Archive for July, 2018

 

Operation Bad Timing II: The Soundtrack – Pistons and Valves and Seals, Oh My (God Everything Sucks)

Jul 23, 2018 in mikuvan

Here we go! With the head  now off, it was time to extract the pistons and either repair or replace them while the Chinesium head was on its way. This post covers roughly the week of July 1st. The plan was to pull pistons #2, 3, and 4 out and appraise them for damage. Pistons 3 and 4 were part of the knocking-induced head gasket explosion, so they were the most suspect to me. Cylinder 2 merely showed less-than-factory compression (around 90 PSI), so I wanted to see what problems it had, and to practice my piston-replacement operations on it if need be.

The first step to being about to get to them is to remove the oil pan. Gee, this thing was stuck on a lot harder than I remember… granted, I haven’t personally opened it myself since the Great Accidental Partial Engine Rebuild ceremony, and it seems like they slathered the whole thing in silicone and slammed it on there hard. I ended up having to bend up a corner of the pan to get enough leverage to pry the rest of it off.

This corner was later hammered back into shape, but whether it’ll seal again is another question!

Ahh, we meet again. I removed the connecting rod cap of piston #2 and shoved it out the top while inspecting the crankshaft journal for any damage or abrasion.

Here’s piston #2 in all of its oil-grunged glory. I know for a fact that Mikuvan has been burning oil through the valve stem seals (at least) for the past roughly 10,000 miles, and it shows.

I decided at this point to just use all 3 of the remaining pistons in the original kit that I bought – the original piston which was replaced in the GAPER (still a very unfortunate acronym) was #3, which was one of the now-untrusted ones. Since #1 showed nearly factory compression, I was just going to leave it alone.

This meant making….

Big Chuck’s Automotive Special Tool #BCA-9001-3939-A, Mikuvan Piston Pusher. The factory manual showed an object not unlike this, which led me to conclude it was just two tubes. Well guess what, I also have two tubes and a hydraulic press. The larger tube is a 1.25″ OD thick-wall tube, whose bore I enlarged to 15/16″ to clear the 22mm piston rod, and with two notches machined out to accommodate the piston’s flat face. The tube was in fact originally bought for either creating the hubs of Chibikart or Chibi-Mikuvan’s steering uprights.

It was then easy to push the piston pin out and free it up. Part of my rage-ordering of every component I might need was a new set of crank and connecting rod bearings, and I decided to just go ahead and put them on anyway because why not, I already had this stuff out.

Essentially I was working with the assumption that everything which has touched a pre-ignition event is immediately suspect out to like 2 layers of the network away. In a way, it’s like how I repair my motor controllers: if one FET lets go, its friend on the same half-bridge is replaced, the gate driver is replaced, and all power supply components that are semiconductors nearby are replaced; after all, if you already are heating up the board for reflow, you MIGHT AS WELL.

With my post-facto knowledge, I now understand that this is a better assumption for higher-strung newer engines, or ones built for high performance and racing, in which the stakes are much higher if something goes wrong. Mikuvan’s engine is rather the opposite, an understressed low-revving truck engine which only ever made 107HP out of 2.4 liters new and had an incredible 8.5:1 compression.

My adventures consulting my vanstylists, “car guy” friends, and the Internet at large including Mitsubishi Delica owner forums/groups and reading in general about engine explosion scenarios, has forced me to conclude this: All Internet car advice is horrible and irrelevant.

You need to decide what is best for your application by Kalman filtering your own experiences in with all the differing advice you’ll get, mostly from “car guys” who insist that things must be done a specific way or it’s not worth doing at all.

I luckily have the upside of having a lot of mechanical system intuition that made me question “car guy” advice – do I REEEEEEEALLY need this? Is this the ONLY way things happen? Maybe if I actually did have the turbo Evo engine… And then some from my trusted mechanics who have in the past advised me on what I could conceivably get away with versus what would fail right away, which I was more trying to gauge. I know I’m not doing anything truly correctly, so how topologically-correct can I remain?

Anyways, in conclusion, I could have probably run Piston #2 just fine after replacing the rings, but again, Might as Well if I have the parts handy. So on a new piston and rings go. I learned a great deal about the neckeardry that goes into piston rings doing research on them; these are one of the Insta-Fail scenarios, if you put in the rings upside down or inside-out, they will not seal properly or prevent oil burning. If you don’t install them in a certain rotation (phasing, clocking) according to the factory manual, you could get compression issues right away and uneven wear in the cylinder long term.

