lock MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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W
ARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
W arning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fi\
tted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitt\
ed seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensio\
ner fitted seatbelts and the clock spring, should be removed if there is a chance o\
f them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be rem\
oved.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-\
SRS air bags) has been carefully studied.

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 7
46. Rocker arm
47. Rush adjuster
48. Oil delivery body
49. Spark plug
50. Valve spring retainer lock51. Valve spring retainer
52. Valve spring
53. Inlet valve stem seal
54. Exhaust valve stem seal



D 
 
C






C 



B 



A 



A 

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 9
Removal guidelines
 
A


Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.
 
B


Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.
 
C


Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.
Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.
Fitting guidelines



A 
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Indicator marks
Colour of main
body: greyColour of main
body: grey/green
Inlet sideExhaust side
Valve
Valve guide
Valve stem
seal

ENGINE – CAMSHAFT, VALVE STEM SEAL11-10



B 
Fitting the valve spring
Fit the valve spring so that the end of the valve spring which has
the smaller radius is on the rocker arm side.



C 
Fitting the valve spring retainer lock
In the same way as when the valve spring retainer lock was
removed, compress the valve spring using the special tool for
compressing valve springs (MD998772), and fit the valve spring
retainer lock.



D 
Fitting the rush adjuster
Caution
If a rush adjuster is being reused, it must be washed and
inspected before fitting.
(Ref: Engine Service Manual)



E 
Fitting the camshaft
1. Remove any sealant from the cylinder head.
2. Apply engine oil to the camshaft cams and journals.
3. Fit the camshaft to the cylinder head.
Caution
Ensure that the inlet and exhaust sides are not the wrong way
round.



F 
Fitting the camshaft bearing cap No.4, the camshaft
bearing cap No.3, the camshaft bearing cap No.5, the
camshaft bearing cap No.2, the rear camshaft bearing
cap, and the front camshaft bearing cap
1. Set the camshaft dowel pins in the position shown in the
diagram.Rocker arm side
Front of engine<inlet side>
<exhaust side>
slit
slit
Approx. 4°dowel pins
inlet sideexhaust side

ENGINE – CAMSHAFT, VALVE STEM SEAL
11-13



K 
Fitting the camshaft position sensing cylinder (inlet
side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



L 
Fitting the camshaft position sensing cylinder (exhaust
side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
Note
Under pressure from the exhaust valve spring, it will turn slightly
in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position
approximately 45° to the exhaust camshaft dowel pin.
3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



M 
Fitting the locker cover assembly
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.
Semi-dry sealant: Three bond 1207D
2. Fit the rocker cover assembly onto the cylinder head.



N 
Connecting the radiator upper hose
1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose.<Intake side> dowel pin
pane
pane (small)
dowel pin approx. 45º
pane (large)
Front of engine
Protrusion
water outlet
fittingindicator marks

ENGINE – TIMING BELT, TIMING BELT B
11-21
10. Power steering oil pressure switch connector
11.Heat protector
12. Power steering oil pump ASSY
13. Power steering oil pump bracket
14. Idler pulley
15. Crank angle sensor16. Crankshaft sprocket
17. Crankshaft sensing blade
•Adjust the tension of the timing belt B
<Only after fitting>
18. Timing belt B tensioner
19. Timing belt B
Removal guidelines
 
A


Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all
the timing marks until the No.1 cylinder is in the compressor top
dead centre position.
Caution
Turn the crankshaft in the normal way.
2. Remove the rubber plug from the rear cover of the timing belt,
and prepare the special tool for adjusting bolts (MD998738).
 
C






C 



C 



B 



A 
 
D






A 


B


(engine oil)
Timing marks
Timing belt
valence

ENGINE – TIMING BELT, TIMING BELT B11-22
3. Twist the special tool for adjusting bolts (MD998738) by hand
until it touches the tensioner arm.
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and
then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.
Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
direction (clockwise direction) on the back of the belt.
 
B


Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.
 
C


Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.timing belt tensioner
arm
bolt for fitting the timing belt
tensioner
wire or pin
Crankshaft
sprocket

ENGINE – TIMING BELT, TIMING BELT B11-24
2. <Measuring the amount of give>
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
<when adjusted> 5~7mm
<when replaced> 5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3. <When using MUT-II/III>
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
approx. 100 N
amount of
give
pull lightly with fingertips

ENGINE – TIMING BELT, TIMING BELT B11-26



F 
Fitting the timing belt
1. Check that all the timing marks for the camshaft sprocket, the
crankshaft sprocket and the oil pump sprocket are aligned.
2. After the timing marks for the oil pump sprocket have been
aligned, remove the plug from the cylinder block and insert a
posidrive (+) with a diameter of 8 mm into the plug hole. Check
that more than 60 mm of the shaft of the screwdriver can be
inserted. If the screwdriver strikes the balancer shaft and can
only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one
complete turn, realign the timing marks, and check that more
than 60 mm of the screwdriver can be inserted. Do not remove
the screwdriver until the timing belt has been fitted.
3. Install the timing belt in accordance with the following guidelines
so that the side that is under tension does not get slack.
(1) Fit the timing belt around the crankshaft sprocket first, then
the oil pump sprocket and then fit it around the idler pulley.
(2) Fit the timing belt around the camshaft sprocket (exhaust
side) and hold it in place with a paper clip at the position
shown in the diagram.
timing marks
camshaft
sprocket (inlet
side)
timing
marks
crankshaft
sprocket
camshaft
sprocket
(exhaust
side)
timing
marks
oil pump
sprocket
plug
more than
60 mm
screwdriver
balancer shaft
camshaft
sprocket (inlet
side)
tensioner pulley
crankshaft
sprocket
camshaft
sprocket
(exhaust side)
idler
pulley
oil pump
sprocket
paper
clip

ENGINE – TIMING BELT, TIMING BELT B
11-27
(3) Use a wrench to align the timing marks on the rocker cover and
the camshaft sprocket, and whilst doing so, fit the timing belt
around the camshaft sprocket (inlet side) and hold it in place
with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley.
(5) Remove the two paper clips.
Caution
After the timing belt has been installed, apply some force in
an anti-clockwise direction to the camshaft sprocket and
check once more that all the timing marks are in the correct
position when the side of the belt under tension is taught.
4. Using the special wrench for the tensioner pulley socket
(MD998767), tense the timing belt by turning the tensioner
pulley in the direction shown in the diagram, and temporarily
tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.



G 
Adjusting the tension of the timing belt
1. Remove the rubber plug from the rear cover of the timing belt
and put the special adjusting bolt (MD998738) in position.
Slowly twist the adjusting bolt a little at a time, so that the wire
or pin inserted when fitting the auto-tensioner, only moves a
little.
Caution
There is a possibility that the wire or pin inserted in the
auto-tensioner may break if the adjusting bolt is twisted
with a spanner or a similar tool, so it must be twisted by
hand.
2. Turn the crankshaft a quarter turn in an anti-clockwise direction.
3. Turn the crankshaft in a clockwise direction, realign all the timing
marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had
been temporarily tightened.paper clips