Overhaul (3.8): Other Mitsubishi Eclipse IV

TIMING BELT

Replace the belt if any of the following conditions exist.

Scheme 605

Scheme 606

Scheme 607

Scheme 608

1. Hardening of rubber backing. Back side is glossy without resilience and leaves no indent when pressed with fingernail.
2. Cracks on rubber back.
3. Cracks or peeling of canvas.
4. Cracks on tooth bottom.
5. Cracks on belt.
6. Abnormal wear of belt sides. Normal wear is indicated if the sides are sharp as if cut by a knife. Abnormal wear is indicated if the sides are ragged.
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 tooth.

TENSIONER PULLEY AND IDLER PULLEY

Turn the pulley. If it does not rotate smoothly, or develops noise or excessive play, replace the pulley.

Scheme 609

Scheme 610

Scheme 611

1. Check for oil leaks. If oil leaks are evident, replace the auto-tensioner.
2. Check the rod end for wear or damage and replace the auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto-tensioner. Standard value: 12 mm (0.5 inch)
4. Press the rod with a force of 98 to 196 N (22 to 44 pounds) and measure the movement of the rod. If the measured value is out of the standard value, replace the auto-tensioner. Standard value: 1.0 mm (0.03 inch) or less

ROCKER ARM SHAFT

Check the rocker arm mounting areas of the rocker arm shafts for wear or damage. Replace as necessary.

Scheme 612

1. Check the roller surface and replace the rocker arm if recesses, damage or heat seizure is observed.
2. Check roller rotation and replace the rocker arm if uneven rotation or roller backlash of the roller is observed.
3. Check the inside diameter and replace the rocker arm if damage or seizure is observed.

Scheme 613

1. Check the camshaft bearing journals for damage and binding. If the journals are binding, check the cylinder head for damage. Also check the cylinder head for clogged oil holes.
2. Check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident.
3. Check the cam surface for abnormal wear and damage and replace if necessary. Also measure the cam height and replace if out of minimum limit. Standard value: STANDARD VALUE SPECIFICATIONS STANDARD VALUE MINIMUM LIMIT A: Intake low speed cam A 33.55 mm (1.321 in) 33.05 mm (1.301 in) B: Intake low speed cam B 37.35 mm (1.4705 in) 36.85 mm (1.451 in) C: Intake high speed cam 37.21 mm (1.465 in) 36.71 mm (1.445 in) D: Exhaust cam 37.87 mm (1.491 in) 37.37 mm (1.471 in)

LASH ADJUSTERS

Scheme 614

Scheme 615

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Scheme 617

Scheme 618

Scheme 619

Scheme 620

1. Prepare three containers and approximately 5 dm3 (30.5 quart) of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.
2. Place the lash adjuster in container A and clean its outside surface. NOTE: Use a nylon brush if deposits are hard to remove. 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.
3. While gently pushing down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442, move the plunger through five to ten strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil. NOTE: If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.
4. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. 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.
5. Place the lash adjuster in container B. Then, gently push down the internal steel ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442 and move the plunger through five to ten strokes until it slides smoothly. This operation will clean the lash adjuster's pressure chamber.
6. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber. 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.
7. Place the lash adjuster in container C. Then, gently push down the internal steel ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.
8. 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 release the steel ball and allow the pressure chamber to fill with diesel fuel.
9. Remove the 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. NOTE: If the lash adjuster contracts or moves, repeat steps 7 through 9 again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts or moves after performing these steps.
10. Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Install the lash adjuster onto the engine as soon as possible.

Scheme 621

Required Special Tools

1. MB991999: Valve Stem Seal Installer
2. MD998051: Cylinder Head Bolt Wrench
3. MD998735: Valve Spring Compressor
4. MD998772: Valve Spring Compressor

VALVE GUIDES

Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace the valve guide, valve, or both.

Standard value

< Intake > 0.02 - 0.05 mm (0.0008 - 0.0019 inch)

< Exhaust > 0.04 - 0.06 mm (0.0016 - 0.0023 inch)

Limit

< Intake > 0.10 mm (0.003 inch)

< Exhaust > 0.15 mm (0.005 inch)

Scheme 622

VALVE SEAT

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 > 48.33 mm (1.903 inches)

< Exhaust > 50.70 mm (1.996 inches)

Limit

< Intake > 48.83 mm (1.922 inches)

< Exhaust > 51.20 mm (2.02 inches)

Scheme 623

VALVE SEAT RECONDITIONING PROCEDURE

Scheme 624

1. Using the special tool or a seat grinder, correct to obtain the specified seat width and angle.
2. After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection.

