Overhaul - Evolution: Other Mitsubishi Lancer IX

TIMING BELT

Check the timing belt closely. Replace the belt with a new one if any of the following defects are evident

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1. Hardening of rubber backing. Back side is glossy without resilience and leaves no indent when pressed with fingernail.
2. Surface cracks on the backing rubber.
3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.
6. Abnormal wear on the belt sides. NOTE: The sides of the belt are normal if they are sharp as if cut by a knife.
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 teeth.

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1. Check the auto-tensioner for leaks from the sealed sections. Replace it if leaky.
2. Check the rod end for wear and other damage. Replace the auto-tensioner if the rod is badly worn or damaged.
3. Measure the extension length of the rod. If it is not within the standard value range, 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) and measure the amount of retraction. If the measurement exceeds the standard value, replace the auto-tensioner. Standard value: 1.0 mm (0.04 inch) or less

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CAMSHAFT

Measure the cam height and replace the camshaft if any height exceeds the specified limit.

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1. Standard value: Intake: 35.79 mm (1.41 inches) Exhaust: 35.49 mm (1.40 inches)
2. Limit: Intake: 35.29 mm (1.39 inches) Exhaust: 34.99 mm (1.38 inches)

LASH ADJUSTERS

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1. Prepare three containers and approximately five liters of diesel fuel. Pour into each container the diesel fuel in an amount enough for a lash adjuster placed in the container in its upright position to completely submerge.
2. Place the lash adjuster in container A and wash its outside surface. NOTE: Use a nylon brush if there are hard-to-remove deposits. CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
3. While gently pushing the internal steel ball using the special tool MD998442, move the plunger in and out 5 - 10 times to eliminate stiffness in the plunger and expel contaminated oil. NOTE: The plunger must be free from jamming and any other abnormalities. If a defect is found in plunger operation, replace the lash adjuster. CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container A. Never direct it against any person.
4. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the diesel fuel from the pressure chamber. CAUTION: The steel ball spring of the lash adjuster is extremely weak. The lash adjuster's functionality may be badly affected if the special tool is inserted too strongly.
5. Soak the lash adjuster in the diesel fuel in container B. Move the plunger in and out 5 - 10 times by gently pushing the internal steel ball using the special tool MD998442 until the plunger moves smoothly to wash the lash adjuster's pressure chamber. CAUTION: The hole in the side of the lash adjuster must be directed toward the inside of container B. Never direct it against any person.
6. Take the lash adjuster out of the container, then move the plunger by pushing the steel ball gently to discharge the 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. Soak the lash adjuster in the diesel fuel in container C. Gently push the internal steel ball using the special tool MD998442.
8. Place the lash adjuster upright with the plunger at the top. Push the plunger firmly until it makes a full stroke, then return the plunger slowly and release the hold of the steel ball to allow the pressure chamber to be filled with diesel fuel.
9. Take the lash adjuster out of the container, place it upright with the plunger at the top, and push the plunger firmly. The plunger must not move at all. NOTE: If the lash adjuster contracts, perform the operations 7 through 9 again. Replace the lash adjuster if it still contracts even after the pressure chamber has completely been filled with diesel fuel (air has been bled).
10. Keep the serviced lash adjusters in their upright positions to prevent diesel fuel from spilling out. Protect them from dust or other foreign matter. Install the lash adjusters onto the engine as soon as possible.

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Required Special Tools

1. MB991654: Cylinder Head Bolt Wrench (12)
2. MD998735: Valve Spring Compressor
3. MD998737: Valve Stem Seal Installer
4. MD998772: Valve Spring Compressor

<< D >> VALVE HANDLING PRECAUTIONS

Sodium reacts violently with water or moisture generation heat and liberating hydrogen. It must be handled with utmost care because otherwise the following dangerous conditions may result

1. Loss of eyesight if sodium gets in eyes.
2. Burns if sodium contact skin.
3. Fire hazard.

1. Handling of Sodium-filled Exhaust Valves Sodium-filled exhaust valves are not dangerous and may be handled in the same way as ordinary valves unless they are broken. Never try to break the valves and expose sodium to the air. When worn exhaust valves are to be discarded, have them disposed of by a salvage company equipped with special disposal system, notifying them that the valves contain sodium. Should the exhaust valves be broken, neutralize sodium using the method described below, and discard the valves in the same way as ordinary valves. CAUTION: Do not let the solution contact the eyes or the skin. Should it get in the eyes, immediately flush them with clean water thoroughly, and receive medical attention. When it contacts he skin, wash with ample amounts of clean water.
2. How to Neutralize Sodium Place a container filled with more than 10 liters (10.6 qt) of water in a well ventilated large space. Wear rubber gloves and goggles, and carefully take out broken valves from the cylinder head. CAUTION: Valves must be neutralize one at a time. Put a valve in the container only after sodium in the preceding one has completely reacted with water. Put a broken valves in the water-filled container and quickly get away from the container at least 2 or 3 m (6.6 or 9.8 ft) Keep fire away from the container during the neutralization. The resulting hydrogen gas is highly explosive. NOTE: The reaction occurs when water enters the cavity in he valve. Hydrogen gas may be trapped inside the valve, temporarily blocking the water passage. In such a case, wait until hydrogen gas in released and remaining sodium reacts with water. After the neutralization of sodium, water in the container contains sodium hydroxide and is highly alkaline. The water solution should be disposed of according to local regulations.