There are just so many small details to get “right” that all affect long term operation, yet are presented to you as life-or-death scenarios, which you have to distill out for applicability.

I suppose the advice is all bent towards people who would rather not jiggle with their engine internals on a regular basis.  But hey you know what an electric motor is? It’s one round thing that spins inside of another round thing. I heard the kids are into them these days.

My “car guy” friends absolutely begged me to hone the cylinder bores before installing the pistons again. Another one of my mulling conclusions is that everyone seems to think Mikuvan is more fucked than it actually is, with talks of cylinder wall scoring damage as if I ran the thing without oil up a mountain.

I do rather think the cylinder walls were all fine, but again doing my Kalman Filter research it seems like putting in new piston rings on a previously worn-in surface wouldn’t do me much good in the long run, and buying a simple flexible hone and sticking it on a drill is not hard. So that’s what I did!

I alternated pushing the hone with spraying the area down with WD-40 (you’re apparently supposed to use a dedicated honing oil for Best Results™) while the crankshaft below was covered by a few shop towels to prevent the metal particles and abrasive dust from falling on the journals. I cleaned the journals afterwards with some brake cleaner regardless.

Using “Irritating 1-purpose dedicated automotive tool #21892″, a piston ring compressor, I loaded the new #2 piston in with a healthy dousing of motor oil (you’re supposed to use dedicated assembly oil for  Best Results™). There are SO. MANY. stupid irritating one-purpose tools to do things expediently.

I have to wonder if all this is just entrenched through generations of automotive engineering and service or if there is an actual reason there’s a squiggley-shaped object called a Distributor Hold-Down Wrench. Boy that would have sure saved me a lot of time when I was dismantling most of vantruck’s accessory belt drives off to assembly a specific order of socket universal joints and extensions to loosen its distributor hold-down bolt.

And here I thought the world of drones and 3D printers were a horrifying mess of tribal knowledge – I clearly have never actually worked on cars up until this point. That is a hundred and twenty years of tribal knowledge.

After feeling pretty good about piston 2, it was time to do the same thing to #3 and #4. I was expecting more gore here for sure.

Here they are extracted. #3 on the right was replaced during the GAPER, but it and #4 show some pretty serious signs of oil burning.

They also both had stuck piston rings, #4 moreso than #3. Grunge filled nearly the entire volume of the oil control rings, which were probably doing dubious controlling at this point. So something was bound to fail sooner or later. The further back in the engine, the more it butts up against the firewall (which is actually behind me) and presumably the hotter they get. I’d like to think this is why cylinder #1 has barely shown any problems – it’s first in line to get water, cooling air, and oil pressure.

Control-C Control-V the whole procedure – cylinder honing and cleaning, piston swap, rings, and bearings… to pistons 3 and 4 and back in they go. I figured I did it mostly right if it still turned by breaker bar as easily as it used to.

For now, I put a few towels over the whole thing and went back inside to inspect and work on the cylinder head itself.

The intake manifold is seperated from the head by a few mix-and-match nuts and bolts. This was a little weird to me, since I was expecting all studs and nuts versus half of them being hex-head screws – maybe that was factory, or maybe someone’s been in here before.

Nevertheless, this was when I discovered that this thing DOES have an EGR system. As I mentioned before, the EGR valve was always drawn in isolation with little context of where it actually was. By my guess, I thought it sat behind the cylinder head, and when I didn’t feel it there, I assumed that it was a CA-spec emissions versus REAL AMERICA spec difference. It turns out the damn thing is nested in the U-turn that the intake runners make from the throttle body. The small center tube between the four larger intake runners is the EGR passage, and it mates up with a similar passage which dives through the head and pops out near exhaust valve #4.

What?! Well, either way, this passage was very clogged – not all the way closed, but significantly. Given that I’d never had any EGR-associated idling problems, I decided to leave it alone – I just filled the whole cavity with brake cleaner and came back a few hours later to blow it out with shop air, whatever I could get was it!

The cylinder head itself was fairly caked with oil grunge, with cylinders 3 and 4 being the worst as expected.

