Mitsubishi Outlander manuals

Mitsubishi Outlander: Cylinder Head and Valves

REMOVAL AND INSTALLATION

Mitsubishi Outlander. Engine Overhaul

Removal steps

  1. Cylinder head bolt
  2. Cylinder head bolt washer
  3. Cylinder head bolt & washer assembly
  4. Cylinder head assembly
  5. Cylinder head gasket
  6. Engine oil control valve (OCV) filter
  7. Retainer lock
  8. Valve spring retainer
  9. Valve spring
  10. Intake valve
  11. Retainer lock
  12. Valve spring retainer
  13. Valve spring
  14. Exhaust valve
  15. Valve stem seal
  16. Valve stem seal
  17. Intake valve guide
  18. Exhaust valve guide
  19. Intake valve seat
  20. Exhaust valve seat
  21. Cylinder head

Required Special Tool:

REMOVAL SERVICE POINTS

RETAINER LOCK REMOVAL

CAUTION

Be careful not to allow retainer holder C to interfere with the wall of the tappet hole and to damage it.

Use a special tool MD998735, and MB992089 to compress the valve spring and to remove the retainer lock.

NOTE: Store removed parts such as valves and springs with tags describing cylinder Number and installed position attached for reassembly.

Mitsubishi Outlander. Engine Overhaul

VALVE STEM SEAL REMOVAL

Use special tool MB992085 to firmly pinch the base (larger external shape) of the stem seal and twist it right and left for pulling out.

Mitsubishi Outlander. Engine Overhaul

INSTALLATION SERVICE POINTS

VALVE STEM SEAL INSTALLATION

CAUTION

1. Apply a thin coat of engine oil to a new valve stem seal.

Mitsubishi Outlander. Engine Overhaul

2. Use special tool MD998737 to press fit the valve stem seal into the valve guide with the valve stem used as a guide.

Mitsubishi Outlander. Engine Overhaul

RETAINER LOCK INSTALLATION

Use a special tool MD998735, and MB992089 to compress the valve spring and to install the retainer lock.

Mitsubishi Outlander. Engine Overhaul

CYLINDER HEAD GASKET / CYLINDER HEAD ASSEMBLY INSTALLATION

1. Completely remove the liquid gasket on the upper plane of the cylinder block and the lower plane of the cylinder head.

CAUTION

Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.

2. Degrease the place specified in the illustration.

Mitsubishi Outlander. Engine Overhaul

3. As shown in the illustration, apply a 2.5 +- 0.5 mm (0.1 +- 0.02 inch) of sealant to the top face of cylinder block.

Specified sealant: Three bond 1217G or exact equivalent

4. Install the cylinder head gasket.

NOTE: Check that the center of the liquid gasket is located toward the cylinder gasket in the position specified in the illustration.

5. As shown in the illustration, apply a 2.5 +- 0.5 mm (0.1 +- 0.02 inch) of sealant to the top face of cylinder head gasket.

Specified sealant: Three bond 1217G or exact equivalent

6. Install the cylinder head assembly.

Mitsubishi Outlander. Engine Overhaul

CYLINDER HEAD BOLT INSTALLATION

1. Install new cylinder head bolts and washers in the following procedure.

NOTE: Cylinder head bolts and washers must not be reused.

2. Apply an appropriate amount of engine oil to top and bottom surfaces of washers and threaded portion of bolts.

3. Install cylinder head bolts to the cylinder head.

NOTE: Bolts and washers are different parts for bolts on the timing chain side.

4. Tighten cylinder head bolts in several steps to the specified tightening torque of 35 +- 2 N*m (26 +- 1 ft-lb) according to the assembly order.

Mitsubishi Outlander. Engine Overhaul

5. Put a paint mark on all of cylinder head bolt heads and cylinder head.

CAUTION

6. Tighten the cylinder head 90º according to the tightening order. Tighten it further 90º and make sure that the paint mark on the cylinder head bolt is in a straight line with that on the cylinder head.

Mitsubishi Outlander. Engine Overhaul

INSPECTION

CYLINDER HEAD

1. Check the cylinder head for water leakage, gas leakage, damage or cracks before cleaning.

2. Completely remove oil, scale, sealant, carbon, etc. After cleaning oil passages, blow air to make sure that they are not clogged.

CAUTION

The grinding limit shall be within 0.2 mm (0.008 inch) in combination with the cylinder block to be assembled.

