11D 1.8L Overhaul Mirage

8/10/2019 11D 1.8L Overhaul Mirage

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ENGINE

OVERHAU


2/55

11D-2

ENGINE OVERHAUL

el

.8L> -

Genera

Descriptions

TYPe

Number of cylinders

Combustion chamber

Total displacement dm3 (cu.in.)

Cylinder bore mm (in.)

Piston stroke mm (in.)

Compression ratio

GENERAL INFORMATION

GENERAL SPECIFICATION

Specificatio

In-line OHV

4

Pentroof typ

1,834

(1

11.9

81 O 3.19)

89.0 (3.50)

9.5


3/55

ENGINE OVERHAUL - Spe

~~~ -~

Camshaft cam height mm (in.)

SPEC FI

CAT10

NS

Intake 37.11 (1

SERVICE SPECIFICATIONS

Exhaust

___________~

Items Standard

7.15 (1

Cylinder head flatness

*Total resurfacing depth

of

both cylinder head and cylinder block

Less tha

Cylinder head grinding

~~~~~

Cylinder head overall height mm (in.)

I

119.9 -


4/55

11D-4

ENGINE OVERHAUL c1.8L> - Spec

Connecting rod big end side clearance mm (in.)

Items Standard

0.10 0.

Piston pin

O.D.

mm (in.) 19.0 .75

Crankshaft journal oil clearance mm (in.) 0.02 0.

Piston pin press-in oad [at room temperature]

N

(Ibs.)

4900 - 1

1 .lo20

Crankshaft pin oil clearance mm (in.) I 0.02 0.

Crankshaft end play mm (in.)

I 0.05 0.

Crankshaft journal

O.D.

mm (in.)

50 1.97

Cylinder block gasket surface flatness mm (in.)

j

0.05

.0


5/55

ENGINE OVERHAUL

- Spec

TORQUE SPECIFICATIONS

Ignition coil 10

Spark plug 25

Crankshaft bolt 181

~~

Generator brace (M10)

Generator brace (MB)