My goal with this head was to replace the front oil seal, the eight hydraulic valve lifters (the round bumpies poking out of the upside-down camshaft on the top left), and the eight valve stem seams, which cause the oil burning and vape cloud on startup behavior. While I had the valves dismantled, I was just going to casually clean them and the chambers they sit in – casually meaning yes, I know I’m supposed to take everything off and chuck this thing in some ultrasonic cleaner filled with teratogens, but I think the application is not strenuous enough to warrant it.

This…. is where I got to use “Irritating 1-purpose dedicated automotive tool #37985″, a valve spring compressor. It also ranks as the most terrifying tool I’ve used yet, since it’s literally stamped sheet metal holding onto an angry die spring, and that’s supposed to be an okay thing. I’ve witnessed a suspension spring/strut compressor tool being used before. That is something I will never voluntarily stand next to if I can help it.

It turns out all that holds the valve springs on are these two little taper-lock bushings, literally called “valve spring retainer locks” and similar. I’m frankly amazed they don’t just shear off all the time. Once you compress the valve spring, you bean it downwards to unseat the taper lock, upon which these little halves fall out. Whatever, I’ve already suspended my belief that combustion engines are actually things that work okay for long enough, let’s continue!

 

Yes, the valve stem seams were all very crispy. On the left, a new one. On the right, the hardened and bloated lump that was in it. Sure as hell not doing any sealing, as all of the valves came out with very oil-covered stems and backsides.

I’d also noticed some mild leaks on the camshaft, which is explained by its own hard-as-a-rock seal on the right.

In dismantling and cleaning the valves – mostly wire brushing with some brake cleaner love – I found the reason for cylinder #2 showing slightly low compression: I had a cracked exhaust valve. Very unfortunate, as this means I can no longer just put this head back together. I immediately jumped on eBay and searched down some new-old-stock valves. No matter what, it means a delay in putting things back together.

I was otherwise going to replace ONLY this exhaust valve – I figure all the other ones have already met their own valve seats for a long time, and redoing all 8 would involve having to clean and re-grind the valve seats also. By this point, too, I was also getting tired of the dozens of minute small manufacturing processes that all have to be done and special tools that have to be used, to make things work “correctly” – I wasn’t planning on performing the valve seat grinding/polishing operation at all on the replacement exhaust valve either, just a quick cleanup of the existing valve seat and making them be friends by thermo-mechanical coercion.

Natural technological progression is really an evolutionary process unto itself – you end up with systems that have thousands of micro-optimizations in different places for different things, instead of clean-sheet designing something with the knowledge of the system you now have. That takes a lot of time and money, I suppose. Having researched obsolete combustion engine technologies in the past, it makes me wonder if one or the other design was just invented at a bad time when metallurgy and manufacturing couldn’t support it existing yet and they really were fundamentally better concepts which could do away with much of the “every page in the engineering textbook” experience so far.

It also made me appreciate, and maybe mildly envy, the people who got their engineering career starts working on vehicles, the “car guy” friend in high school everyone probably had, including me. Frustrating folk knowledge aside, you really do get a sampling of every engineering industry in making a working automobile, a huge head start on the pratical side of things. I like to think I gained some of this edge by working on my robots and silly e-vehicles, which perhaps lends me to criticizing the combustion engine industrial complex now.

Waiting on the valves meant I put a temporary stop to work on this head for a little while, enough that on the following Monday morning, I awoke to a pleasant gift from the Chinesium Fairy….

Well, it’s cylinder head shaped, so we’re off to a good start. Stay tuned for more!!?

 

Operation Bad Timing II: The Soundtrack; or Zen and the Art of Van Maintenance

Jul 17, 2018 in mikuvan

It all started with a timing belt inspection.

With almost 230,000 miles on the clock now starting from its 151,000 mile humble beginnings, Mikuvan is essentially a cultural institution in my sphere of influence. It’s just assumed to always be around, and it really has been a relatively (emphasis on relatively) pain-free experience. Originally a hare-brained experiment in what if I built myself an electric car, which I swear to all of the gods who made themselves known these past 2 weeks will still happen, it means I’m physically coming up on service internals I never imagined I’d have to deal with again, because… .and I quote myself out of context from 5 years ago, “It’ll probably last like 10,000 miles if that”.

