Overhaul - Except Evolution: Other Mitsubishi Lancer IX

<< B >> CAMSHAFT SPROCKET BOLT LOOSENING

Use special tools MB990767 and MD998719 to prevent the camshaft sprocket from turning, and then loosen the camshaft sprocket bolt.

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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.

TENSIONER PULLEY

Check the pulley for smooth rotation, without play and are not noisy.

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1. Fit a new O-ring and grommet onto the injector.
2. Apply clean engine oil or gasoline to the injector O-ring.
3. Fit the injector onto the fuel rail, turning it to the left and right as it goes in.
4. Check that the injector rotates smoothly.
5. Check that the clearance between the injector connector and the fuel rail is uniform (A = B).

CAMSHAFT

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

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1. Standard value: Intake: 37.86 mm (1.49 inches) Exhaust: 37.67 mm (1.48 inches)
2. Limit: Intake: 37.36 mm (1.47 inches) Exhaust: 37.17 mm (1.46 inches)

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1. Prepare three containers and approximately 5 dm 3 (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.
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 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will removed dirty oil. 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. 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.
5. Place the lash adjuster in container B. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter) or special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster's 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.
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.
7. Place the lash adjuster in container C. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442. 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.
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. Also, check that the lash adjuster's height matches that of a new lash adjuster. NOTE: If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.
10. Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.

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Required Special Tools

1. MB991653: Cylinder Head Bolt Wrench
2. MD998772: Valve Spring Compressor
3. MD998735: Valve Spring Compressor
4. MD998774: Valve Stem Seal Installer

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: 0.04 - 0.06 mm (0.0016 - 0.0024 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: 49.30 mm (1.9409 inches) Exhaust: 49.35 mm (1.9429 inches)
2. Limit Intake: 49.80 mm (1.9606 inches) Exhaust: 49.85 mm (1.9626 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 «VALVE SEAT»(ref-183617-S03516054652005081800000) in INSPECTION).

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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: 31.80 - 31.83 mm (1.2520 - 1.2531 inches) 0.6 oversize: 32.10 - 32.13 mm (1.2638 - 1.2650 inches) Exhaust valve seat hole diameter 0.3 oversize: 29.30 - 29.32 mm (1.1535 - 1.1543 inches) 0.6 oversize: 29.60 - 29.62 mm (1.1654 - 1.1661 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-183617-S27028229472005081800000) ).

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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: 11.05 - 11.07 mm (0.4350 - 0.4358 inch) 0.25 oversize: 11.25 - 11.27 mm (0.4429 - 0.4337 inch) 0.50 oversize: 11.50 - 11.52 mm (0.4528 - 0.4535 inch)
3. Press-fit the valve guide until it projects by the specified amount. Standard value: 14.0 mm (0.551 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 Tool

1. MD998717: Crankshaft Front Oil Seal Installer