecting rod bearing +BF F A + 9. Piston pin
FD+ 4. Piston and connecting rod 10. Piston
FE+ 5. Connecting rod bearing 11. Connecting rod
FC+ 6. Piston ring No.1 12. Bolt
 ENGINE OVERHAUL <I .8L> - Piston and Connecting Rod 11D-43
REMOVAL SERVICE POINTS
+A, CONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
number rod big end for correct reassembly.
(2) Keep the removed connecting rods, caps, and bearings
in order according to the cylinder number.

ZEN04

I Piston pin setting tool MIT216941 I 46, PISTON PIN REMOVAL

~~~ ~

8 MIT310142 Piston Support

9 MIT48143 Press Pin
10 2 16943 Stop Screw
11 10396 Nut

1 --&
Press
pin
+I
W& Piston,pin

Front mark

Connecting rod
guide pin

I 7EN0979 I
11D-44 ENGINE OVERHAUL c1.8L> - Piston and Connecting Rod

INSTALLATION SERVICE POINTS

F A + PISTON PIN INSTALLATION
(1) 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.
(2) Using the markings on the press pin, adjust the stop
screw to the depth as shown below.
Depth: Refer to the operating instructions on the
special tool.

(3) Place the base on press support blocks.

(4) Slide the piston pin over the threaded end of the press
Piston pin pin, and thread the correct guide pin up against it.
r=l (5) Coat the piston pin with oil, and with the connecting rod
held in position, slide the guide pin through the piston
and connecting rod.
(6) Press the piston pin through the connecting rod until the
Frc guide pin contacts the stop screw.
(7) Remove the piston assembly from the base. Remove
the guide pin and press pin from the assembly.
rod IMPORTANT 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.

I ?EN0980

(8) Check that the piston moves smoothly.

 ENGINE OVERHAUL <1.8L> - Piston and Connecting Rod 11D-45
I I
. Side rail

Spacer

I ' 9EN0730 I Size Identificationcolor

Standard size None

Side rail end
0.50 mm O.S. Blue

1.OO mm O.S. Yellow

' \ 7EN0451

bC( PISTON RING NO.2/PISTON RING NO.l

INSTALLATION
(1) Using a ring expander, fit ring No.2 and ring No.1 with
their identification marks facing upward (on the piston
crown side).
Identification mark:
No.1 ring: T
No.2 ring: T2

\ 7EN0452

Identification mark 'IT" NOTE

The piston ring is stamped with the following size mark.

Size 1 Size mark I

Standard size 1 None I
0.50 mm O.S. 50

1.OO mm O.S. 100

11D-46 ENGINE OVERHAUL <1.8L> - Piston and Connecting Rod
Umer side rail No.1 ring ,D+ PISTON AND CONNECTING ROD ASSEMBLY

Timing
belt side +$T-), _I1Piston pin
INSTALLATI 0N
(1) Apply oil to the piston, piston ring, and oil ring.
(2) Align the gaps of the piston rings and oil rings (side rails
and spacer) as shown.
(3) With the piston crown’s front arrow mark pointing toward
the timing belt side, press the piston and connecting rod
\ A
- I
Lower side rail
assembly into the cylinder from the top of the cylinder.
IV0.2 rinq

I andspacer 6EN0549 I
(4) Compress the piston rings tightly with a suitable ring
compressiontool, then press the piston and connecting
rod fully into the cylinder. Do not strike the piston hard
since the piston rings may break and the crank pin may
be nicked.

Crankshaft FE( CONNECTING ROD BEARING INSTALLATION

(1) When replacing the bearings and/or crankshaft, read off
Check digit the identification mark on the crankshaft (as illustrated),
NO 4 and select a bearing according to the following table.
N0.3 Crank pin O.D.
No.2 identification
No.1 mark

Crankshaft journal
O.D. identification
mark
Brown

2 s2 Black

3 s3 Green

Z9EN0128

Connecting rod bearing

Identification
I

,-T%l color
Identification

I 9EN0129 I
 ENGINE OVERHAUL c1.8L> - Piston and Connecting Rod * 11D-47
F F d CONNECTING ROD CAP INSTALLATION
(1) Aligning the marks made during disassembly, fit the
bearing cap onto the connecting rod. If the connecting
rod is new and has no index mark, ensure that the bearing
ider No.
locking notches are both on the same side.

Notches

DEN0051

(2) Check that the connecting rod big end side clearance
confirms with specification.
-
Standard value: 0.10 0.25 mm (.0039 - .0098 in.)
Limit: 0.4 mm (.016 in.)

bGdCONNECTlNG ROD CAP NUT TIGHTENING

(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method. the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Neckingcan be checked by running a nut with your fingers
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
nut.