I can’t find the damn figure on this website, but I know I said something like it.

Well, almost 80,000 miles later, here I am. Since the “Great Accidental Partial Engine Rebuild of 2015“, I’ve actually barely gone inside except to feed its increasingly untenable thirst for motor oil. That, believe it or not, was itself over 50,000 miles ago too (I have the service papers from that still – 178K!). The past abonormally-cold winter finally pushed a number of wear components over the edge, it seems, and I wound up after the cold season with an almost two-stroke-esque oil consumption level of < 400 miles per quart and a complementary vape cloud per start.  So you know something like this was coming anyway, just a matter of when and how.

(Oh yeah – I made a number of other deferred-maintenance level repairs when it got warmer, but those will need to be handled separately now!)

We begin on the night of June 28th.

I was to leave for a weeklong southern-fried van adventure covering most of the Blue Ridge Parkway and Skyline Drive, and diving back to Atlanta through the Smoky Mountains forest roads, part of which I ran after Dragon Con 2016. Essentially wandering down in a casual manner for no good reason besides to be not in Boston, because every opportunity I have, fuck this place. The startup’s hardware status was finally to the point where I felt comfortable leaving it to the other members of the company (a story still building up which I owe everyone… put it on my I swear to God list); I’d already punted, up to this point, several of my usual trips because you don’t leave your hardware before it launches, like the opposite of a ship’s captain but with equal amounts of dodging icebergs.

So naturally, having experienced basically no van trouble in 2.5 Dragon Cons (my benchmark for “It Has Been ____ Days Since an Injury” of vans), it was almost a given that I’d make trouble for myself! Gee, I haven’t looked at the timing belt in a whole bunch of miles – let’s see how it’s doing.

Yup, that there’s a timing belt. Hmm, it looks physically in good shape, but the tension is a little out since it’s worn down. So, how do I tension this thing again? Let’s not go back home to bring out the manual, or go upstairs to read my own damn blog post, and instead just take my best memory-stab at it.

You may be wondering How I ended up in this position why I chose to perform what to normal people and sensible mechanics is highly invasive, expensive, and complex engine surgery the day I was to leave for a multi-thousand mile road trip. Don’t question me – and if you did, I wouldn’t have a good answer. All I can say is since we did it the first time, I was confident I could get in and out in around an hour.

That was only a little wrong – there were a few stuck bolts in the way, which caused the procedure to take until after nightfall. Uh oh.

Alright, let’s see, how do you retension this thing? A quick gander at the online Ukranian-hosted rebuild manual gives me…

Cool, I’ll just loosen the tensioner and breaker-bar the crank pulley to move the timing belt 2 tee…. oh, shit, there’s no spring, that’s right. Mikuvan didn’t come with a tensioner spring – we always set the tension manually, and this was relayed to my van salon when they did the Great Accidental Partial Engine Rebuild. So they didn’t unbend some Smart Car’s front suspension to wind me a new spring either.

I immediately skipped several teeth on the belt.  It was then that I realized I was probably not going on my trip.

A sensible person would probably just Uberlyft home and try again during daylight, but I was already invested deeply into this rapidly sinking venture. Nope, I was gonna drive home tonight. I know this damn thing inside and out. I built it. I summoned it back into existence. So I stuffed the belt back on!

 

 

….and, in the dark, proceeded to misalign the timing belt by 2 teeth. Great! Non-interference engine, let me just pop it back over, right? An afternoon’s work to dig back in, right? Looks like I just aligned the mark we made a long time ago instead of the (impossible to see in the dark) factory-stamped timing dimple, right?

Sadly, the damage was done. The timing was artificially advanced by the belt misalignment, causing massive and horrible pinging (pre-ignition) as soon as I gave it any load; which only happened when I goosed it to get onto the main road.  It idled and crawled slowly out of the side roads fine, which gave me a false sense of security. I tried to limp it back as gently as possible, sounding like a diesel school bus the entire way. It’s interesting to think that if I had gotten it a tooth off the other direction, the timing would have been artificially retarded, yielding just horrible gas mileage and less power…..which I might have just wrote off as “eh, it always does that I guess”.

That’s it; I cooked my own goose. Until a lot of money was spent or time was used up, Mikuvan was down, possibly for good. With compression lost between two cylinders, it was clear that at least the head gasket was gone in that area, with possible piston and cylinder wall damage which often follows bad pre-ignition under load.

