11B 1.5L Overhaul

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ENGIN

OVERHA

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11 B-2

ENGINE OVERHAUL

-

Gen

Description

TYPe

Number of cylinders

Combustion chamber

Total displacement dm3 (cu, in)

Cylinder bore mm (in.)

Piston stroke mm (in.)

GENERAL INFORMATION

Spe

In-li

4

Hem

1,46

75.5

82.0

GENERAL SPECIFICATION

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ENGINE OVERHAUL

- S

SPECIFICATIONS

S E RV C E S

P

EC IF CAT I NS

Standartem

qocker arms, rocker shafts, and camshaft

~ _

Camshaft cam height

rnrn

(in.) Intake-primary

I 38.78 (1

Intake-secondary 38.78 (1

Exhaust

39.10 (1

2ylinder head and valves

Cylinder head gasket surface flatness

mm

(in.)

I

Less th

l

ylinder head gasket surface grinding limit

(including grindingof cylinder block gasket surface) mm (in.)

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Item Standard

Crankshaft iournal diameter mm (in.) 48.0 (1.89

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

4900

-

14

Crankshaft pin oil clearance mm (in.)

Connecting rod big end side clearance mm (in.)

0.01

-

0.0

0.10

-

0.2

0.02

-

0.0

rankshaft ournal oil clearance mm (in.)

Cylinder block gasket surface flatness mm (in.)

~ _ _ _ _ _ _ _ _ _

_

~

~

0.05 (.020

~

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ENGINE OVERHAUL c1.5L>

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Generator brace bolt (generator side)

Generator brace bolt (tightened with water pump)

Generator pivot bolt nut

Oil dipstick guide bolt

_ _ _ _ . _ _ _ _ ~ _ _ _ _

TORQUE SPECIFICATIONS

Generator and ignition system

Water pump pulley bolt

Crankshaft pulley bolt

Spark plug

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11B-6

ENGINE OVERHAUL c1S L i

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Item

Exhaust manifold nut

Rocker cover bolt

Rocker shaft bolt

~~

Cylinder head bolt r ighten to

49

Nm

(35

ft.lbs.), then completely loos

retightenas described.]

Oil pan bolt

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ENGINE OVERHAUL c1 .5L>

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Specified sealant

Mitsubishi Genuine Part No.

