Overhaul - Lancer Evolution: Other Mitsubishi Lancer X

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES

Note. The number in square brackets shows the genuine part number.

LIQUID GASKET (FIPG)

FIPG is used for some parts in the engine. It is necessary to pay attention to an application amount, application procedure and applied surface condition for this gasket to fully achieve its purpose.

Too small application amount of FIPG or the dirty surface where the FIPG is applied might cause the FIPG leakage. Too large application amount of FIPG overflows and might clog or narrow the passage of water or oil. It is absolutely essential that the surface where the FIPG is applied must be cleaned and the appropriate amount of FIPG must be evenly applied to prevent the leakage from the connected area.

FIPG used for engine parts hardens reacting with moisture in the air, and is usually used for metal flanges.

CLEANING OF GASKET SURFACE

Completely remove all deposits from the gasket surface with a gasket scraper or wire brush. Make sure that the surface to which FIPG is applied is smooth.

Completely remove all the old FIPG, which might be remaining in the installation hole, the thread hole or among the components.

Sufficiently clean the surface where the FIPG is applied using the degreasing agent such as white gasoline.

CAMSHAFT

Measure camshaft height (camshaft major axis). If the height is less than the limit, replace the camshaft.

Standard value

Intake: 44.1 mm (1.74 inches)

Exhaust: 45.0 mm (1.77 inches)

Limit

Intake: 43.6 mm (1.72 inches)

Exhaust: 44.5 mm (1.75 inches)

Scheme 236

Scheme 237

Scheme 238

1. Thoroughly wipe oil on the outside diameter of the camshaft and the inside diameter of the bearing.
2. Install the bearing to the camshaft.
3. Put straightly the plastigage having the length of the bearing width on the journal axis, centering the axis.
4. Carefully install the bearing cap. Tighten the bolt as instructed in >> B << Bolt Installation Point.
5. Remove the bolt and the bearing cap carefully.
6. Measure the plastigage whose width is most compressed using the scale printed on the plastigage bag. When the measured value deviates from the standard one, replace the bearing. Standard value: 0.035 - 0.072 mm (0.0014 - 0.0028 inch) CAUTION: When the bearing is used again, be careful not to reverse the cylinder head side and the camshaft side during installation.

Scheme 239

1. Measure the valve tappet at the illustrated position. If the measured value is not in agreement with the value in the table corresponding to the identification mark, replace the valve tappet.
2. The valve tappet has an identification mark and stamping of thickness at illustrated positions. There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 mm (0.1181 inch) and 3.690 mm (0.1453 inch).

VALVE TAPPET THICKNESS

Scheme 240

Required Special Tools

1. MD998735: Valve Spring Compressor
2. MB992089: Retainer Holder
3. MB992085: Valve Stem Seal Pliers
4. MD998737: Valve Stem Seal Installer

VALVE GUIDE

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

Standard value

Intake 0.020 - 0.047 mm (0.0008 - 0.0019 inch)

Exhaust 0.030 - 0.057 mm (0.0012 - 0.0022 inch)

Limit

Intake 0.10 mm (0.004 inch)

Exhaust 0.15 mm (0.006 inch)

Scheme 241

VALVE SEAT

Assemble the valve, then measure the contact width. If the measurement exceeds the specified limit, replace the valve seat.

Standard value

Intake: 1.16 - 1.46 mm (0.046 - 0.058 inch)

Exhaust: 1.35 - 1.65 mm (0.053 - 0.065 inch)

Scheme 242

Scheme 243

1. Check clearance between valve guide and valve and replace the valve guide if necessary before repairing the valve seat.
2. Repair the valve seat so that seat width and seat angle are to the specified shape.
3. Lap valve and valve seat with lapping compound after repairing valve seat.

