MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

ENGINE – Engine Adjustments11-5
2. AUTO TENSIONER CHECK
(1) Stop the engine from the idle speed and check that the
belt rests within the auto tensioner pulley width.
(2) Remove the drive belt.
(For the removal of the drive belt, refer to P.11-9.)
(3) Fit a spinner handle or similar tool into the tool mounting
hole of the auto tensioner and turn the tensioner clockwise
and counterclockwise to ensure that it does not bind.
(4) If step (1) or (3), or both, have been checked abnormally,
replace the auto tensioner.
(5) Reinstall the drive belt.
3. LASH ADJUSTER CHECK
NOTE
If an unusual knocking noise can be heard immediately after
the engine has started or while it is running and if that is
probably attributable to the lash adjuster, make the following
checks.
(1) Check the engine oil and add or change oil as necessary.
NOTE
(1) If the engine oil level is low, air is taken in through
the oil screen, entering the oil passage.
(2) If the oil level is too high, the cranks agitate oil causing
oil to trap a large amount of air.
(3) Air does not easily separate from a deteriorated oil
that can contain an increased amount of air.
When air trapped in oil for these reasons gets into the
high-pressure chamber of the lash adjuster, the air in
the high-pressure chamber is compressed to shrink the
lash adjuster excessively while the valve is opening,
resulting in an unusual noise occurring. This is the same
symptom developing when the valve clearance is adjusted
to an excessive value.
The problem in this case is gone when air is released
from the lash adjuster.
(2) Start the engine and carry out several cycles (10 or less)
of mild racing*.
If the noise is gone after racing, it indicates that air has
been released from the high-pressure chamber of the
lash adjuster, restoring the lash adjuster to normal
operating conditions.
*: Gradually (extending over a 30-sec. period) increase
the engine speed from idle speed to 3,000 r/min and
then reduce it down to the idle speed gradually
(extending over a 30-sec. period).
NOTE
(1) If the vehicle is parked on a slope for a long time,
the amount of oil in the lash adjuster will decrease,
causing air to get into the high-pressure chamber
when the engine is started.
(2) After the vehicle has been parked for a long time,
oil drains out of the oil passage and it takes a long
time for the oil to reach the lash adjuster. This can
cause air to get into the high-pressure chamber.
Tool mounting hole
Good
MAX
MIN
High-pressure
chamber

ENGINE – Engine Adjustments11-6
(3) If the noise is not eliminated by racing, follow these steps
to check the lash adjuster.
a. Stop the engine.
b. Bring no. 1 cylinder to TDC on the compression stroke.
c. Push the rocker arms indicated by arrow A on the
left to see if they go down.
d. Slowly turn the crankshaft clockwise 360
.
e. Perform the same step as step c for rocker arms
indicated by arrow B.
f. Push the part of the rocker arm which contacts the
top of the lash adjuster. If the rocker arm can be
easily moved down to the bottom, the lash adjuster
is defective, requiring replacement.
When the lash adjuster is replaced, be sure first to
bleed the lash adjuster of air before installation. Then,
perform steps a through e to ensure that no abnormal
symptoms are noted.
NOTE
(1) The leak-down test is an effective means to
accurately determine if the lash adjuster is
operational or not.
(2) For the leak-down test and bleeding procedures,
refer to ENGINE WORKSHOP MANUAL.
If the rocker arm is felt binding and cannot be
pushed downward as you push it, the lash adjuster
is operational. Check for other possible causes
for the noise.
(4) Lash adjuster replacement
Caution
From the cylinder from which the lash adjuster is
to be removed, turn the crankshaft to lower the piston,
as the valve contacts the piston when pushed down.
A rocker arm cannot be removed if it is lifted by the
cam. If this is the case, turn the crankshaft so that
the arm is not lifted.
a. Using the special tool, push the valve downward to
remove the roller rocker arm.
b. Remove the lash adjuster from the cylinder head.
c. Mount a brandnew lash adjuster which has been bled
of air in the cylinder head.
d. Using the special tool, lower the valve and install
the roller rocker arm.
NOTE
To mount the roller rocker arm, first place the pivot
side of the rocker arm on the lash adjuster, then push
down the valve; next, place the slipper side of the
rocker arm on the valve system side.Timing belt side
ABABAA B B
MD998782
MD998782

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 – Engine Adjustments11-8
(5) Set compression gauge to one of the spark plug holes.
(6) Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value
(at engine speed of 250 r/min): 11.5 kg/cm
2
Limit (at engine speed of 250 r/min): 9.7 kg/cm2
(7) Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 1.0 kg/cm
2
(8) If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps (5) through (7).
a. If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
b. If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
(9) Connect the crank angle sensor connector.
(10)Install the spark plugs.
(11) Install the ignition coil and connect the ignition coil
connector.
(12)Erase the diagnosis codes by keeping the battery minus
(–) cable disconnected for more than 10 seconds.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
8. MANIFOLD VACUUM CHECK
(1) Before inspection, set the vehicle to the pre-inspection
condition.
(2) Connect a tachometer connector.
(3) Attach a three-way union to the vacuum hose between
the fuel pressure regulator valve and the intake manifold,
and connect a vacuum gauge.
(4) Start the engine and check that idle speed is within
standard value.
Standard value: 850 ± 50 r/min
5. Check the manifold vacuum at idling.
Limit: Min. 55 kPa {410 mmHg}
Compression gauge
Vacuum gauge
Fuel pressure
regulator valve