(3) Install each nut to the bolt and finger-tighten it. Then
tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm (15 ft.lbs.).
11D-48 ENGINE OVERHAUL <1.8L> - Piston and Connecting Rod
I [ I I 1 Paint mark (5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the bolt end at the position 90"
to 100" from the paint mark made on the nut in the direction
of tightening the nut.
(7) Give a 90" to 100" turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. If the nut is turned less than go", proper fastening
performance may not be expected. When
I I ' 0 I l l 6AEQ298
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened(exceedingIOO"), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).

INSPECTION 11300850173

PISTON RING
(1) Check for side clearance.
If the limit is exceeded, replace the ring or piston, or
both.
Standard value:
No.1:
No.2:
0.03
0.02
- 0.07
- 0.06
mm (.0012
mm (.0008
-- .0028 in.)
.0024 in.)
Limit:
No.1: 0.1 mm (.0039 in.)
No.2: 0.1 mm (.0039 in.)
ENGINE OVERHAUL <1.8L> - Piston and Connecting Rod 11D-49
(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, measurethe end gap with a feeler
gauge.
If the end gap is excessive, replace the piston ring.
Standard value:
-
No.1: 0.25 0.40 mm (.0098 - .0157 in.)
-
No.2: 0.40 0.55 mm (.0157 - .0217 in.)
Oil: 0.20 - 0.60 mm (.0078 - .0236 in.)
Limit:
No.1, No.2: 0.8 mm (.031 in.)
Oil: 1.0 mm (.039 in.)

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC

GAUGING MATERIAL METHOD)
(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: 0.02 - 0.05 mm (.0008 - .0020 in.)
Limit: 0.1 mm (.004 in.)
11D-50 ENGINE OVERHAUL c1.8L> - Crankshaft and Cylinder Block
CRANKSHAFT AND CYLINDER BLOCK 11300870179

REMOVAL AND INSTALLATION

Nm
ft.lbs.

98 Nm
71 ft.lbs.

A9EN0729

Removal steps
.El 1. Flywheel bolt <M/T> .
B
+ 14. Bearing cap
2. Plate <M/T> .A+ 15. Crankshaft bearing, lower
3. Adapter plate <M/T> 16. Crankshaft
4. Flywheel (Non-disassemblable F A 4 17. Thrust plate
parts) <M/T> .A+ 18. Crankshaft bearing, upper
5. Adapter plate <M/T> 19. Cylinder block
.E+ 6. Drive plate bolt <An> Caution
7. Adapter plate <An> Do not remove any of the bolts “ A of the flywheel
8. Drive plate <A/T>
9. Rear plate shown in the illustration. The balance of the flexible
10. Bell housing cover type flywheel is adjusted in an assembled condition.
,D+ 11. Rear oil seal case Removing the bolt, therefore, can cause the flexible
b C + 12. Rear oil seal flywheel to be out of balance, giving damage to the
.
B
+ 13. Bearing cap bolt flywheel.
 ENGINE OVERHAUL <1.8L> - Crankshaft and Cylinder Block 11D-51
INSTALLATION SERVICE POINTS
F A ( CRANKSHAFT BEARING INSTALLATION
9-
e Check digit (1) When replacing the bearings, crankshaft and/or cylinder

j4-
(Y

Crank pin O.D. block, read off the identification mark on the crankshaft
identification and cylinder block (as illustrated), and select a bearing
(3 mark
according to the flollowing table.
N0.5 c

N0.4 *(Y
N0.3 *(Y M-
Journal O.D.
No.2 c identification

Identification Identification Identification Identification

mark mark mark color

1 Black

2 s3 Green

2 Black

Green
Z9ENO13C
Yellow

2ylinder block 3

1T'
No.3 No.2

N+T/ Identifica-
tion mark
Cylinder
bore I.D.
identifica-
tion
- 1220 '
for cylin-
der block
bearing
bore I.D.

Timing belt side

(2) Install bearings having an oil groove to the cylinder block.

(3) Install bearings having no oil groove onto the bearing
caps.
(4) Install the thrust bearings at the No.3 upper bearing with
the grooved side toward the crankshaft web.
11D-52 ENGINE OVERHAUL c1.8L> - Crankshaft and Cylinder Block
.B+ BEARING CAP/BEARING CAP BOLT
INSTALLATION
(1) Install the bearing cap so their arrow is positioned on
the timing belt side.
(2) When reusingthe bearing cap bolt, measure that its shank

u
Length of shank
length dose not exceed the specified limit. Replace the
bolt if this measurement exceeds the limint.
Limit: max. 71.1 mm (2.799 in.)
(3) Apply engine oil to the bolt thread and flange of the bolt.
