MITSUBISHI LANCER EVOLUTION VI 1999 Repair Manual

ENGINE – Timing Belt11-26
(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
(7) Abnormal wear on teeth.
(8) Missing tooth.
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace
as necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(4) Press the rod with a force of 98 to 196 N and measure
its protrusion.
(5) If the measured value is 1 mm or more shorter than the
value obtained in step (3), replace the auto tensioner.
12 mm
98 to 196 N
Movement

ENGINE – Fuel and Emission Control Parts11-27
FUEL AND EMISSION CONTROL PARTS
REMOVAL AND INSTALLATION
1
2 3
456
78 9
1011
12
1314
15
16
9 Nm 11 N m
9 Nm 11 N m
18 Nm
Removal steps
1. Throttle body
C2. Throttle body gasket
3. Fuel return pipe
B4. Fuel pressure regulator
5. O-ring
6. Insulator
7. Insulator
A8. Injector9. O-ring
10. Grommet
11. Delivery pipe
12. Vacuum hose and vacuum pipe
13. Vacuum tank
14. Vacuum tank bracket
15. Solenoid valve
16. Solenoid valve bracket

ENGINE – Fuel and Emission Control Parts11-28
INSTALLATION SERVICE POINTS
AINJECTORS INSTALLATION
(1) Before installing an injector, the rubber O-ring must be
lubricated with a drop of clean engine oil to aid in
installation.
(2) Install injector top end. Be careful not to damage O-ring
during installation.
BFUEL PRESSURE REGULATOR INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring.
Insert the fuel pressure regulator into the delivery pipe
being careful not to damage the O-ring.
Caution
Be sure not to let engine oil get into the delivery
pipe.
(2) Check that the fuel pressure regulator turns smoothly.
If it does not turn smoothly, the O-ring may be trapped.
Remove the fuel pressure regulator and check the O-ring
for damage, and then re-insert it into the delivery pipe
and check once again.
CGASKET INSTALLATION
Position the projection as shown in the illustration.
1EN0388
Grommet
O-ring
Projection

ENGINE – Secondary Air System and Intake Manifold11-29
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION
1 23 4 5
6
7
8 910
11
11 N m
35 Nm 24 Nm
11 N m
19 Nm
30 Nm 35 Nm 24 Nm
49 Nm 21 Nm
13 Nm
21 Nm
35 Nm
Removal steps
1. Exhaust manifold heat protector
2. Vacuum hose and vacuum pipe
B3. Air pipe assembly
4. Air control valve gasket
5. Air control valve assembly
6. Engine hangerA7. Air control valve bracket
8. Intake manifold stay
9. Alternator brace stay
10. Intake manifold
11. Intake manifold gasket

ENGINE – Secondary Air System and Intake Manifold11-30
INSTALLATION SERVICE POINTS
AAIR CONTROL VALVE BRACKET INSTALLATION
(1) Attach the air control valve bracket and the engine hanger
to the intake manifold using bolts and nuts with which
the intake manifold is also installed to the engine.
(2) Tighten the bolts and nuts to the specified torque in the
sequence given in the illustration.
BAIR PIPE ASSEMBLY INSTALLATION
(1) Install the air pipe assembly to the exhaust manifold and
to the air control valve and secure it provisionally by
tightening the fasteners handtight.
(2) Tighten the fasteners to the specified torque in the
sequence given in the illustration.
(3)
(2) (1)
(3)
(2)(1)(4)

ENGINE – Exhaust Manifold11-31
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
1
2 3 4
5
67 8
9 1011 1213 14
15
16
17 18 19
9 Nm19 Nm41 Nm16 Nm
12 Nm59 Nm
59 Nm
59 Nm
54 Nm14 Nm 49 Nm
41 Nm
10 Nm10 Nm 11 Nm
29 Nm
30 Nm
Head mark 7: 9 Nm
Head mark 10: 13 Nm
Removal steps
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting
5. Exhaust fitting gasket
6. Air outlet fitting
C7. Air outlet fitting gasket
8. Oil return pipe
B9. Gasket
B10. Oil return pipe gasket
(Oil pan side)11. Oil return pipe gasket
(Turbocharger side)
12. Turbocharger assembly
13. Turbocharger gasket
14. Oil pipe
15. Water pipe
16. Water pipe
17. Turbocharger
A18. Exhaust manifold
19. Exhaust manifold gasket

ENGINE – Exhaust Manifold11-32
INSTALLATION SERVICE POINTS
AEXHAUST MANIFOLD INSTALLATION
Tighten the exhaust manifold mounting nuts to the specified
torque in the sequence given in the illustration.
BGASKET / OIL RETURN GASKET INSTALLATION
EVOLUTION IV AND V
Install the gasket with the silicon-printed side toward the oil
pan and with the tabbed end directed as shown.
EVOLUTION VI
(1) Install the gasket with the tabbed end directed as shown.
(2) Apply sealant to both sides of the oil return pipe gasket
and leave it for 20 minutes to dry before installing. Tighten
the mounting bolts to the specified torque.
Specified sealant:
3M
TM AAD Part No. 8731 or equivalent
NOTE
If mounting bolts with head mark 7 have been used,
be sure to replace them with bolts having head mark
10.
1234 5 6
789
Timing belt side
Oil pan
Oil return
pipe gasket Silicon print
Timing belt side
Oil pan
Oil return
pipe gasket
Oil pan
Oil return
pipe
Gasket

ENGINE – Exhaust Manifold11-33
CGASKET INSTALLATION
Position the projection as shown in the illustration.
Projection

ENGINE – Water Pump and Water Hose11-34
WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION <EVOLUTION VI>
1
2
3 4
5
67 8
9
10 11
12
13
1415 16
14 Nm10 Nm
22 Nm11 Nm
11 Nm 24 Nm 24 Nm
29 Nm 9.8 Nm 13 Nm
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
E5. Water temperature sensor
D6. Water temperature gauge unit
7. Thermostat
8. Water outlet fitting9. Thermostat housing
10. Thermostat housing gasket
A11. O-ring
A12. Water inlet pipe
A13. O-ring
14. Water pump
15. Water pump gasket
16. Knock sensor

ENGINE – Water Pump and Water Hose11-35
REMOVAL AND INSTALLATION <EVOLUTION IV or V>
1
2
3 4
567 8
9 11
12
13
1415 16
14 Nm 22 Nm11 Nm 24 Nm24 Nm
29 Nm 13 Nm
10
13 Nm
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
E5. Water temperature sensor
D6. Water temperature gauge unit
7. Water inlet fitting
8. ThermostatC9. Water outlet fitting
B10. Thermostat housing
A11. O-ring
A12. Water inlet pipe
A13. O-ring
14. Water pump
15. Water pump gasket
16. Knock sensor