tow MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

ENGINE – Engine Adjustments11-7
4. LASH ADJUSTER REPLACEMENT
Refer to (4) of the preceding paragraph.
5. IGNITION TIMING CHECK
Check that ignition timing is at the standard value.
Standard value: approx. 5
BTDC
NOTE
Ignition timing is variable within about ±7
, even under normal
operating.
6. IDLE SPEED CHECK AND IDLE MIXTURE
CHECK
(1) Run the engine at 2,000 to 3,000 r/min for 2 minutes.
(2) Check the CO and HC contents at idle.
Standard value
CO contents: 0.6% or less
HC contents: 300 ppm or less
7. COMPRESSION PRESSURE CHECK
(1) Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
(2) Remove all of the spark plugs.
(3) Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
(4) Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
(1) Keep away from the spark plug hole when
cranking.
(2) If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
Crank angle
sensor connector

ENGINE – Oil Pan11-14
REMOVAL SERVICE POINT
AOIL PAN REMOVAL
INSTALLATION SERVICE POINTS
ADRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
BOIL RETURN PIPE GASKET INSTALLATION
Install the gasket with the printed portion toward the oil pan.
MD998727MD998727
Drain plug gasket
Oil pan side
GasketPrinted portion

ENGINE – Cylinder Head Gasket11-17
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Fuel Discharge Prevention
(2) Engine Oil Removal
(3) Strut Tower Bar Removal
(4) Timing Belt Removal (Refer to P.11-21.)
(5) Thermostat Case Assembly Removal
(Refer to GROUP 14 – Water Hose Pipe.)
(6) Front Exhaust Pipe Removal (Refer to GROUP 15.)Post-installation Operation
(1) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(2) Thermostat Case Assembly Installation
(Refer to GROUP 14 – Water Hose Pipe.)
(3) Engine Oil Filling
(4) Timing Belt Installation (Refer to P.11-21.)
(5) Strut Tower Bar Installation
(6) Accelerator Cable Adjustment
O-ringDelivery pipe
Engine oil
12 – 15 {1.2 – 1.5}
5
9 {0.9}5 {0.5} 3 {0.3} 10 {1.0}
19
14
153
16
18
10
17
8
9
8
11
8
7
201
2
Unit: Nm {kgf
m}
18
6
3
13
12 4
Removal steps
1. Center cover
2. Accelerator cable connection
3. Ignition coil connector
4. Ignition coil
5. Crank angle sensor connector
6. Crank angle sensor bracket con-
nection
7. Brake booster vacuum hose con-
nection
8. Vacuum hose connection
9. TPS connector
10. ISC motor connector11. Water hose connection
12. Oxygen sensor connector
13. Injector connector
14. Cam position sensor connector
15. Coolant temperature sensor con-
nector
16. Water temperature gauge unit con-
nector
17. Control harness
D18. Fuel pipe pressure hose connection
19. Fuel return hose connection
20. Oil level gauge guide assembly

ENGINE – Cylinder Head Gasket11-20
(3) Tighten the bolts by the following procedure.
StepOperation
1Tighten to 78 Nm {8.0 kgf
m} in the order shown in the
illustration.
2Fully loosen in the reverse order of that shown in the
illustration.
3Tighten to 20 Nm {2.0 kgf
m} in the order shown in the
illustration.
4Mark the head of the cylinder head bolt and cylinder head
by paint, then tighten 90
of a turn in the order shown in
the illustration.
5Tighten 90
of a turn in the order shown in the illustration.
Check that the painted mark of the head bolt is lined up
with that of the cylinder head.
Caution
(1) Always make a tightening angle just 90
. If it is less
than 90
, the head bolt will be loosened.
(2) If it is more than 90
, remove the head bolt and repeat
the procedure from step 1.
COIL RETURN PIPE GASKET INSTALLATION
Install the gasket with the printed portion toward the oil pan.
DHIGH-PRESSURE FUEL HOSE INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring,
then fit the O-ring in the delivery pipe.
Caution
Do not let any engine oil get into the delivery pipe.
(2) Check that the high pressure hose turns smoothly.
If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-install
the hose to the delivery pipe and check that the hose
turns smoothly.
(3) Tighten the mounting bolts to the specification.
Intake sideMB991654
Exhaust sideFront of engine
Step 4
90