Scheme 244

Scheme 245

1. Scrape the valve seat to be replaced from inside to make its wall thickness thin before pulling out.
2. Repair the valve seat hole of the cylinder head to match it with the diameter of the oversize valve seat to be press fitted. Intake valve seat bore diameter: 0.3 O.S.: 36.22 - 36.24 mm (1.426 - 1.427 inches) Exhaust valve seat bore diameter: 0.3 O.S.: 30.22 - 30.24 mm (1.190 - 1.191 inches)
3. Press fit the valve seat, taking care not to score the cylinder head bore at room temperature.
4. Ream the valve seat. Refer to " «REPAIR PROCEDURE OF VALVE SEAT»(ref-289385-S10847093192008063000000) ".

Scheme 246

1. Pull out the valve guide with a press toward the cylinder block side.
2. Ream the valve guide hole of the cylinder head to match it with the diameter of the oversize valve guide to be press fitted. CAUTION: Do not use a valve guide with the same size as that of the pulled out valve guide because it cannot be press fitted. Valve guide bore diameter 0.25 O.S.: 11.23 - 11.25 mm (0.442 - 0.443 inch)
3. Press fit the valve guide to the illustrated dimension. Standard value: 14.6 - 15.2 mm (0.57 - 0.60 inch) NOTE: Press fit the valve guide from the cylinder head top surface.
4. After pressing fit the valve guide, insert a new valve to check for sliding.

Scheme 247

Required Special Tools

1. MB991346: Top Cover Wrench
2. MB991883: Flywheel Stopper

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)

Oil clearance can be easily measured by using a "plastigage".

When using a "plastigage," perform measurement in the following procedure.

Scheme 248

Scheme 249

1. Fully wipe oil off the outside diameter of the crankshaft and inside diameter of the bearing.
2. Assemble the crankshaft.
3. Place a plastigage in length equal to the bearing width on the journal shaft straight in alignment with the shaft center.
4. Carefully install the bearing cap and tighten the bolt according to the main point of installation >> B <<.
5. Remove the bolt, and then carefully remove the crankshaft bearing cap.
6. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag. Standard value: No. 1, 2, 4, 5: 0.039 - 0.065 mm (0.0015 - 0.0026 inch) No. 3: 0.051 - 0.077 mm (0.0020 - 0.0030 inch) Limit: 0.10 mm (0.004 inch)

Scheme 250

Scheme 251

1. Visually check the cylinder block for scratch, rust and corrosion. Use a flaw detecting agent to check for cracks. If it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block using a straight edge and thickness gauge. If distortion exceeds the limit, grind and repair it. A gasket or the like must not be adhered to the top surface of the cylinder block during measurement. Distortion on bottom Standard value: Within 0.05 mm (0.002 inch) Limit: 0.2 mm (0.01 inch) Grinding limit: 0.2 mm (0.01 inch)
3. Check the cylinder bore for scoring or seizure. If faulty, correct (boring) or replace.
4. Measure the bore and cylindricity of the cylinder using a cylinder gauge. If the cylinder is excessively worn, repair the cylinder and replace the piston and piston rings. Measuring points are as shown in the illustration. Standard value Cylinder bore: 86 mm (3.4 inches) Cylindricity: 0.010 mm or less (0.0004 inch)

Scheme 252

1. Oversize pistons should be based on the largest bore cylinder. PISTONS SIZE SPECIFICATIONS Size Size mark 0.25 mm (0.010 inch) oversize 25 NOTE: The size mark is stamped on the piston top.
2. In case of 0.25 mm (0.010 inch) oversized piston, a hole shall be bored through the cylinder block so that the clearance can have the standard value. The standard measuring point for the outside piston diameter is at shown in the illustration.
3. Based on the measured piston outside diameter (O.D.), calculate the boring finish dimension. Boring finish dimension = Piston O.D. + 0.03 - 0.05 mm (0.001 - 0.002 inch) < Clearance between piston O.D. and cylinder > -0.02 mm (0.001 inch) < honing margin >
4. Bore each cylinders to the calculated boring finish dimension. CAUTION: To prevent distortion caused by heat increased during boring, bore the cylinders in the following order: No.2, No.1, No.3.
5. Hone the cylinders to the final finish dimension (piston O.D. + piston-to-cylinder clearance).
6. Check the clearance between the pistons and cylinders. Standard value: 0.03 - 0.05 mm (0.001 - 0.002 inch) NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.