timing belt MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

ENGINE OVERHAUL -Timing Belt11B-13
TIMING BELT
REMOVAL AND INSTALLATION
1
11±1N•m
2
3
4 56
7
8
910
11 1213
14 15
16 1718
192021 2223
2425
26
27
2829
30
313233
34
35
49±6N•m
21±4N•m
23±3N•m
11±1N•m11±1N•m
88±10 N•m
35±6N•m
54±5N•m 19±3N•m 46±3N•m 9±1N•m162±5N•m3.5±0.5 N•m
49±9N•m
8.8±1.0 N•m 49±5N•m
Removal steps
1. Timing belt front upper cover
2. Timing belt front center cover
3. Timing belt front lower cover
4. Power steering pump bracket
AA""MA5. Timing belt
"LA6. Tensioner pulley
7. Tensioner arm
"KA8. Auto tensioner
9. Idler pulley
10. Crank angle sensor
AB""JA11. Oil pump sprocket
AC""IA12. Crankshaft bolt
AD""IA13. Crankshaft sprocket
"IA14. Crankshaft sensing blade
15. Tensioner B
AE""HA16. Timing belt B
AF""GA17. Counter balance shaft sprocket
"FA18. SpacerAG""EA19. Crankshaft sprocket B
20. Crankshaft key
21. Breather hose
22. PCV hose
23. PCV valve
24. PCV valve gasket
25. Oil filler cap
"DA26. Rocker cover
"DA27. Rocker cover gasket A
28. Rocker cover gasket B
"CA29. Semi-circular packing
"BA30. Engine support bracket
AH""AA31. Camshaft sprocket bolt
32. Camshaft sprocket
33. Timing belt rear right cover
34. Timing belt rear left upper cover
35. Timing belt rear left lower cover

ENGINE OVERHAUL -Timing Belt11B-14
REMOVAL SERVICE POINTS
AA"TIMING BELT REMOVAL
1. To ensure that the timing belt is assembled in the same
direction when reused, using chalk, etc., make an arrow
showing the rotation direction on the back surface of
the timing belt.
2. Position the exhaust camshaft sprocket’s timing mark by
approx. one tooth before the No. 1 cylinder compression
top dead centre.
Caution
When removed at the compression top dead centre,
since the exhaust camshaft is at the position pressing
down on the valve, the sprocket could rotate in reverse
due to the force of the valve spring creating a
hazardous situation.
3. Loosen the lock nut for the tensioner pulley, and remove
the timing belt.
AB"OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips driver (shaft diameter 8 mm) to stop the
counter balance shaft left from rotating.
3. Loosen the flange bolt.
4. Remove the oil pump sprocket.
AC"CRANKSHAFT BOLT REMOVAL
1. Fix the flywheel with the special tool.
2. Remove the crankshaft bolt.
AD"CRANKSHAFT SPROCKET REMOVAL
Use the special tool to remove the sprocket if it is stuck
and hard to remove.
Timing marks
Phillips driver
MD998781
MD998778

ENGINE OVERHAUL -Timing Belt11B-15
AE"TIMING BELT B REMOVAL
To ensure that the timing belt is assembled in the same
direction when reused, using chalk, etc., make an arrow
showing the rotation direction on the back surface of the
timing belt.
AF"COUNTER BALANCE SHAFT SPROCKET
REMOVAL
1. Fix the counter balance shaft sprocket with the special
tool.
2. Remove the installation bolt of the counter balance shaft.
AG"CRANKSHAFT SPROCKET B REMOVAL
Use the special tool to remove the sprocket if it is stuck
and hard to remove.
AH"CAMSHAFT SPROCKET BOLT REMOVAL
Hold the hexagon part of the camshaft with a wrench, and
remove the camshaft sprocket bolt.
INSTALLATION SERVICE POINTS
"AACAMSHAFT SPROCKET BOLT INSTALLATION
Hold the hexagon part of the camshaft with a wrench, and
tighten the camshaft sprocket bolt at the specified torque
88±10 N•m.
MD998785
MD998778

ENGINE OVERHAUL -Timing Belt11B-16
"BAENGINE SUPPORT BRACKET INSTALLATION
Before tightening, apply sealant on the bolt at the position
shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"CASEMI-CIRCULAR PACKING INSTALLATION
Apply sealant at the position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"DAROCKER COVER/ROCKER COVER GASKET A
INSTALLATION
1. Apply form-in-place gasket on the rocker cover at the
position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
2. Install the rocker cover gasket A onto the rocker cover
before the form-in-place gasket hardens.
10 mm
Semi-circular
packing
Cylinder head10 mm
Timing belt side