SEAL ANT S

Item

Water pump

Engine coolant temperature sensor 3M Nut Locking Part No.417

+--

ngine coolant temperature gauge unit 3M ATD Part No.8660 or equ

~~~~~

t

I Front case


I oil

pan


I

Oil pressure switch

I

3M ATD Part No.8660 or eq

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11B-8


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SPECIAL TOOLS

Tool

number and name Supersession

Tool

MB990767

End yoke holder

Use with MD998715

MB990767-01

Use with

MIT30

MD998011

Crankshaft rear oil seal

installer

MD998011-01

Use with

MB990938-01

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ENGINE

OVERHAUL c1.5L>

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Tool

Tool number and name

MD998772

Valve spring

compressor

MD998780

Piston pin setting tool

MD998781

Flywheel stopper

Supersession

General service

MIT216941

General service

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Generato

9EN0268

REMOVAL SER

+A F CRANKSHA

(1)

Lockthe lywhe

tool shown in t

bolt.

INSTALLATION

F A + DISTRIBUT

(1) Turn the crank

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11B-12 ENGINE OVERHAUL

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TIMING

BELT

REMOVAL AND INSTALLATION

8

88 Nm

64 ft.lbs. \

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ENGINE OVERHAUL

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REMOVAL SER

+A F TIMING BEL

TENSIONER

(1)

Using pliers, g

in the illustratio

lug. Then, rem

(2) Remove the tim

timing belt.

(3) If the timing be

belt to indicate

it. This will ens

reused.

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(2)

Install the tens

case, and then

(3) Grip the other e

then hook it on

illustration.

(4) Move the timin

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ENGINE OVERHAUL

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(3) Keeping the te

timing belt on

sprocket, and

4) Loosen the tim

by 1/4 to 1/2 o

to apply tensio

(5)

Turn the crank

all timing mark

Caution

This procedur

to apply tensi

to turn the cra

turn the crank

(6) Tighten the tim

specified torqu

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11

B-16 ENGINE OVERHAUL c1.5L> -

Canvas

worn

exposing

rubb

Z8EN0068

I

(7) Abnormal wea

Initial stage:Ca

texture gone, wh

Final stageCan

reduced)

(8) Missing teeth.

TENSIONER

PUL

(1) Check the pull

are not noisy.

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ENGINE OVERHAUL - Fuel and E

FUEL

AND EMISSION CONTROL SYSTE


11

Nrn

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11 B-18

ENGINE OVERHAUL c1.5L> - Fuel and E

INSTALLATION

.A+ INJECTOR I

(1) Fit a new O-rin

(2) Apply clean eng

(3) Fit the injector

right as it goes

(4) Check that the

Caution

If the injector

may be bindin

from the fuel r

injector.

.B+ FUEL PRES

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ENGINE OVERHAUL c1.5L> - Water

P

WATER PUMP AND WATER HOSE

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11B-20

ENGINE OVERHAUL - Water

P

INSTALLATION

,A+ WATER PUM

(1)

Clean the sea

case and cylin

2) Apply a 3

mm

area shown in

pump within 1

(3) After installatio

engine or let co

that time.

Specified sea

Mitsubishi

equivalent

b B + O-RINGWA

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ENGINE OVERHAUL

=

In take a

INTAKE AND EXHAUST MANIFOLDS


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11

B-22

ENGINE OVERHAUL

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Rocker

ROCKER

ARMS AND

CAMSHAFT


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ENGINE OVERHAUL

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Rocker

REMOVAL SER

+A,ROCKER A

REMOVAL

Caution

If the lash adjust

Refer to

118-24.)

Set special ool MD

free and falling to

INSTALLATION

F A + LASH ADJU

Caution

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11B-24

ENGINE OVERHAUL

c1.5L> -

Rocker

Outside Inside Filling

cleaning cleaning diesel fuel

INSPECTION

CAMSHAFT

(1)

Measure the ca

height exceed

Standard valu

Intake:

38

Exhaust:

Intake: 38

Exhaust:

Limit:

LASH

ADJUSTER

Caution

1. The lash

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ENGINE

OVERHAUL

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Rocker

, iesel fuel 6 E N 1 7 0 1

(5)

Remove he las

down he steel b

diesel fuel from

(6)

Fit special tool

(7)

Place the lash a

down the intern

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11B-26

ENGINE OVERHAUL - Rocker

6 E N 1 7 0 4

I

Division

=

1

rnrn

(.04n.)

MD998440

/

(12)Remove he la

the lash adjus

plunger firmly

check that the

new lash adjus

NOTE

If lash adjuste

through (12) a

Replace he las

these steps.

(13)Set the lash ad

down tester).

(14)After the plung

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ENGINE OVERHAUL c1.5L> - Cylind

CYLINDER HEAD AND VALVES


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11

B-28

ENGINE OVERHAUL

-

Cylinde

1EN0486

REMOVAL SER

+ A b CYLINDER H

+ B b RETAINER L

(1)

Tag removed v

noting their cyl

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ENGINE OVERHAUL - Cylinde

Painted

end

I SDrina re-

taine;

Stem seal

.

Spring

seat

b B + VALVE SPRI

(1)

Install the valve

the rocker arm

