1991 MITSUBISHI ECLIPSE lock
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S-60ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft
3EN040
7LUOOO6
27. REMOVAL OF SILENT SHAFT REAR BEARINGUsing the special tool, remove the rear bearing from
A=cylinder block..i
INSPECTION
SILENT SHAFTNOSRUEl(1) Check oil holes for clogging.
(2) Check journal for seizure, damage, and contact with
bearing. If there is anything wrong with the journal, replace
silent shaft, bearing or front case assembly.
(3) Check the silent shaft oil clearance. If the clearance is
excessively due to wear, replace the silent shaft bearing
silent shaft or front case assembly.
Standard value:
Front
Right
0.030-0.060 mm (.0012-.0024 in.)
LeftO.O20-0.064 mm (.OOOS-.0021 in.)
Rear
Right
Left
0.050-0.091 mm (.0020-.0036 in.) rt
0.050-0.091 mm (.0020-.0036 in.1-4FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check left silent shaft front bearing section for wear,
damage and seizure. If there is anything wrong with the
section, replace the front case.
(3) Check the front case for cracks and other damage. Replacecracked or damaged front case.
OIL SEALNOORCMAO
(1) Check the oil seal lip for wear and damage. Replace oil sealif
necessan/.(2) Check the oil seal lip for deterioration. Replace oil seal if
necessary.
OIL PRESSURE SWITCH
(1) Connect a tester (ohm range) between the terminal and thebody and check for conductivity. If there is no conductivity,
replace the switch.
Page 346 of 1216
9-62ENGINE -4.8L Engine> -Front Case, Oil Pump and Silent Shaft
OIL RELIEF PLUNGER(1) Check that the relief plunger slides smoothly.
(2) Check the relief spring for breakage.
3EN044J
MD998280
3EN270
0M D998304
SERVICE POINTS OF REASSEMBLYNOBRHAF
27. INSTALLATION OF SILENT SHAFT REAR BEARING
(1) Apply engine oil to the rear bearing outer circumferenceand bearing hole in cylinder block.
(2) Using the special tool and a hammer, drive the rear
bearing into cylinder block.
26. INSTALLATION OF SILENT SHAFT FRONT BEARING(1) Install two guide pins included in the special tool set to
the threaded holes in cylinder block.
(2) Set the front bearing on the special tool so that the
ratchet ball of special tool fits in the oil hole in bearing.
(3) Apply engine oil to the bearing outer circumference andbearing hole in cylinder block.
(4) Set the special tool on guide pins and drive the bearing
into cylinder block.
22. INSTALLATION OF CRANKSHAFT OIL SEALUsing the special tool, install the crankshaft oil seal into
front case.
Page 347 of 1216
ENGINE <1.8L Engine> -Front Case, Oil Pump and Silent Shaft9-63
aSocket wrench/
3EN271
MD998285R
Fasten toqether with
the timtins under cover
C
belt tensioner3ENOOWTiming marks
16. / 15. INSTALLATION OF OIL PUMP GEARS(1) Align the timing mark on the drive gear with that on
driven gear and install them into front case.
(2) Apply amplely engine oil to the gears.
3EN046
21. INSTALLATlON OF SILENT SHAFT OIL SEAL
Using a socket wrench, press-in the silent shaft oil seal intofront case.
17. INSTALLATION OF FRONT CASE(1) Set the special tool on the front end of crankshaft and
apply engine oil to the outer circumference of the
special tool.
(2) Install the front case using three different sizes of bolts
as shown.
Code
A
B
C
Bolt size
(diameter x length) mm (in.)8
x 20 (.32 x .79)8
x 25 (.32 x .98)
8 x 40 (32 x 1.57)
Head mark
“4”
“4”“4”
14. INSTALLATION OF FLANGE BOLT
Insert a Phillips screwdriver [shank diameter 8 mm (32 in.)]into the plug hole on the left side of cylinder block to block
the silent shaft, then tighten the flange bolt.
Page 348 of 1216
9-64ENGINE 4.8L Engine> -Front Case, Oil Pump and Silent Shaft
13.
INSTALLATlON OF OIL PUMP COVER GASKETInstall a new oil pump cover gasket in the groove of the
front case.
Front caseWhen installing the gasket, face the round side to the oil
pump cover.
3LUOO3 I
Flat iron plate
3EN184
MD998054
/
-----me
tCoat with
engine oil
6LUO26
12. INSTALLATION OF OIL PUMP OIL SEALInstall the oil seal into the oil pump cover, making sure that
its lip is in correct direction.