I

23

49

~~~

Lock bolt

Adjusting bolt

~~

Generator pivot nut

23

10

44


6/55

11

D-6

ENGINE

OVERHAUL -

Spec

Items Nm

~~

Water pump 24

Water inlet pipe 14

Thermostat case 24

Water inlet fitting

18

14

10

___

~ _ _

__

Water outlet fitting

Engine coolant temperature gauge unit

Engine coolant temperature sensor 29

~

Rocker arm shaft 31


7/55

ENGINE OVERHAUL - Specificatio

Items

~

Specified sealant

Water pump

Thermostat case

Engine coolant tempera-

ture sensor

Engine coolant tempera-

ture gauge unit

Oil pressure switch

Water outlet fitting

Front case

Oil pan

Mitsubishi Genuine Part No.MD970389 or equi


3M Nut Locking Part No.4171 or equivalent

3M ATD Part No.8660 or equivalent

3M ATD Part No.8660 or equivalent




SEALANT


8/55


9/55

ENGINE

OVERHAUL c1.8L>

-

Spe

Tool

Tool

number and name

MB991659

Guide

D

MD998440

Leak down tester

MD998441

Lash adjuster retainer

Supersession


10/55

11

D-10

ENGINE OVERHAUL c1.8L> - Generator an

ENERATOR AND IGNITION SYSTEM

REMOVAL AND INSTALLATION


11/55

ENGINE OVERHAUL

-

Generator an

Z9EN0268

REMOVAL SERVICE

+ A b CRANKSHAFT B

(1)

Lock the flywheel or d

tool shown in the illu

bolt.

INSTALLATION SER

.A( CAM POSITION S

(1) Clean the sealant ap

sensor support and

INSTALLATION


12/55

11D-12

ENGINE OVERHAUL -

Tim

TIMING

BELT



13/55

ENGINE OVERHAUL -

Tim

REMOVAL SERVIC

+A F TIMING BELT R

(1) Mark the belt ru

reinstallation.

(2) Loosen the tension

(3) Insert a cross-tip scr

arm as shown illus

(4)

Move the screwdriv

arrow, and tighten

this position.

(5)

Remove the timing

NOTE

(1)

Water oil on the

the removed im

be kept free from

in cleaning solv


14/55

11D-14

ENGINE OVERHAUL

- Tim

F C qTENSIONER SPR

(1) Install the tensioner

case, and then hook

to the front case rib

(2) Grip the spring end

onto the tensioner a

.D

TIMING BELT INS

(1) Align the crankshaft s

mark on the front ca

sprocket three teeth


15/55

ENGINE OVERHAUL -

Tim

(6)

Turn the crankshaft

Caution

This procedure util

to apply tension e

to turn the cranks

turn the crankshaf

(7)

Check that the timin

(8)

Tighten the timing

specified torque.

INSPECTION

TIMING

BELT

Check the timing belt cl

one if any of the follow


16/55

11D-16

ENGINE OVERHAUL - Tim

TENSIONER PULLER

(1)

Check the pulley fo

are not

noisy.

l E N 0 5 3 8


17/55

ENGINE OVERHAUL

- Fuel and

Emis

FUEL AND EMISSION CONTROL SYSTEM


vF4rsm


18/55

11D-18 ENGINE OVERHAUL

- Fuel

and Emiss

I

Injector

connector

I

INSTALLATION SER

FA + INJECTORS INS

(1)

Fit a new O-ring an

2)

Apply clean engine

(3) Fit the injector onto

right as it goes in.

(4) Check that the injec

(5)

Check that the clear


19/55

ENGINE OVERHAUL c1.8L> - Intake and E

INTAKE AND EXHAUST MANIFOLDS


2


20/55

11

D-20

ENGINE OVERHAUL c1.8L> - Intake and E

INSTALLATION SER

.A+ EXHAUST MANIF

(1)

Install he exhaust ma

in the illustration, an

(2) Tighten the all

bolts


21/55

ENGINE OVERHAUL - Water Pump

WATER PUMP AND WATER HOSE


2


22/55

11

D-22

ENGINE OVERHAUL

-

Water Pump

3

nm .I2

n )

w 9EN0505

INSTALLATION SER

.A( WATER PUMP IN

(1) Clean the sealant app

case and cylinder bl

(2) Apply a

3

mm (.12 in

area shown in the illu

pump within

15

minu

Specified sealant:

Mitsubishi Ge

equivalent

(3) After installation, wai

engine or let coolant

that time.


23/55

ENGINE OVERHAUL c1.8L> - Water Pump

F D I HERMOSTAT IN

(1) Install the thermost

top.

.Ed OUTLET Fl lTlNG

(1) Clean the sealant ap

cylinder head.

(2) Apply a 3 mm (.12


24/55

11

D-24

ENGINE OVERHAUL - Rocker Arm

ROCKER A RMS

AND

CAMSHAFT


4

3


25/55

ENGINE OVERHAUL

- Rocker Arm

REMOVAL SERVIC

+A,ROCKER ARM A

REMOVAL

Caution