PEN0477

(4) Tighten the bearing cap bolts to 25 Nrn (18 ft.lbs.) torque
in the sequence shown.

Arrow 6 E NO624

(5) Make a paint mark on the head of each bolt.

(6) Make a paint mark on the bearing cap at the position
90" to 100" from the paint mark on the bolt head in
the direction of tightening the bolt.
(7) Give a 90" to 100" turn to the bolt in the tightening
sequence. Make sure that the paint mark on the bolt
and that on the bearing cap are in alignment.
Caution
1 If the bolt is turned less than go", proper fastening
I

performance may not be expected. When

tightening the bolt, therefore, be careful to .give
a sufficient turn to it.
2. If the bolt is overtightened (exceeding loo"),
Isasen the bolt completely and then retighten it
by repeating the tightening procedure from step
(11.

(8) Check that the crankshaft rotates smoothly.

(9) Measure the end play in the crankshaft. If the
measurement exceeds the specified limit, replace the
crankshaft bearings.
Standard value: 0.05 - 0.25 mm (.0020 - .0098 in.)
Limit: 0.4 mm (.016 in.)
ENGINE OVERHAUL <1.8L> - Crankshaft and Cylinder Block 11D-53
b C ( REAR OIL SEAL INSTALLATION

'76

Z9EN0077

FDdSEALANT APPLICATION TO OIL SEAL CASE

Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent

.Ed DRIVE PLATE BOLT/FLWHEEL BOLT

INSTALLATION
(1) Remove all the remaining sealant from bolts and thread
holes of crankshaft.
(2) Apply engine oil to the flange of bolt.
(3) Apply engine oil into the thread holes of crankshaft.
(4) Apply specified sealant to the thread of bolt.

:m Z9EN0102
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
(5) Tighten the bolts to specified torque.

INSPECTION 11300880158

CRANKSHAFT JOURNAL OIL CLEARANCE

(PLASTIGAGE METHOD)
(1) Remove oil from the crankshaftjournal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
bearing and place it on the 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 Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.02 - 0.04 mm (.0008 - .0016 in.)
Limit: 0.1 mm (.004 in.)
11D-54 ENGINE OVERHAUL <1.8L> - Crankshaft and Cylinder Block

CYLINDER BLOCK
(1) Visually check for cracks, rust, and corrosion, and inspect
the cylinder block using a flaw detecting agent. Rectify
defects where possible or replace the cylinder block.
(2) Ensure that the top surface is free of gasket chips and
other foreign material.Check the cylinder blocktop surface
for distortion using a straight edge and feeler gauge.
Standard value: 0.05 mm (.0020 in.) or less
Limit: 0.1 mm (.OM in.)
(3) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm (.008 in.)
The total thickness of the stock allowed to be
removed from cylinder block and mating cylinder
head 0.2 mm (.008 in.) at maximum.
Cylinder block height (when new):
263.5 mm (10.374 in.)
(4) Check the cylinder walls for cracks and seizure marks.
If defects are evident, bore all the cylinders to oversize
or replace the cylinder block.

(5) Using a cylinder gauge, measure each cylinder bore and

cylindricity. If any cylinder is severely worn, bore all the
cylinders to oversize and replace the piston and piston
rings accordingly. Take measurements at the points
shown.
Standard value:
Cylinder bore I.D.: 81.0 mm (3.19 in.)
Cylindricity: 0.01 mm (.0004 in.) or less

BORING CYLINDER
(1) Oversize pistons should be based on the largest bore
cylinder.
Piston size identification

Thrust 0.50 rnm O.S. 0.50

direction
Piston O.D. 1 .OO rnm O.S. 1.oo
NOTE
Z6EN0554
The size mark is stamped on the piston top.
(2) Measure the outside diameter of piston to be used.
Measure it in thrust direction as shown.
(3) Based on the measured piston O.D., calculate the boring
finish dimension.
Boring finish dimension = Piston O.D. + (Clearance
-
between piston O.D. and cylinder) 0.02 mm (.0008
in.) (honing margin)
ENGINE OVERHAUL <I .8L> - Crankshaft and Cylinder Block 11D-55
(4) Bore each cylinders to the calculated boring finish
dimension.
Caution
To prevent distortion caused by heat increased during
boring, bore the cylinders in the following order: No.2,
N0.4, No.1, No.3.
(5) Hone the cylinders to the final finish dimension (Piston
O.D. + Piston-to-cylinder clearance).
(6) Check the clearance between piston and cylinder.
Standard value:
0.02 - 0.04 mm (.0008 - .0016 in.)
NOTE
When boring cylinders, finish all of four cylinders to the
same oversize. Do not bore only one cylinder to an
oversize.