Let’s summarize the failure chain:

  1. I insisted on pressing forward with a complex and involved repair in the dark
  2. I checked neither my own documentation on the repair, nor the factory service manual for the entire service procedure, relying on memory of something I did over 5 years ago.
  3. I then proceeded to mis-remember the hardware configuration and performed a service procedure incompatible with the state I had left the engine in.
  4. Not stopping there, I tried to remedy it also in the dark, mis-recognizing an alignment feature.
  5. I also didn’t use a timing light or tool to verify that the timing was still correct – doing so would have immediately shown me that the timing was too far out of line.

The God-King had betrayed a fatal flaw, hubris; easy to taunt, easy to trick.

And so, on the morning of June 30th, when I was supposed to be carving up the Shenandoah Valley, Operation BAD TIMING II: THE SOUNDTRACK began. This was going to be deep.

It took me a while to decide to take on the task myself – I had an entire spreadsheet of options, from trying to source a junkyard engine, to buying an entire parts van (I had been stalking this Craigslist post for a non-running but good body condition Mitsubishi cargo van – the seller had sent me photos of it previously but I declined due to the price at the time), to just asking my van salon for an estimate “Make it Happen™”.

It was a hard decision, but performing this operation was to be a soul-searching mission for myself.

  • If I was so bad at paying attention to detail and glossing over important information to get myself into this position, what does that say about my leadership role at a company I co-founded to the people working for it?
  • Could I reasonably scope my work each day, seeing as how I can no longer just rail on a project until it’s done because of the need to ensure the continued operation of the company and development of our hardware? This might be the newest thing for me, honestly, having to adhere to a regular schedule not just for myself, but for other people. I wanted to limit myself to only thinking and working on it during weekends and after the business day – vaguely defined for us, but still a block of time when everyone’s around – was over.
  • Will I be thorough in all the operations I needed to do to bring the engine back from an unknown damaged state, not skip steps unnecessarily and take shortcuts which will bite me in the ass? Will our hardware be subject to similar requirements!? How would I even know what thorough engineering and design is if I never do it myself?

Okay, enough mangsty philosophy. Time to mark all the connectors of the ECU harness and little hoses and start stripping things down. My goal was to get to the head gasket itself by the end of the weekend.

By the way, if you ever need to rebuild a Mitsubishi 4G64 SOHC 8-valve engine in a truck/van application, here it is in all its gory, bloody detail. There’s quite a lot of English-language information for the JDM/international Delicas, but actually not much information for those who own the USDM vans since they are substantially different. Since I’ve been saved by my own blog posts a few times, consider this also an entry into the annals of “how to unfuck your van” for the owner community.

I marked literally everything. I had watched some of the action when the guys at Smooth Automotive were taking the head apart, and they said to me that really if you look at it, everything goes together in one way only. Yeah, sure, all the connectors are unique and they have logical wire lengths which can put them only in a few spots. But there’s a lot of them. That’s scary. I never touched Mikuvan’s engine harness for this reason, because at the root of things I’m still not a car guy by historical experience. Honestly, it took a year of wrenching on vantruck to get me to this point where I just sighed and said yeah, it’s just like the FiTech rig but spread out over a few cables.

Really, it wasn’t so bad after that.

It was in doing a lot of this that I finally recognized where a lot of the EFI-related parts on Mikuvan were, which I learned on Vantruck performing the EFI conversion. I had only otherwise inklings that yeah there’s a throttle position sensor and idle air control servo and breather tube and manifold absolute pressure sensor and eeeeeeeeeeeeeeeehhhhhhhhhhhhhhhhhh. As it turns out, too, it does actually have a EGR valve – I had assumed the California emissions versions did but Federal did not, because the EGR valve was always shown in the manual in isolation, and when I felt around the area of the head I thought it was in, it wasn’t there, so I wrote it off as nonexistent. You’ll love where it actually was.

It actually only took an hour to get to this point. after pushing the connectors aside, disconnecting the throttle and transmission cables, and removing the multi-purpose brackety thing on top of the valve cover. A real mechanic would laugh, but remember, I erred on the side of cautiously labelling and marking (and taking photos!) for reconstruction ease later.