ENGINE – Crankshaft Pulley11-9
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
Under Cover RemovalPost-installation Operation
Drive Belt Tension Adjustment (Refer to P.11-4.)
Under Cover Installation
1
2
25 {2.5}
Unit: Nm {kgf
m}
Removal steps
A1. Drive belt
2. Crankshaft pulley
REMOVAL SERVICE POINT
ADRIVE BELT REMOVAL
(1) Align the hole in the auto tensioner bracket with that
in the arm and insert a screwdriver into the holes.
(2) Remove the drive belt.
Phillips
screwdriver
Hole in arm
Auto tensioner
Hole in bracket

ENGINE – Camshaft and Camshaft Oil Seal11-10
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
(1) Engine Coolant Draining and Refilling
(2) Air Hose C Removal and Installation
(Refer to GROUP 15 – Intercooler.)
(3) Spark Plug Cable and Ignition Coil Assembly Removal
and Installation(4) Air Pipe Removal and Installation
(Refer to GROUP 15 – Air Control Valve.)
(5) Timing Belt Removal and Installation
(Refer to P.11-21.)
22 {2.2}
Unit: Nm {kgf
m}
10 {1.0}9 {0.9}
3.4 {0.35}
20 {2.0}
88 {9.0} 12 – 15 {1.2 – 1.5}
1
53 4
6
2
14
15
17 16
13
12
11 10 9 8 7
Removal steps
1. Breather hose connection
2. PCV hose connection
3. Crank angle sensor bracket con-
nection
4. Control harness connection
5. Rocker cover
6. Radiator upper hose connection
7. Cover
E8. Cam position sensing cylinder9. Cam position sensor support
10. Semi-circular packing
AD11. Camshaft sprocket
C12. Camshaft oil seal
B13. Front cam cap
B14. Rear cam cap
B15. Cam cap
A16. Camshaft (exhaust side)
A17. Camshaft (intake side)

ENGINE – Camshaft and Camshaft Oil Seal11-11
Grease and adhesive application points
Timing belt side
Semi-drying sealant: THREEBOND 1207D
Lip 10 mm
10 mm10 mm
Semi-drying sealant:
THREEBOND 1207FEngine oil
Semi-drying sealant: THREEBOND 1207DTiming belt side
26
φ 3 mm
REMOVAL SERVICE POINT
ACAMSHAFT SPROCKET REMOVAL
INSTALLATION SERVICE POINTS
ACAMSHAFT INSTALLATION
(1) Apply engine oil to the cams and journals of the camshaft.
(2) Mount the camshaft on the cylinder head.
Caution
Make sure that the camshaft has a unique orientation
for installation, the intake side and exhaust side. The
exhaust camshaft has a slit in the rear end face.
MB990767
MD998719
Camshaft sprocket side
Camshaft (exhaust side)Slit

ENGINE – Camshaft and Camshaft Oil Seal11-12
BCAM CAP / REAR CAP / FRONT CAM CAP
INSTALLATION
(1) Locate the camshaft dowel pins as illustrated.
(2) Temporarily tighten cam cap in two to three steps, then
torque it to specification.
Tightening torque: 20 Nm {2.0 kgf
m}
CCAMSHAFT OIL SEAL INSTALLATION
(1) Apply engine oil to the entire periphery of the oil seal
lip.
(2) Pressfit the oil seal as shown.
DCAMSHAFT SPROCKET INSTALLATION
As you did during removal, secure the camshaft sprocket
with the special tool and tighten bolt to specification.
Tightening torque: 88 Nm {9.0 kgf
m}
ECAM POSITION SENSING CYLINDER
Install the cam position sensing cylinder so that the ID paint
on the cam position sensing cylinder is 90
with respect to
the camshaft dowel pin as shown.
Intake side Approx. 12
Dowel pin
Exhaust side
MD998713
ID paintDowel pin
90

ENGINE – Oil Pan11-13
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
(1) Under Cover Removal and Installation
(2) Front Exhaust Pipe Removal and Installation
(Refer to GROUP 15.)(3) Oil Level Gauge Removal and Installation
(4) Engine Oil Draining and Supplying
A: 6 × 8 mm
B: 6 × 10 mm
Identification of bolt location
Semi-drying sealant: THREEBOND 1207Dφ 4 mm
Bolt
hole
Groove
8
AB
B 8
B
B B
3
78
6 451 2
39 {4.0}
39 – 44 {4.0 – 4.5}7 {0.7}26 {2.6}30 {3.1} 9 {0.9}
Washer
assembled bolt
9 {0.9}
Flange bolt
10 {1.0}
Unit: Nm {kgf
m}
Removal steps
1. Starter
2. Oil return pipe
B3. Oil return pipe gasket
4. Engine oil cooler return pipe5. Bell housing cover
6. Drain plug
A7. Drain plug gasket
A8. Oil pan

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