If the lash adjuster

Refer to 11D-26.)

(1) Set special tool MD

coming free and fal

INSTAL LA TION SE

F A + LASH

ADJUSTE

Caution

If the lash adjuster


26/55

11

D-26

ENGINE OVERHAUL - Rocker Arm

FE( OIL SEAL INSTA

INSPECTION

CAMSHAFT

(1)

Measure he cam he

height exceeds the


27/55

ENGINE OVERHAUL - Rocker

Arm

D998441

6 E N 1 7 0 0

(3)

Fit special tool MD9

(4) While gently pushing

special tool MD9984

10

strokes until t slide

stiffness in the plung

oil.

Caution

The steel ball sprin

adjusters functiona

wire is pushed in h

NOTE

If

the plunger remain

otherwise abnormal,


28/55

11

D-28

ENGINE

OVERHAUL

- Rocker Arm

7n3

(9)

Place the lash adjust

down the internal ste

Caution

Do

not use contai

performed in conta

the pressure chamb

diesel fuel.

(10)Stand the lash adjus

push the plunger do

its greatest possible

then release he stee

to fill with diesel fue


29/55

ENGINE

OVERHAUL

c1.8L>

-

Rocker Arm

6 E N 1 7 0 4

(19)Remove he lash ad

the lash adjuster w

plunger firmly and

check that the lash

new lash adjuster.

NOTE

If lash adjuster con

through (19) again

Replace he lash adj

these steps.

(20)Stand the lash adj

spilling out. Do not

contaminated by dir

adjuster onto the e


30/55

11D-30

ENGINE OVERHAUL - Cylinder H

CYLINDER HEAD AND VALVES



31/55

ENGINE OVERHAUL

-

Cylinder H

REMOVAL SERVIC

+ A b CYLINDER HEA

(1)

Loosen the cylinde

4 B b

ETAINER LOC

(1) Tag removed valve

noting their cylinder

reassembly. Store t


32/55

11D-32

ENGINE OVERHAUL

c1.8L> -

Cylinder H

I I

Painted

e n d

INSTALLATION SER

F A + VALVE STEM SE

(1)

Install the valve spr

(2) Install a new valve st

in the illustration.

Caution

1.

Do not reuse re

2.

The valve stem

correct special

result in oil lea

FBA

VALVE SPRING

(1) Install the valve spr

the rocker arm side


33/55

ENGINE OVERHAUL

-

Cylinder H

Timing

belt side

9EN0518

(4) Tighten the bolts in

torqued to 74 Nm

(MB991653).

(5)

Loosen all bolts ful

(6) Retighten the bolts

is torqued to

20

N

(7) Make paint marks o

cylinder head as sh

(8) In accordancewith t

bolt by 90

(1/4

tu

(9) Tighten each bolt b

that the paint marks

are aligned.


34/55

11

D-34

ENGINE OVERHAUL c1.8L> = Cylinder H

Valve seat contact

I

I

6EN0542

VALVE

(1)

Check the valve fac

uneven or incomple

(2)

If the margin is les

Standard value:

Intake: 1.0 mm

Exhaust: 1.3 m

Intake:

0.5

mm

Exhaust:

0.8

m

Limit:

(3)

Measure the valve

than specified, repla

Standard value:

Intake: 110.15

Exhaust: 113.7


35/55

ENGINE OVERHAUL

- Cylinder H

Valve

stem end

D E N 0 2 1 2

VALVE SEAT

(1)

Assemble the valv

projection between

spring seating surfac

specified limit, repla

Standard value:

Intake: 49.30 m

Exhaust: 49.35

Intake: 49.80 m

Exhaust: 49.85

Limit


36/55

11D-36

ENGINE OVERHAUL

-

Cylinder H

VALVE GUIDE REPLA

(1) Using a press, push

(2) Rebore he valve gu

block side.

the oversize valve

Caution

Do not install

a

va

Valve guide hole

0.05

O.S.:

11.0

0.25

O.S.:

11.2

0.50

O.S.:

11.5


37/55

ENGINE OVERHAUL

- Oil Pum

OIL PUMP AND OIL PAN

REMOVAL AND INSTALLA TION

11

D-38


38/55

ENGINE OVERHAUL

-

Oil

Pump

~ MD998727

REMOVAL SERVIC

+A,OIL PAN REMOV

(1)

Remove the oil pan

(2) Knock the special to

block as shown in t

(3) Tapping the side of

the oil pankylinder b

pan.

+BF

OUTER ROTOR/

(1) Make alignment dot

reference in reassem

ENGINE OVERHAUL Oil Pump


39/55

-

F C dFRONT OIL SEA

(1) Place the special to

apply engine oil to

(2) Apply engine oil to th

along the guide by h

Tap the oil seal into

11

D-40

ENGINE OVERHAUL

-

Oil

Pum


40/55

. OIL FILTER INS

(1) Clean the filter mou

(2)

Apply clean engine

(3) Screw on the

oil