8. APPLICATION OF SEALANT TO OIL PAN(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply sealant into groove of oil pan flange, ~keeping clear of
holes as shown. The width of sealant bead as sqeezed outof tube should be about 4 mm
(.I6 in.).
Caution
After application of sealant, do not exceed l’5 minutes
before installing the oil pan.
Specified sealant: MITSUBISHI GENUINE PART N
O.
MD997110 or equivalent
2. INSTALLATION OF OIL PRESSURE
SWlTCHCoat the threads of switch with sealant and install the
switch using the special tool.
Specified sealant: MOPAR Part No.4318034 or equiva-
lent
Caution
1. Keep the end of threaded portion clear of sealant.2. Avoid an
overtightening.
1. APPLICATION OF ENGINE OIL TO OIL FILTERApply a thin coat of engine oil to the packing surface.
,.Caution
Do not apply oil too much.
Page 352 of 1216
9-68ENGINE <1.8L Engine> - Piston and Connecting Rod
r-Size and maker marks
No. 1Barrel
faced
1
1 Size and maker marks
L
INo.2
ti2zza
Tapered
Barrelfaced
1 EN064
-1 No. 1 rina aarGap of
upper8. INSTALLATION OF
NO.2 PISTON RING/7. NO. 1
PISTON RINGInstall the No. 2 piston ring and then the No. 1 piston ring
with a piston ring expander.
Caution
1. The No. 1 and No.2 piston rings have a different
cross section. Be sure to install them in correct
positions.
2.Install the No. 1 and No.2 piston rings with the size
mark and maker mark on ring surface toward the
piston top.
4. INSTALLATION OF PISTON AND CONNECTlNG ROD
ASSEMBLY(1) Liberally coat engine oil on the circumference of the
piston, piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate crankshaft so that crank pin is on center of
cylinder bore.
Bearing
bltab notches
DEN057(4) Use suitable thread protectors on connecting rod bolts
before inserting piston and connecting rod assembly
into cylinder block. Care must be taken not to nick crank
pin.(5) Using a suitable piston ring compressor tool, install
piston and connecting rod assembly into cylinder block.
Caution
Insert the front mark (arrow) on the top of the
piston so it faces the engine front (timing belt side).
2. INSTALLATION OF CONNECTING ROD CAPLining up the marks put at the time of disassembly, install
the connecting rod cap on the connecting rod.
If the connecting rod is new without such marks, position
the bearing block tab notches in rod and cap on the same
side as illustrated.
. CHECKING CONNECTING ROD BIG END SIDE CLEAR-
ANCE
Connecting rod big end side clearance:
0.1-0.25 mm (.0039-.0098 in.)
Limit: 0.4 mm (016 in.)
Page 355 of 1216
ENGINE - Crankshaft, Flwvheel and Drive Plate9-71
3EN30’lrrow mark toward
cap No,
I
RING GEAR (Engine with a manual transaxle)Check the ring gear for worn, damaged or broken teeth.
Replace the ring gear if teeth are faulty, and also check the
starter motor pinion.
Ring Gear Replacement Procedure(1) Strike outer circumference of ring gear at several points.
Caution
The ring gear cannot be removed if it is heated.(2) Install the ring gear on flywheel after heating the ring gear
to
260-280°C (500-536°F) for shrink fit.
FLYWHEEL (Engine with a manual transaxle)
(1) Visually check the clutch disc friction surface of flywheel forridge wear, streaks and seizure. Replace as necessary.
(2) If the flywheel
runout exceeds the limit, replace it.
Limit: 0.13 mm (0051 in.)
DRIVE PLATE (Engine with an automatic transaxle)Replace if deformed, damaged or cracked.
SERVICE POINTS OF REASSEMBLY
NOSUDAA
15. INSTALLATION OF UPPER BEARINGWhen reusing the main bearings, install them in their
original positions by referring to location marking made at
the time of removal.
Be sure that oil holes in bearings align with those in cylinder
block.
13. INSTALLATION OF LOWER BEARINGMake sure that a bearing without oil groove is used as
lower bearing.
12. INSTALLATION OF BEARING CAP(1) Install the bearing caps with their arrow mark directed
toward the timing belt side of engine. Cap numbers
must be in correct order.(2) Tighten cap bolts in the sequence of center,
No.2,
No.4. front and rear cap bolts.
