length MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

ENGINE – Service Specifications / Sealants / Special Tools11-2
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Basic ignition timing5
BTDC ± 3
–
Ignition timing (at idle)Approx. 5
BTDC–
Idle speed rpm850 ± 50–
CO contents %0.6 or less–
HC contents ppm300 or less–
Compression pressure kg/cm2 – rpm11.5 – 250Min. 9.7 – 250
Compression pressure difference of all cylinders kg/cm2–Max. 1.0
Intake manifold vacuum kPa {mmHg}–Min. 55 {410}
Cylinder head bolt shank length mm–99.4
SEALANTS
ItemsSpecified sealants
Rocker coverSemi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g)
Oil panSemi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)
NOTE:
Given in [ ] are MITSUBISHI GENUINE PART numbers.
SPECIAL TOOLS
ToolNumberNameUse
MD998782Valve lifter setReplacing the lash adjuster
MB990767End yoke holderHolding the crankshaft pulley
Holding the camshaft sprocket

ENGINE – Cylinder Head Gasket11-19
REMOVAL SERVICE POINT
ACYLINDER HEAD BOLT REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
INSTALLATION SERVICE POINTS
ACYLINDER HEAD GASKET INSTALLATION
(1) Wipe off all oil and grease from the gasket mounting
surface.
(2) Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.
BCYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 99.4 mm
(2) Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
Intake sideMB991654
Exhaust sideFront of engine
Cylinder head bolt
Washer
(Engine
oil)
Cylinder
head A

ENGINE COOLING – Water Pump14-5
WATER PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Coolant Draining and Supplying
(Refer to P.14-2.)Timing Belt and Timing Belt B Removal and Installation
(Refer to GROUP 11.)
12 – 15 {1.2 – 1.5} 24 {2.4}
8 × 22 8 × 14
Bolt specifications
8 × 24
Screw diameter × length mm
1
2
4
3
2
22 {2.2}
8 × 70
Unit: Nm {kgfm}
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
A4. O-ring
INSTALLATION SERVICE POINT
AO-RING INSTALLATION
Fit the O-ring in the O-ring groove in the water inlet pipe,
and coat the outer circumference of the O-ring or the inside
surface of the water pump with water before inserting the
pipe.
Water pump
O-ring
Water inlet pipe

MANUAL TRANSMISSION OVERHAUL – Transmission22B-16
DISASSEMBLY SERVICE POINTS
A
SPRING PIN REMOVAL
Shift the 5th-reverse shift fork in the direction shown in the
illustration.
B
3RD-4TH SPEED SHIFT RAIL / 3RD-4TH SPEED
SHIFT FORK / 5TH-REVERSE SPEED SHIFT
RAIL / 5TH-REVERSE SPEED SHIFT FORK
REMOVAL
Pull out the shift rails from the shift rail holes in the clutch
housing.
C
CENTER DIFFERENTIAL / OUTPUT SHAFT /
INPUT SHAFT REMOVAL
Remove the input shaft, output shaft and center differential
together.
ADJUSTMENT BEFORE REASSEMBLY
SPACER SELECTION FOR ADJUSTING INPUT SHAFT
END PLAY / OUTPUT SHAFT PRELOAD /
DIFFERENTIAL PRELOAD
(1) Install the input shaft, output shaft and center differential
as a set to the clutch housing.
(2) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the input shaft rear bearing at the
positions shown in the illustration.
5th-reverse
shift fork
5th-reverse
shift rail3rd-4th
speed
shift rail
Output shaft
Center
differentialInput
shaft
Output shaft
Center
differentialInput
shaft
Solders

MANUAL TRANSMISSION OVERHAUL – Transmission22B-17
(3) Place two pieces of solder (1.6 mm in diameter and approx.
10 mm in length) on the transmission case at the positions
shown in the illustration.
(4) Install the bearing outer race.
(5) Install the transmission case and tighten the bolts to the
specified torque.
(6) Remove the transmission case. If the solder is not crushed,
repeat the steps (2) through (5) using the solder with
larger diameter.
(7) Measure the thickness of the crushed solder with a
micrometer and select spacers that will provide the
standard end play/preload value.
Standard value:
Input shaft end play 0 – 0.17 mm . . . . . . . . . .
Output shaft end play 0.13 – 0.18 mm . . . . . . . .
Center differential preload 0.05 – 0.11 mm . . . .
REASSEMBLY SERVICE POINTS

AINPUT SHAFT / OUTPUT SHAFT / CENTER
DIFFERENTIAL INSTALLATION
Install the input shaft, output shaft and differential as a unit.

B5TH-REVERSE SPEED SHIFT FORK /
5TH-REVERSE SPEED SHIFT RAIL / 3RD-4TH
SPEED SHIFT FORK / 3RD-4TH SPEED SHIFT
RAIL INSTALLATION
(1) Install the 3rd-4th speed shift rails and fork, and
5th-reverse speed shift rail and fork.
Solders
Solders
Output shaft
Center
differentialInput
shaft
3rd-4th speed
shift fork
5th-reverse
speed shift fork5th-reverse
speed shift rail
3rd-4th speed
shift rail

REAR AXLE – Differential Carrier <EVOLUTION-IV, EVOLUTION-V GSR>27-40
REMOVAL SERVICE POINT
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
(1) Using a jack, support the differential carrier from its
underside.
(2) Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
442
5
5

REAR AXLE – Differential Carrier <EVOLUTION-V RS>27-42
REMOVAL SERVICE POINTS
APROPELLER SHAFT DISCONNECTION
Make an alignment mark on the companion flange and flange
yoke, then disconnect the propeller shaft from the companion
flange.
Caution
Suspend the propeller shaft from the body with a wire
to prevent the bend at the joint from catching and
damaging the joint boot.
BREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY REMOVAL
(1) Using a jack, support the differential carrier from its
underside.
(2) Remove the rear crossmember mounting bolts and
remove the differential carrier, where it is attached to
the rear crossmember, from the vehicle.
INSTALLATION SERVICE POINTS
AREAR CROSSMEMBER AND DIFFERENTIAL
CARRIER ASSEMBLY INSTALLATION
Tighten the rear crossmember mounting bolts in the numerical
order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the rear crossmember mounting holes have
different diameters between front and rear. This is the reason
for specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the companion flange with that
of the flange yoke at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 105
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 70
13
3
442
5
5

REAR SUSPENSION – Rear Suspension Assembly34-5
REMOVAL SERVICE POINTS
ABRAKE CALIPER ASSEMBLY REMOVAL
Remove the brake caliper assembly and secure it with a
wire.
BPROPELLER SHAFT DISCONNECTION
(1) Make an alignment mark on the differential carrier
companion flange and propeller shaft flange yoke.
(2) Remove the mounting bolts and nuts of the differential
carrier and propeller shaft.
CCROSSMEMBER MOUNTING BOLT REMOVAL
Support the differential case with a garage jack or transmission
jack and then remove the crossmember mounting bolt.
INSTALLATION SERVICE POINTS
ACROSSMEMBER MOUNTING BOLT
INSTALLATION
Tighten the mounting bolts in the numerical order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the crossmember mounting holes have different
diameters between front and rear. This is the reason for
specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
44
2
55

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D