Paint colors:

Intake: Ora

Exhaust: Y

I

6EN0437

b C + RETAINER L

(1)

The valve spring

bottom end of th

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11B-30

ENGINE OVERHAUL c1.5L> - Cylind

(7) Make paint ma

cylinder head

(8) In accordance w

bolt by 90(1/4

(9) Tighten each b

that the paint m

are aligned.

Caution

If the bolts ar

90(1/4 turn),

with sufficien

If the bolts are

completely rem

procedure ag

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ENGINE

OVERHAUL

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Cylind

I

Contact

(must be in

center of face)

Margin

6EN0542

VALVES

1) Check the valv

uneven or inco

(2) If the margin i

Standard valu

Intake: 1.0

Exhaust:

1

Intake: 0.5

Exhaust: 1

Limit:

(3) Measure the v

than specified,

Standard valu

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11B-32

ENGINE OVERHAUL - Cylind

Valve stem end

D E N 0 2 1 2

I

0.9

-

1.3 mm

0.9

-

1.3 mm

(.035 - .051 in.) (.035

-

,051 in.)

\ /

VALVE SEATS

(1)

Assemble the

projection betw

spring seating

specified limit,

Standard valu

Intake: 43

Exhaust: 4

Intake: 44

Exhaust: 4

Limit:

VALVE SEAT R

(1) Before correct

between the va

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ENGINE OVERHAUL

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Cvlind

VALVE GUIDE

(1)

Using a press, p

(2) Rebore he valv

block side.

the oversize va

Caution

Do

not install

Valve guide h

0.05

O.S.:

0.25 O.S.:

0.50 O.S.:

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11B-34

ENGINE

OVERHAUL

- Oil P

ENGINE OVERHAUL Oil

P

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-

\

REMOVAL SER

MD998727

4 A F O I L PAN RE

(1) Remove the oi

2 ) Knock the spec

block as show

(3)

Tapping the sid

the oil pan/cylin

pan.

INSTALLATION

.A+ FRONT CAS

(1)

Clean the seal

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11 B-36

ENGINE OVERHAUL

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Oil

P

1EN050

b C d OIL PAN IN

(1)

Clean the mati

block.

(2) Apply a 4 mm

oil pan flange.

minutes after a

Specified seal

Mitsubishi

equivalent.

(3)

Tighten the oil

(4) After installatio

engine or let eng

that time.

c1.5L>

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ENGINE OVERHAUL

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Oil

(3) Check the side

gauge.

Standard valu

(4) Check the bod

Standard valu

Limit: 0.35

m

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Pistons

PISTONS AND CONNECTING RODS


&

~ p p ~ yngine oil to all

moving parts before

installation.

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ENGINE OVERHAUL

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Pistons

Item No. Pa

Piston pin setting

tool

MIT216941

REMOVAL SER

+A F CONNECTIN

(1)

Mark the cylind

rod big end for

(2)

Keep the remo

in order accord

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11 B-40

ENGINE OVERHAUL

-

Pistons a

INSTALLATION

F A + PISTON PIN

(1)

Thread the stop

base. Fit the co

Insert the press

the piston supp

screw.

(2) Using the mark

screw to the de

Depth: Refer

special tool.

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ENGINE

OVERHAUL

-

Pistons

~~

Size

STD

Upper side rail

Spacer

Lower side rail

A6EN0585

Side rail gap

d

,B+ OIL RING IN

(1) Fit the oil ring s

fit the upper an

NOTE

1)

The space

direction.

N

bottom.

(2) Spacer and

0.50

mm

O.S.

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11 B-42

ENGINE

OVERHAUL

-

Pistons

No.1

ring

Piston pin

Side rail

No.2

ring and

I spacer

- .

bEFl0549 I

iming belt

side

b D + PISTON AN

(1)

Apply oil to the

(2)

Align the gaps

and spacer) as

(3) With the piston

the timing belt s

assembly into

INSTALLATI

(4)

Compress the

compression to

rod fully into th

ENGINE OVERHAUL

Pistons

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Connecting rod bearing

dentification mark

Identification color stamped Position

painted position

l E N 0 5 4 4

WF+

CONNECTIN

(1)

Aligning the m

bearing cap on

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11

B-44

ENGINE OVERHAUL

c1.5L> - Pistons

I l l 6AE0298

~ ~

90"

to

100" I

I

Pa'nt mark

(5) Make a paint

6) Make a paint m

to 100" from the

of tightening th

(7) Give a

90"

to

the paint mark

alignment.

Caution

1.

If the nut

is

performan

tightening

a sufficien

2.

If the nut

is

the nut c

repeating

ENGINE OVERHAUL

Pistons

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CRANKSHAFT PI

GAUGING MATER

(1)

Remove oil fro

bearing.

(2)

Cut the plastic

the width

of

b

in parallel with

(3)

Install the conn

nuts to the spe

nut tightening

(4) Carefully remo

11

8-46

ENGINE O VERHAUL Cranksh

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CRANKSHAFT AND CYLINDER BLOCK

REMOVAL AND INSPECTION

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11B-48 ENGINE

OVERHAUL c1.5L>

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Cranksh

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Cyl'nder block Timing belt side

~

~

Cranks haft bearing

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11B 1.5L Overhaul

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Transcript of 11B 1.5L Overhaul