(3) Cap bolts should be tightened evenly in 2 to 3 steps
before they are finally tightened.
(4) Make certain that the crankshaft turns freely and has a
proper end play by checking the clearance between
center main bearing thrust flange and connecting rod
big end bearing.
Crankshaft end play:
0.05-0.18 mm (.0020-.0071 in.)
Limit:0.25 mm (.0098 in.)
Page 356 of 1216
9-72ENGINE <1.8L Engine> -Crankshaft, Flywheel and Drive Plate/Cylinder Block
PressOil seal
I
MD99801 1
/
Oil seal case1 EN06L
CYLINDER BLOCK
i//
199.
INSTALLATlON OF REAR OIL SEAL
Install oil seal in the crankshaft rear oil seal case. Using the
special tool, press fit the oil seal all the way in without tiltingiii
it.DISASSEMBLY AND REASSEMBLY
FORWARD
50-70 Nm37-50 ft.lbs.
30-42 Nm22-30 ft.lbs.
NDBVF-A
110-130 Nm80-94 ft.lbs.1. Exhaust pipe support bracket
2. Front roll stopper bracket
3. Rear roll stopper bracket
4. Left engine support bracket5. Cylinder block6. Engine mount bracket
3EN0092
INSPECTIONl Visually check the cylinder block for scores, rust and
corrosion. Also check for cracks or any other faults by using
the magnaflux method. Correct or replace the block if
faulty.
lMeasure the cylinder bore with a cylinder gauge at three
levels and in two directions A and
B as shown. If
out-of-round or taper is more than specified or if the
cylinder walls are badly scuffed or scored, the cylinder
&block should be rebored and honed, and new oversize
_pistons and rings fitted.
Measuring points are as shown.
Cylinder bore: 80.8 mm (3.173 in.)
Out-of-round and taper: 0.01 mm (.0004 in.)
Page 357 of 1216
ENGINE <1.8L Engine> - Cylinder Block9-73
lIf cylinder top ridge is worn in stages, smooth out with a
ridge reamer.
l Oversize pistons are available in four sizes.
Piston oversizes and marks:0.25 mm
(.OlO in.) OS. 0.25
0.50 mm
(.020 in.) O.S. 0.50
0.75 mm
(.030 in.) O.S. 0.75
1
.OO mm (.039 in.) O.S. 1.00
lTo rebore the cylinder to an oversize, keep the specified
clearance between the oversize piston and the bore, and
make sure that all pistons used are of the same oversize.
The standard measurement of the piston outside diameter
is taken at a level 2 mm (0787 in.) above the bottom of thepiston skirt and across the thrust faces.
Piston-to-cylinder wall clearance:
0.01-0.03 mm (.0004-.0012 in.)
Thrustdirectiol
6ENOdl Check for damage and cracks.
l Check top surface for flatness. If excessive distortion is
evident, grind minimum stock within the limit or replace.
Flatness of gasket surface:
StandardLess than 0.05 mm (0020 in.)
Limit0.1 mm (.004 in.)
Overall height: 285.2 mm (11.228 in.)
Limit285 mm (11.220 in.)
Caution
If cylinder head gasket surface has already been
ground, the thickness of the removed stock should be
included in the grinding limit of -0.2 mm (-.008 in.).
CYLINDER
REBORINGNOBVEBA(1) Determine the oversize pistons to be used with reference
to the cylinder with the largest bore.
(2) Measure the piston
O.D. at the measuring point.
NOTEThere are four piston oversizes available: 0.25 mm
(.OlOin.), 0.50 mm
(.020 in.), 0.75 mm (.030 in.) and 1.00 mm
(.039 in.).
(3) Based on the measured piston O.D., calculate the boring
dimension as follows:
Boring dimension = [Piston O.D.] + [Piston-to-cylinder
clearance 0.03 to 0.05 mm
(.0012 to .0020 in.)] - [Honing
allowance 0.02 mm
(.0008 in.)]
(4) Bore each cylinder to the calculated boring dimension.
Caution
To prevent distortion caused by temperature rise
during boring, work in the order of
No.2 to No.4 to
No. 1 to No.3 cylinders.(5) Hone to final finish dimension [Piston O.D.]
+ [Piston-to-cylinder clearance].
(6) Check piston to cylinder clearance.
Standard value: 0.01-0.03 mm (.0004-.0012 in.)