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Note. Do not confuse the stem seals for intake valves with

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1. Install the valve spring seat.
2. Using special tool MD998737, install a new stem seal to the valve guide.

VALVE GUIDE

Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace the valve guide or valve, or both.

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1. Standard value: Intake: 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Exhaust: 0.05 - 0.09 mm (0.0020 - 0.0035 inch)
2. Limit: Intake: 0.10 mm (0.0039 inch) Exhaust: 0.15 mm (0.0059 inch)

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.

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1. Standard value: Intake: 49.20 mm (1.9370 inches) Exhaust: 48.40 mm (1.9055 inches)
2. Limit Intake: 49.70 mm (1.9567 inches) Exhaust: 48.90 mm (1.9252 inches)

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1. Before correcting the valve seat, check the clearance between the valve guide and valve. If necessary, replace the valve guide.
2. Using the appropriate special tool or seat grinder, correct the valve seat to achieve the specified seat width and angle.
3. After correcting the valve seat, lap the valve and valve seat using lapping compound. Then, check the valve stem projection (refer to ).

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1. Cut the valve seat to be replaced from the inside to reduce the wall thickness. Then, remove the valve seat.
2. Rebore the valve seat hole in the cylinder head to match the selected oversize valve seat diameter. Intake valve seat hole diameter 0.3 oversize: 35.30 - 35.33 mm (1.3898 - 1.3909 inches) 0.6 oversize: 35.60 - 35.63 mm (1.4016 - 1.4028 inches) Exhaust valve seat hole diameter 0.3 oversize: 33.30 - 33.33 mm (1.3110 - 1.3122 inches) 0.6 oversize: 33.60 - 33.63 mm (1.3228 - 1.3240 inches)
3. Prevent galling of the cylinder head bore by cooling the valve seat with liquid nitrogen before press-fitting it.
4. Correct the valve seat to achieve the specified width and angle (refer to «VALVE SEAT RECONDITIONING PROCEDURE»(ref-183210-S02297257042005081200000) ).

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1. Using a press, push the valve guide out toward the cylinder block side.
2. Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. CAUTION: Do not install a valve guide of the same size again. Valve guide hole diameters in cylinder head 0.05 oversize: 12.05 - 12.07 mm (0.4744 - 0.4751 inch) 0.25 oversize: 12.25 - 12.27 mm (0.4823 - 0.4831 inch) 0.50 oversize: 12.50 - 12.52 mm (0.4921 - 0.4929 inch)
3. Press-fit the valve guide until it projects by the specified amount. Standard value: 19.5 mm (0.768 inch) CAUTION: The valve guide must be installed from the upper side of the cylinder head. The valve guides differ in length on the intake and exhaust sides. Valve guide length Intake: 45.5 mm (1.791 inches) Exhaust: 50.5 mm (1.988 inches)
4. After press-fitting the valve guide, insert a new valve and check that it slides smoothly.

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Required Special Tools

1. MB991603: Bearing Installer Stopper
2. MD998162: Plug Wrench
3. MD998285: Crankshaft Front Oil Seal Guide
4. MD998371: Silent Shaft Bearing Puller
5. MD998372: Silent Shaft Bearing Puller
6. MD998375: Crankshaft Front Oil Seal Installer
7. MD998705: Silent Shaft Bearing Installer
8. MD998727: Oil Pan Remover
9. MD998783: Plug Wrench Retainer

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1. Remove all oil pan bolts.
2. Drive in special tool MD998727 between the cylinder block and oil pan. NOTE: Never use a screwdriver or chisel to remove the oil pan. It will deform the oil pan flange and result in oil leakage.
3. Gently hit the special tool on its corner (shoulder), then slide it along the oil pan to remove it.

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1. Fit special tool MD998162 on the plug cap, and then hold it in position with special tool MD998783.
2. Loosen the plug.
3. Remove special tools MD998783 and MD998162 and then the plug cap.

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1. Remove the plug on the side of the cylinder block.
2. Insert a Phillips screwdriver [shank diameter 8 mm (0.3 inch)] into the plug hole to lock the counterbalance shaft.
3. Loosen the flange bolt.