3. For the flatness on the cylinder head bottom, measure distortion using a straight edge and free gauge. If the distortion exceeds the limit, grind and repair it.

Distortion on bottom
Standard value: Within 0.05 mm (0.002 inch)
Limit: 0.2 mm (0.08 inch)
Grinding limit: 0.2 mm (0.008 inch)

Cylinder head height
Standard value: 128.5 mm (5.06 inch)

Mitsubishi Outlander. Engine Overhaul

VALVE

1. Repair the valve seat if contact with the valve seat is poor, uneven or broken.

2. Measure the margin.

If the limit is exceeded, replace the valve.

Standard value:
Intake 1.022 mm (0.0402 inch)
Exhaust 1.094 mm (0.0431 inch)

Limit:
Intake 0.522 mm (0.0206 inch)
Exhaust 0.594 mm (0.0234 inch)

Mitsubishi Outlander. Engine Overhaul

3. Measure overall length of the valve.

If the limit is exceeded, replace the valve.

Standard value:
Intake 113.18 mm (4.456 inch)
Exhaust 105.89 mm (4.169 inch)

Limit:
Intake 112.68 mm (4.436 inch)
Exhaust 105.39 mm (4.149 inch)

Mitsubishi Outlander. Engine Overhaul

VALVE SPRING

1. Measure free height of the spring.

If the limit is exceeded, replace the spring.

Standard value: 47.20 mm (1.858 inch)

2. Measure squareness of the spring.

If the inclination exceeds the limit, replace the spring.

Standard value: 2º or less
Limit: 4º

Mitsubishi Outlander. Engine Overhaul

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 (0.0039 inch)
Exhaust 0.11 mm (0.0043 inch)

Mitsubishi Outlander. Engine Overhaul

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)

CAUTION

If the variation in the width exceeds 0.2 mm even if the contact width is within the standard value, replace or correct the valve sheet.

Mitsubishi Outlander. Engine Overhaul

REPAIR PROCEDURE OF VALVE SEAT

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.

Mitsubishi Outlander. Engine Overhaul

REPLACEMENT PROCEDURE OF VALVE SEAT

1. Scrape the valve seat to be replaced from inside to make its wall thickness thin before pulling out.

Mitsubishi Outlander. Engine Overhaul

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 inch)

Exhaust valve seat bore diameter: 0.3 Over size: 30.22 − 30.24 mm (1.190 − 1.191 inch)

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".

Mitsubishi Outlander. Engine Overhaul

REPLACEMENT PROCEDURE OF VALVE GUIDE

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.

Mitsubishi Outlander. Engine Overhaul

READ NEXT:

 Balancer Chain

REMOVAL AND INSTALLATION Removal steps Drive plate bolt Adapter plate Drive plate Rear oil seal Balancer shaft chain tensioner Balancer shaft tensioner lever Balancer shaft chain guide Balan

 Piston and Connecting Rod

REMOVAL AND INSTALLATION Removal steps Connecting rod cap bolt Connecting rod cap Connecting rod bearing Connecting rod bearing Piston connecting rod assembly Piston ring Number 1 Piston ring

 Crankshaft and Cylinder Block

REMOVAL AND INSTALLATION Removal steps Crankshaft bearing cap bolt Crankshaft bearing cap Crankshaft bearing lower Crankshaft Crankshaft bearing upper Thrust bearing Crankshaft sensing ring

SEE MORE:

 DTC C1035, C1041, C1042, C1043, C1044, C1046, C1047, C1048, C1049, C104B, C104F, C1053, C1057, C105F, C1063, C1067, C105B, C1200, C1204, C1208, C120C

DTC C1035 Mutual monitoring of RR wheel speed sensor CAUTION If there is any problem in the CAN bus lines, an incorrect DTC may be set. Prior to this diagnosis, diagnose the CAN bus lines (Refer to GROUP 54C − CAN Bus Line Diagnostic Flow). Whenever ECU is replaced, ensure that the CAN b

 Symptom Chart, Symptom Procedures

SYMPTOM CHART SYMPTOM PROCEDURES Inspection Procedure 1: When the Brake Pedal is Depressed, Cruise Control System is not Cancelled. COMMENT Malfunction of CAN bus line. The stoplight switch circuit is suspected. TROUBLESHOOTING HINTS (THE MOST LIKELY CAUSES FOR THIS CASE:) Malfunction of CA

© 2010-2021 Copyright www.mioutlander.com