Download - 11D 1.8L Overhaul Mirage
-
8/10/2019 11D 1.8L Overhaul Mirage
1/55
ENGINE
OVERHAU
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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 -
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
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
Mitsubishi Genuine Part No.MD970389 or equi
Mitsubishi Genuine Part No.MD970389 or equi
Mitsubishi Genuine Part No.MD970389 or equi
SEALANT
-
8/10/2019 11D 1.8L Overhaul Mirage
8/55
-
8/10/2019 11D 1.8L Overhaul Mirage
9/55
ENGINE
OVERHAUL c1.8L>
-
Spe
Tool
Tool
number and name
MB991659
Guide
D
MD998440
Leak down tester
MD998441
Lash adjuster retainer
Supersession
-
8/10/2019 11D 1.8L Overhaul Mirage
10/55
11
D-10
ENGINE OVERHAUL c1.8L> - Generator an
ENERATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
12/55
11D-12
ENGINE OVERHAUL -
Tim
TIMING
BELT
REMOVAL AND INSTALLATION
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
16/55
11D-16
ENGINE OVERHAUL - Tim
TENSIONER PULLER
(1)
Check the pulley fo
are not
noisy.
l E N 0 5 3 8
-
8/10/2019 11D 1.8L Overhaul Mirage
17/55
ENGINE OVERHAUL
- Fuel and
Emis
FUEL AND EMISSION CONTROL SYSTEM
REMOVAL AND INSTALLATION
vF4rsm
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
19/55
ENGINE OVERHAUL c1.8L> - Intake and E
INTAKE AND EXHAUST MANIFOLDS
REMOVAL AND INSTALLATION
2
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
21/55
ENGINE OVERHAUL - Water Pump
WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION
2
-
8/10/2019 11D 1.8L Overhaul Mirage
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.
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
24/55
11
D-24
ENGINE OVERHAUL - Rocker Arm
ROCKER A RMS
AND
CAMSHAFT
REMOVAL AND INSTALLATION
4
3
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
26/55
11
D-26
ENGINE OVERHAUL - Rocker Arm
FE( OIL SEAL INSTA
INSPECTION
CAMSHAFT
(1)
Measure he cam he
height exceeds the
-
8/10/2019 11D 1.8L Overhaul Mirage
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,
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
30/55
11D-30
ENGINE OVERHAUL - Cylinder H
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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.
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
37/55
ENGINE OVERHAUL
- Oil Pum
OIL PUMP AND OIL PAN
REMOVAL AND INSTALLA TION
11
D-38
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
42/55
ISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
I
Lubricate all in-
*ternal parts with
engine oil during
/
@-
10
ENGINE OVERHAUL
- Piston and
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
44/55
ENGINE OVERHAUL
-
Piston and
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
50/55
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
ENGINE OVERHAUL
-
Crankshaft a
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
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
-
8/10/2019 11D 1.8L Overhaul Mirage
55/55