Engine Overhaul - 2.0L: Other Mitsubishi Outlander III

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES

Note. The number in square brackets shows the 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 amount causes leakage while too much amount squeezes out to block or narrow water and oil passages. Therefore, it is absolutely essential to apply a correct amount of liquid sealant continuously without break to eliminate leakage from joints.

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. The gasket surface must be free from grease and foreign substances. Be sure to remove old FIPG that has entered mounting holes and screw holes.

INTAKE V.V.T. SPROCKET

Scheme 167

Scheme 168

Scheme 169

1. Seal with a tape all the intake camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the advanced angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the intake camshaft on a vise, install the intake V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the advanced angle, remove the stopper pin.
5. Turn the intake V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 12.5°) NOTE: The stopper pin is locked in the most retarded angle position.
6. After the check, remove the intake V.V.T. sprocket from the intake camshaft
7. Completely remove the tape sealing the intake camshaft ports for the advanced angle and for the retarded angle.

EXHAUST V.V.T. SPROCKET

Scheme 170

Scheme 171

Scheme 172

1. Seal with a tape all the exhaust camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the retarded angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the exhaust camshaft on a vise, install the exhaust V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the retarded angle, remove the stopper pin.
5. Turn the exhaust V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 10°) NOTE: The stopper pin is locked in the most advanced angle position.
6. After the check, remove the exhaust V.V.T. sprocket from the exhaust camshaft
7. Completely remove the tape sealing the exhaust camshaft ports for the advanced angle and for the retarded angle.

CAMSHAFT

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

Standard value

Intake: 43.25 mm (1.703 inches)

Exhaust: 45.00 mm (1.772 inches)

Limit

Intake: 42.75 mm (1.683 inches)

Exhaust: 44.50 mm (1.752 inches)

Scheme 173

Scheme 174

Scheme 175

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 - 0.032 mm (0 - 0.0013 inch) CAUTION: When the bearing is used again, be careful not to reverse the cylinder head side and the camshaft side during installation.

Scheme 176

Scheme 177

1. Check the thickness stamp.
2. If the measured value in the table value is not in agreement with the value in the table to the thickness stamp, replace the valve tappet. There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 (0.1181 inch) and 3.690 mm (0.1453 inch). VALVE TAPPET THICKNESS Thickness mm (in) Thickness stamp 3.000 (0.1181) 3.000 3.015 (0.1187) 3.015 3.030 (0.1193) 3.030 3.045 (0.1199) 3.045 3.060 (0.1205) 3.060 3.075 (0.1211) 3.075 3.270 (0.1287) 3.270 3.090 (0.1217) 3.090 3.105 (0.1222) 3.105 3.120 (0.1228) 3.120 3.135 (0.1234) 3.135 3.150 (0.1240) 3.150 3.165 (0.1246) 3.165 3.180 (0.1252) 3.180 3.195 (0.1258) 3.195 3.210 (0.1264) 3.210 3.225 (0.1270) 3.225 3.240 (0.1276) 3.240 3.255 (0.1281) 3.255 3.270 (0.1287) 3.270 3.285 (0.1293) 3.285 3.300 (0.1299) 3.300 3.210 (0.1264) 3.210 3.225 (0.1270) 3.225 3.300 (0.1299) 3.300 3.315 (0.1305) 3.315 3.330 (0.1311) 3.330 3.345 (0.1317) 3.345 3.360 (0.1323) 3.360 3.375 (0.1329) 3.375 3.390 (0.1335) 3.390 3.405 (0.1341) 3.405 3.420 (0.1346) 3.420 3.435 (0.1352) 3.435 3.450 (0.1358) 3.450 3.465 (0.1364) 3.465 3.480 (0.1370) 3.480 3.495 (0.1376) 3.495 3.510 (0.1382) 3.510 3.525 (0.1388) 3.525 3.540 (0.1394) 3.540 3.555 (0.1400) 3.555 3.570 (0.1406) 3.570 3.585 (0.1411) 3.585 3.600 (0.1417) 3.600 3.615 (0.1423) 3.615 3.630 (0.1429) 3.630 3.645 (0.1435) 3.645 3.660 (0.1441) 3.660 3.675 (0.1447) 3.675 3.690 (0.1453 3.690

Scheme 178

Required Special Tools

1. MD998735: Valve Spring Compressor
2. MB992089: Retainer Holder C
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 - 0.054 mm (0.0012 - 0.0021 inch)

Limit

Intake 0.10 mm (0.004 inch)

Exhaust 0.15 mm (0.006 inch)

Scheme 179

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 180

Scheme 181

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 182

Scheme 183

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 Over size: 36.22 - 36.24 mm (1.426 - 1.427 inches) Exhaust valve seat bore diameter: 0.3 Over size: 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-593049-S16824219482014011300000) ."

Scheme 184

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 Over size: 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 185

Required Special Tools

1. MB991346: Top cover wrench
2. MB991883: Flywheel Stopper
3. MD998718: Rear Oil Seal Installer

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 186

Scheme 187

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: 0.012 - 0.030 mm (0.0005 - 0.0012 inch) Limit: 0.1 mm (0.004 inch)

Scheme 188

Scheme 189

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 (0.0020 inch) Limit: 0.2 mm (0.008 inch) Grinding limit: 0.2 mm (0.008 inch)
3. Check the cylinder wall for scratch or seizure. If there is any defect, replace the cylinder block.
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: 86.0 mm (3.39 inches) Cylindricity: 0.15 mm (0.006 inch)