Painted markStep 5
90

Painted mark
GasketPrinted portion

ENGINE – Timing Belt11-26
D
SEALANT APPLICATION ON ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Specified sealant: THREEBOND 1212D or equivalent
Apply sealant
10 mm
10 mm 10 mm
10 mm
Apply sealant
Apply sealant
E
SPACER INSTALLATION
(1) Apply very thin coat of oil to the outer periphery of the
spacer (oil seal contacting surface).
(2) Install the spacer with the chamfered end toward the
oil seal. Mounting in the reverse direction can damage
the oil seal lip.
F
COUNTERBALANCE SHAFT SPROCKET
INSTALLATION
G
TIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
SpacerOil seal
Chamfer
Timing
marks Timing
marks

ENGINE – Engine Assembly 11- 32
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Fuel Discharge Prevention
(2) Hood Removal
(3) Strut Tower Bar Removal
(4) Air Hose C Removal
(Refer to GROUP 15 – Intercooler.)
(5) Radiator Assembly Removal (Refer to GROUP 14.)
(6) Under Cover Removal
(7) Front Exhaust Pipe Removal (Refer to GROUP 15.)Post-installation Operation
(1) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(2) Under Cover Installation
(3) Radiator Assembly Installation (Refer to GROUP 14.)
(4) Accelerator Cable Adjustment
(5) Air Hose C Installation (Refer to GROUP 15 – Intercooler.)
(6) Strut Tower Bar Installation
(7) Hood Installation
O-ring Delivery pipe
1
2
3
4
5
6
7 8
9
10
11
18 12
Engine oil
5 {0.5}
Unit: Nm {kgf

m}
10 – 12
{1.0 – 1.2}
17 1614 13
10
– 12
{1.0 – 1.2}
15
3 {0.3}
17
8
Removal steps1. Center cover
2. Accelerator cable
3. Brake booster vacuum hose connection
4. Vacuum hose connection
5. Throttle position sensor connector
6. Idle speed control motor connector
7. Heater hose connection
8. Ignition coil connector
9. Crank angle sensor connector
10. Oxygen sensor connector 11. Injector connector
12. Cam position sensor connector
13. Coolant temperature sensor con-
nector
14. Coolant temperature gauge unit connector
15. Vacuum pipe/hose assembly
16. Control harness
 C 17. High-pressure fuel hose connection
18. Fuel return hose connection

MPI – Throttle Body13-37
THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Engine Coolant Draining
(2) Air Hose D Removal
(Refer to GROUP 15 – Intercooler.)
(3) Strut Tower Bar RemovalPost-installation Operation
(1) Strut Tower Bar Installation
(2) Air Hose D Installation
(Refer to GROUP 15 – Intercooler.)
(3) Engine Coolant Supplying
(4) Accelerator Cable Adjustment
34 2
61
7
19 {1.9}
5
Unit: Nm {kgf
m}
5 {0.5}
Removal steps
1. Accelerator cable connection
2. Throttle position sensor connector
3. Idle speed control servo connector
4. Vacuum hose connection5. Water hose connection
6. Throttle body
A7. Throttle body gasket
INSTALLATION SERVICE POINT
ATHROTTLE BODY GASKET INSTALLATION
Place the gasket so that the projecting part is positioned
as shown in the illustration, and then install it between the
intake manifold and the throttle body.
Towards front
of vehicle
Up