fil

mounting surface. T

turn.

Caution

The oil filter must b

available ilter wren

only,

it

will be insu

leaks.

.G+OIL

PRESSURE

(1) Apply

the specified

Specified sealant:

3M

ATD Part

N

ENGINE OVERHAUL

Oil Pum


41/55

-

INSPECTION

OIL PUMP

(1)

Fit the rotors into t

(2)

Check the tip clear

Standard value:

0.

(3) Check the side cle

gauge.

Standard value:

0.

11

D-42

ENGINE OVERHAUL

-

Piston and


42/55

ISTON AND CONNECTING ROD


I

Lubricate all in-

*ternal parts with

engine oil during

/

@-

10

ENGINE OVERHAUL

- Piston and


43/55

number

ZEN04

I

Piston pin setting tool

MIT216941

I

REMOVAL SERVIC

+A, CONNECTING R

(1) Mark the cylinder nu

rod big end for corr

(2)

Keep the removed c

in order according t

46, PISTON PIN RE


44/55

ENGINE OVERHAUL

-

Piston and


45/55

Size

Standard size

0.50 mm O.S.

1 OO

mm O.S.

I

.

Side rail

Spacer

9EN0730

I

I

Side rail end

11

D-46

ENGINE OVERHAUL

-

Piston and


46/55

Umer side rail

No.1

ring

_I1Piston pin

imingelt side

+ T-)

\

I

Lower side

I

0.2 rinq

rail

I andspacer

6EN0549

I

,D+

PISTON AND C

(1)

Apply oil to the pis

(2)

Align the gaps of th

and spacer) as sh

(3)

With the piston cro

the timing belt side

assembly into the

INSTALLAT

0

N

(4) Compress the pist

compression ool, t

rod fully into the cy

since the piston rin

be nicked.

ENGINE OVERHAUL

c1.8L>

-

Piston and


47/55

Notches

ide r No.

DEN0051

F F d

CONNECTING

R

(1) Aligning the marks

bearing cap onto th

rod is new and has n

locking notches are

(2)

Check that the con

confirms with speci

Standard

value: 0.

Limit:

0.4 mm

(.01

11

D-48

ENGINE OVERHAUL

-

Piston and


48/55

I

[ I

I 1

Paint mark

I 0

I l l

6AEQ298

(5)

Make a paint mark

(6) Make a paint mark

to

100

rom the paint

of tightening the nu

(7)

Give a

90

to

100

the paint mark on t

alignment.

Caution

1. If the nut is turn

performance m

tightening the

a sufficient tur

2. If the nut is over

the nut compl

repeating the tig

ENGINE OVERHAUL

-

Piston

and


49/55

(2) Install the piston rin

ring down with a pist

with the ring, to co

the cylinder wall. The

gauge.

If

the end gap is ex

Standard value:

No.1: 0.25

-

0.

No.2: 0.40 - 0.

Oil: 0.20

-

0.60 m

Limit:

No.1, No.2: 0.8

Oil:

1.0

mm (.0

11D-50

ENGINE OVERHAUL c1.8L>

-

Crankshaft a


50/55

CRANKSHAFT AND CYLINDER BLOCK


ENGINE OVERHAUL

-

Crankshaft a


51/55

9 e

Check digit

Y

Crank pin O.D.

identification

(3

j4

mark

N0.5

N0.4

* Y

N0.3 * Y

No.2

Journal

O.D.

identification

Identification

mark

Identifica

mark

INSTALLATION SER

F A ( CRANKSHAFT B

(1) When replacing the

block, read

off

the i

and cylinder block (

according to the flo

11

D-52

ENGINE OVERHAUL

c1.8L>

-

Crankshaft an


52/55

ength of shank

PEN0477

.B+ BEARING CAP/B

INSTALLATION

(1) Install the bearing c

the timing belt side.

(2)

When reusing he bea

length dose not exce

bolt if this measurem

Limit: max. 71.1 m

(3) Apply engine oil to th

4)

Tighten the bearing c

in the sequence sho

ENGINE OVERHAUL

-

Crankshaft a


53/55

76

Z9EN0077

b C( REAR OIL SEAL

FDd SEA L A NT APPLI

Specified sealant:

Mitsubishi Ge

equivalent

11D-54

ENGINE OVERHAUL

-

Crankshaft a


54/55

CYLINDER BLOCK

(1) Visually check for cra

the cylinder block us

defects where poss

(2) Ensure that the top

other foreign materia

for distortion using

Standard value: 0.0

Limit: 0.1 mm .O

limit or replace.

Grinding limit:

0.2

(3) If the distortion is ex

The total thick

removed from c

head 0.2 mm


55/55

Date post:	02-Jun-2018
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11D 1.8L Overhaul Mirage

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