ENGINE OVERHAUL -Timing Belt11B-17
3. Apply form-in-place gasket on the rocker cover at the
position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
4. Install the rocker cover onto the cylinder head before
the form-in-place gasket hardens.
"EACRANKSHAFT SPROCKET B INSTALLATION
Clean the crankshaft sprocket B installation surface before
degreasing the crankshaft sprocket B.
NOTE
Always degrease the surface to prevent a drop in the frictional
coefficient at the pressing section caused by the adherence
of oil.
"FASPACER INSTALLATION
1. Apply a slight amount of oil on the outer periphery of
the spacer (oil seal contact section).
2. Insert the spacer from the chamfered side as shown in
the illustration.
Caution
Reversed insertion of the spacer can cause damage
to the oil seal lip.
"GACOUNTER BALANCE SHAFT SPROCKET
INSTALLATION
1. Fix the counter balance shaft sprocket with the special
tool.
2. Tighten the counter balance shaft sprocket installation
bolt at the specified torque 46±3N•m.
"HATIMING BELT B INSTALLATION
1. Align the crankshaft sprocket B and counter balance shaft
sprocket timing marks with the timing mark on the oil
pump case.
2. Attach the timing belt B to the crankshaft sprocket B
and counter balance shaft sprocket.
Do not loosen the belt tension too much at this time.
Timing belt side
Crankshaft sprocket B
Crankshaft
Degrease
Spacer
Oil seal
Chamfer
MD998785
Timing
marks
Timing
marks

ENGINE OVERHAUL -Timing Belt11B-18
3. Confirm that the tensioner B centre and bolt centre are
positioned as shown in the illustration.
4. Apply tension on the timing belt by lifting tensioner B
in the direction of the arrow with a finger, and tension
the tension side until it is “tight”. Fix tensioner B in this
state by tightening the bolt.
NOTE
Make sure that the tensioner B shaft does not rotate
when tightening the bolt. If the shaft rotates, the timing
belt becomes too tense.
5. Connect the special tool (MB991704) to MUT-IIand the
battery.
6. Connect the special tool (MB991668) to MUT-II.
7. Rotate the crankshaft clockwise two turns, and align each
timing mark.
8. Select “Belt Tension Measurement” from the MUT-IImenu
screen.
9. Separate the special tool (MB991668) 10 to 20 mm from
the centre back between the sprockets (shown with an
arrow), and hold so that it is vertical (inclination within
±15_) in respect to the belt.
10. Lightly tap the section shown with an arrow with fingers,
and measure the belt vibration frequency. If the results
are deviated from the standard value, loosen the bolt,
tension the belt again, and then measure the vibration
frequency again. Repeat this step until the standard value
is attained. Tighten the bolt when the standard value
is attained.
Standard value:
ItemWhen
checkWhen
adjustedWhen
replaced
Vibration frequency Hz52 - 9276 - 9276 - 92
Deflection
(Reference value) mm5-105-75-7
Tensioner
B centre
Installation
bolt centre
Timing
belt B
Belt tension side
Tensioner
B
MB991668
15_ 15_
10 - 20 mm

ENGINE OVERHAUL -Timing Belt11B-19
Caution
(1) Measure when the belt’s surface temperature is
close to room temperature.
(2) Make sure that water or oil, etc., do not get on
the mike.
(3) If strong winds contact the mike or if noise is
generated in the area while measuring, a value
that differs from the actual value may be indicated.
(4) If the measurement is carried out with the mike
contacted against the belt, a value that differs
from the actual value may be indicated.
(5) Do not measure while the engine is running.
11. Disconnect MUT-II.
12. When measuring with the deflection amount, press the
centre of the tensed side of timing belt B with your index
finger in the arrow direction, and confirm that the deflection
is between 5 and 7 mm.
"IACRANKSHAFT BOLT/CRANKSHAFT
SPROCKET/CRANKSHAFT SENSING BLADE
INSTALLATION
1. Clean and degrease the crankshaft sprocket, crankshaft
sprocket installation surface of crankshaft and crankshaft
sensing blade, and then install the crankshaft sprocket
and crankshaft sensing blade.
2. Clean the crankshaft bolt hole section.
3. Apply the minimum required amount of engine oil on the
crankshaft bolt section and upper surface of the washer.
4. Fix the flywheel with the special tool.
5. Tighten the crankshaft bolt at the specified torque 162
±5N•m.
Timing
marks
Timing
marks
Deflection
amount
Crank-
shaft
bolt
WasherCrankshaft
sprocketCrankshaft
sensing blade
Crankshaft
Clean
Degrease
MD998781