INTAKE AND EXHAUST – Intake Manifold15-9
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Fuel Discharge Prevention
(2) Throttle Body Removal (Refer to GROUP 13.)
(3) Front Exhaust Pipe Removal (Refer to P.15-14.)
(4) Air Control Valve Bracket Removal (Refer to P.15-8.)
(5) Strut Tower Bar RemovalPost-installation Operation
(1) Strut Tower Bar Installation
(2) Air Control Valve Bracket Installation
(Refer to P.15-8.)
(3) Front Exhaust Pipe Installation (Refer to P.15-14.)
(4) Throttle Body Installation (Refer to GROUP 13.)
O-ring
Unit: Nm {kgf
m}
15
Engine oil
3 {0.3} 10 – 13 {1.0 – 1.3}
10 – 12
{1.0 – 1.2}
12 – 15 {1.2 – 1.5}
35 {3.6}
9 {0.9}30 {3.1}35 {3.6}20 {2.0}22 {2.2}20 {2.0}
14 14
167
5
17
1521
3
4 6
7 7
19
20
18 8
9 12
1011
13
Removal steps
1. Center cover
2. Ignition coil connector connection
3. Oxygen sensor connector connec-
tion
4. Crank angle sensor connector con-
nection
5. Injector connector connection
6. PCV hose
7. Vacuum hose connection
8. Brake booster vacuum hose con-
nection
9. Vacuum tank, solenoid valve, and
vacuum hose assembly10. Intake manifold stay
11. Oil level gauge guide assembly
12. Vacuum hose and pipe mounting
bolt
13. Fuel return hose connection
A14. Fuel high pressure hose connection
A15. Delivery pipe, injector, and pres-
sure regulator assembly
16. Insulator
17. Insulator
18. Alternator brace stay
19. Intake manifold
20. Intake manifold gasket

ENGINE ELECTRICAL – Charging System16-2
CHARGING SYSTEM
ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Under Cover Removal
(2) Engine Mount Removal
(3) Strut Tower Bar RemovalPost-installation Operation
(1) Strut Tower Bar Installation
(2) Engine Mount Installation
(3) Under Cover Installation
(4) Drive Belt Tension Adjustment
(Refer to GROUP 11 – On-vehicle Service.)
Unit: Nm {kgf
m}
44 {4.5}
7 3
2
6
15 4
24 {2.4} 22 {2.2} 9 {0.9}12 – 15
{1.2 – 1.5}10 – 13
{1.0 – 1.3}
12 {1.2}
Removal steps

A1. Drive belt (Power steering, A/C)

B2. Delivery pipe, injector and pressure
regulator assembly
3. Oil level gauge guide4. Pressure hose connection

C5. Alternator
6. Water pump pulley
7. Alternator brace

MANUAL TRANSMISSION – Transmission Assembly22A-9
REMOVAL SERVICE POINTS
ACLUTCH RELEASE BEARING SEPARATION
(1) Remove the cover from the service hole in the clutch
housing.
(2) While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
(3) Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction A two to three times. Forcibly
prying can cause the release bearing to be damaged.
BDRIVE SHAFT <LH> / DRIVE SHAFT <RH>
DISCONNECTION
(1) To disconnect the left-hand drive shaft, insert a lever
as shown and pry out the shaft from the transmission.
To disconnect the right-hand drive shaft, apply a lever
and a hammer as shown and lever out the shaft from
the transfer assembly using the hammer as a fulcrum.
NOTE
Remove the drive shafts with the hub and knuckle
attached.
Caution
Do not attempt to pull out the drive shaft from the
BJ in this stage since it can cause the TJ to be
damaged. Be sure to remove the drive shaft first from
the transmission side using a lever.
(2) Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
COUTPUT SHAFT REMOVAL
(1) Use the special tools (MB991612, MB990211) to remove
the output shaft.
(2) Use a shop towel to cover the transmission case not
to let foreign material get into it.
Service hole
Release fork
Wedge collar
Release bearing
Trans-
mission
side
Lever
Projection
Hammer
Lever
Output shaft
Transmission caseMB990211
MB991612