PISTON

Replace the piston if scratches or seizure is evident on its surfaces (especially the thrust surface). Replace the piston if it is cracked.

PISTON PIN

1. Insert the piston pin into the piston pin hole with a thumb. You should feel a slight resistance. Replace the piston pin if it can be easily inserted or there is excessive play.
2. The piston and piston pin must be replaced as an assembly.

Scheme 625

Scheme 626

1. Check the piston ring for damage, excessive wear, and breakage. Replace if defects are evident. If the piston has been replaced with a new one, the piston rings must also be replaced with new ones.
2. Check for clearance between the piston ring and ring groove. If the limit is exceeded, replace the ring or piston, or both. Standard value: Number 1: 0.03 - 0.07 mm (0.0012 - 0.0027 inch) Number 2: 0.02 - 0.06 mm (0.0008 - 0.0023 inch) Limit: 0.1 mm (0.003 inch)
3. Insert 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, measure the end gap with a feeler gauge. If the ring gap is excessive, replace the piston ring. Standard value: Number 1: 0.25 - 0.40 mm (0.010 - 0.016 inch) Number 2: 0.35 - 0.50 mm (0.014 - 0.020 inch) Oil: 0.10 - 0.35 mm (0.004 - 0.014 inch) Limit: Number 1, Number 2: 0.8 mm (0.03 inch) Oil: 1.0 mm (0.03 inch)

CRANKSHAFT PIN OIL CLEARANCE < PLASTIC GAUGING MATERIAL METHOD >

The crankshaft oil clearance can be measured easily by using plastic gauging material, as follows

Scheme 627

1. Remove oil from the crankshaft pin and the bearing inner surface.
2. Cut plastic gauging material to the same length as the width of the bearing and place it on the pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified torque.
4. Carefully remove the connecting rod cap.
5. Measure the width of the smashed plastic gauging material at its widest section by using a scale printed on the plastic gauging material bag. Standard value: 0.020 - 0.038 mm (0.0008 - 0.0015 inch) Limit: 0.1 mm (0.003 inch)

CRANKSHAFT REAR OIL SEAL

1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage.

Scheme 628

Scheme 629

1. Visually check for scratches, rust, and corrosion. Use a flaw detecting agent for the check. If defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter. Standard value: 0.05 mm (0.002 inch) Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable limit or replace. Grinding limit: *0.2 mm (0.008 inch) *Includes/combined with cylinder head grinding. Cylinder block height (when new): 227.9 - 228.1 mm (8.972 - 8.980 inches)
4. Check the cylinder walls for scratches and seizure. If defects are evident, correct (bored to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and cylindricality. If worn badly, correct by boring the cylinders to an oversize and replace pistons and piston rings. Measure at the points shown in illustration. Standard value: Cylinder Inside Diameter: 95.0 mm (3.740 inches) Cylindricality: 0.01 mm (0.0003 inch)

Scheme 630

1. Oversize pistons to be used should be determined on the basis of the largest bore cylinder. Piston size identification IDENTIFICATION MARK SPECIFICATION SIZE IDENTIFICATION MARK 0.25 mm (0.010 in) Oversize diameter 0.25 0.50 mm (0.020 in) Oversize diameter 0.50 NOTE: Size mark is stamped on the piston top.
2. Measure the outside diameter of the piston to be used. Measure it in the thrust direction as shown in illustration.
3. Based on the measured piston Outside Diameter (OD), calculate the boring finish dimension. Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin) CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders in the order of number 2, number 4, number 6, number 1, number 3 and number 5.
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder). Standard value: Cylinder Inside Diameter: 95.0 mm (3.740 inches) Cylindricality: 0.01 mm (0.0003 inch)
6. Check the clearance between the piston and cylinder. Clearance between piston and cylinder: 0.03 - 0.05 mm (0.0012 - 0.0020 inch) NOTE: When boring cylinders, finish all six cylinders to the same oversize. Do not bore only one cylinder to an oversize.

SEALANTS

SEALANTS SPECIFICATION CHART