ENGINE OVERHAUL -Timing Belt11B-20
"JAOIL PUMP SPROCKET INSTALLATION
1. Stop the rotation of the counter balance shaft in the same
manner as for removal.
2. Install the oil pump sprocket.
3. Apply the minimum required amount of engine oil on the
flange nut seat surface.
4. Tighten the flange nut at the specified torque 54±5
N•m.
"KAAUTO TENSIONER INSTALLATION
1. If the auto tensioner rod is in the extended state, set
it with the following steps.
(1) Set the rod of the auto tensioner into a vice so that
it is straight and not inclined.
(2) Press in the rod gradually with the vice, and align
the rod’s set hole A with the cylinder’s set hole B.
(3) Insert a wire (diameter 1.4 mm) into the set holes.
(4) Remove the auto tensioner from the vice.
2. Install the auto tensioner.
Do not remove the wire until the timing belt has been
installed.
"LATENSIONER PULLEY INSTALLATION
Set the tensioner pulley as shown in the illustration.
"MATIMING BELT INSTALLATION
1. Set the timing mark on the exhaust side camshaft sprocket
so that it is deviated by one tooth in the counterclockwise
direction from the timing mark on the rocker cover.
NOTE
Even if the sprocket and rocker cover timing marks are
aligned, the exhaust camshaft will return in the
counterclockwise direction by the force of the valve spring
and will stabilize at a position deviated by one tooth.
Phillips driver
A
B
Tensioner pulley holes
Timing marks

ENGINE OVERHAUL -Timing Belt11B-21
2. Align the timing mark of the intake side camshaft sprocket
to the timing mark on the rocker cover.
NOTE
Even when the sprocket and rocker cover timing marks
are aligned, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
3. Shift and set the crankshaft sprocket timing mark by one
tooth in the counterclockwise direction in the same manner
as the exhaust side camshaft sprocket.
4. Align the oil pump sprocket timing marks.
5. When aligning the oil pump sprocket timing marks, remove
the cylinder block plug, and insert an 8 mm shaft diameter
Phillips driver into the plug hole, and confirm that the
driver shaft can be inserted by 60 mm or more. Do not
remove the Phillips driver until the timing belt has been
attached. If the driver shaft contacts the silent shaft and
only enters 20 to 25 mm, rotate the sprocket once, align
the timing marks again, and then confirm that the Phillips
driver can be inserted by 60 mm or more.
6. Remove the Phillips driver, and set the oil pump sprocket
at a position returned by one tooth in the counterclockwise
direction.
7. Attach the timing belt to the exhaust side camshaft
sprocket, and fix with a paper clip at the position shown
in the illustration.
Timing marks
Phillips driverPlug
Timing
marks

ENGINE OVERHAUL -Timing Belt11B-22
8. Rotate the intake side camshaft sprocket in the
counterclockwise direction. Attach the belt at a position
where the timing mark is deviated by one tooth in the
counterclockwise direction, and then fix with a paper clip.
NOTE
Even if the belt is attached at a position deviated by
one tooth, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
9. Rotate the exhaust side camshaft sprocket in the
clockwise direction, and confirm that the intake side
camshaft sprocket’s timing marks are aligned when the
timing marks are aligned.
10. Attach the timing belt in the order of the idler pulley,
oil pump sprocket and crankshaft sprocket.
NOTE
Attach the timing belt so that it is not deflected.
11. Attach the timing belt to the tensioner pulley.
NOTE
The timing belt can be attached easily to the tensioner
pulley by rotating the intake side camshaft sprocket slightly
in the counterclockwise direction.
12. Rotate the crankshaft sprocket slightly in the clockwise
direction, and remove the timing belt deflection on the
idler pulley side.
13. Confirm that the timing marks on the crankshaft, oil pump
and exhaust camshaft are each deviated by one tooth
in the counterclockwise direction.
Timing marks Timing marks
Crankshaft
sprocketOil pump
sprocket
Crankshaft
sprocket
Crankshaft sprocket