I also went ahead and removed the exhaust manifold, which was 1. cracked severely, and 2. took another half-hour of gently massaging and milking stuck nuts and bolts. Any antiseize lube I put on those threads has long evaporated.

The valve cover comes off after its two bolts are loosened. Most of the gear up here looks relatively new (since Great Accidental Partial Engine Rebuild, or GAPER….what an unfortunate acronym…  involved a head rebuild) despite the operating condition of the engine since I pretty diligently perform oil changes and whatnot.

How do you change oil on an engine which eats a quart of it every few hundred miles? Well, you keep it topped off and after 5000 or so miles, you do it anyway. Just adding more oil all the time doesn’t make existing grunge go away .

 

Ten giant socket cap screws later, and the head is ready to come off! This is the only place I’ve found on the whole powertrain which uses socket hardware. I wonder why? They’re M12 fine-thread screws with a 10mm socket drive.

 

Actually, wait up. There is a Bracket of Irritation directly under the intake manifold, seemingly there to give it more support, which is NOT DOCUMENTED in the USDM factory manual, as far as I can tell!

It took 10 minutes of gently prying at the head before I finally figured out that something was causing it to spring back each time. This 14mm-drive, M10 bolt is accessed from underneath and behind the suspension/engine mounting member. Just stick your arm behind the driver’s side wheel and poke it upwards past the fuel filter.

(Remember: I have no lift or hoist system, or even a garage. I’m on the ground in a gravelly, disintegrating parking lot with jackstands only as a means to lift the whole thing. This is literally “How to un-fuck your van in the most painful, laborious fashion possible”)

Alright, now the Bracket of Irritation is free. It’s time to yank the head assembly off and…

Yup, that’s a head-gasket alright. As I suspected, it blew out between cylinders 3 and 4, most likely as a consequence of severe pre-iginiton under load.

I’m not just out to stuff a new one on and call it a day. I’m told that once an engine fails due to pre-ignition, everything inside is suspect, from pistons to rings to bearings. It was on the docket while I was deep, brah to go ahead and pull the #3 and #4 pistons associated with the failure plus #2 which showed low compression and inspect them thoroughly. The worst thing would be to bodge it back together then have pistons implode later.

#1 still showed factory-spec compression, so I decided from the get-go to leave it alone. This actually means I can use my leftover 3 pistons from the GAPER (…what an unfortunate acronym again).  I ordered a new set of both crankshaft and connecting rod bearings just in case.

It seems that cylinders 2-4 have also been burning oil for a while, with #2 being the worst. I suspect it began in earnest late last fall into winter (which was a fairly unprecendented cold one) when I really started noticing smoking on cold starts. Yet this damned thing took me to Atlanta and back in January, and regularly got hooned around town thereafter and I didn’t even notice any power loss.

Call me silly for going back on my EV conversion word this many times and digging this deep in to ewwww, internal combustion, but something this hard for me to kill kind of deserves my best shot at getting it working again, eh?

So on the docket for this guy was cleaning the valves and seats (no regrinding or re-lapping, which I declared out of neckbearding scope unless I found serious damage) and new valve stem seals, which were clearly not very seal-y any more. I don’t know what a typical “old car rebuild” service interval is, but for the wear parts to let go after 50K is a little disappointing. However, I also don’t know what the gold standard of the time period was – maybe 50K per comprehensive service was actually phenomenal in the 1980s?

Nevertheless, it was time to clean everything up, scrape the old chunks of gasket off, and put the patient on the operating table.

Around this time, I found a resource which, if true, could be a boon to USDM van-mongers.

A complete Chinesium head assembly for the 4G64 8-valve SOHC? Sure, why not! These engines’ bloodlines made it all the way up to like, last year in a few Chinese car models, and still live on otherwise as industrial engines for forklifts and generators.

I was now determined to do my usual exploration of resources for the greater good of the community. It also offered me a backup solution (if true) in case my head repair failed or I discovered some kind of terminal damage that is beyond my skill and resource to fix correctly.

I hit the button on this order on Sunday afternoon, and soon, the thing was due in on Friday after July 4th. What’s actually going to be in the box!? Hell if I know – if I received a Chinese junkyard head that got run through a dishwasher, I was gonna be happy.

Coming up next: Diving even deeper into the valves and pistons themselves.