TSB's

Fixing a leaky Mitsu

An oil leak from the front of the engine may be seen on some 2008 and later Mitsubishi Outlander (w/2.4L engine), 2008 and later Lancers and 2008 Lancer Evolution engines built prior to April 8, 2008.

The leak may be traced to the area where the timing chain case, engine block and cylinder head meet, due to a misapplication of sealant during assembly.

 Supplies required for the repair:

* Loctite 5900 Flange Sealant or equivalent

* 120-150 grit sandpaper

* Non-chlorinated brake cleaner

* Safety glasses

* Water pump gasket P/N MN187246

* Cooling line gasket P/N MN187247

Following service manual instructions (Group 14 – Cooling), remove the water pump. Drain coolant for re-use. Water pump removal is best done from underneath the vehicle.

Thoroughly clean the area where the cylinder head, engine block and timing case meet and allow to dry completely.

Cover the indicated water pump openings with tape to avoid contamination.

Remove any existing sealant visible in the area to be prepped for new sealant.

Using sandpaper, prepare the surface of the area for the application of new sealant. Be careful not to damage aluminum surfaces.

Clean the area again using non-chlorinated brake cleaner and allow to dry completely.

Apply new sealant where the timing chain case, engine block and cylinder head meet as indicated. Allow the sealant to dry for 30 minutes.

Degrease the new sealant with non-chlorinated brake cleaner and apply sealant a second time over a slightly larger area and allow to dry for 30 minutes.

Reinstall the water pump and the drive belt in the reverse order of disassembly. Do not attempt to install the water pump until the sealant has dried for at least 30 minutes.

Cutaway view of the affected area. Note the area to be prepped for new sealant.
<p>Cutaway view of the affected area. Note the area to be prepped for new sealant.</p>

An example of the first application of new sealant. Allow this to dry for 30 minutes, then degrease again with brake cleaner.
<p>An example of the first application of new sealant. Allow this to dry for 30 minutes, then degrease again with brake cleaner.</p>
The first application of sealant should feature a width of 3mm and a build-up height of 3mm.
<p>The first application of sealant should feature a width of 3mm and a build-up height of 3mm.</p>
The second application of sealant should be done over a slightly larger area. Allow this second application to dry for 30 minutes before installing the water pump.
<p>The second application of sealant should be done over a slightly larger area. Allow this second application to dry for 30 minutes before installing the water pump.</p>
The second application of sealant should be approximately 12mm wide and about 4mm high.
<p>The second application of sealant should be approximately 12mm wide and about 4mm high.</p>

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