engine MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

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

ENGINE – Crankshaft Oil Seal11-15
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
4
3 2
1
5127 – 137
{13.0 – 14.0}
3
Unit: Nm {kgf
m} Engine oil
5
Crankshaft front oil seal removal
steps
Timing belt and timing belt B
(Refer to P.11-21.)
Crank angle sensor
(Refer to GROUP 16.)
1. Crankshaft sprocket B
2. Key
C3. Crankshaft front oil sealCrankshaft rear oil seal removal
steps
Transmission assembly
Clutch cover and disc
AB4. Flywheel
A5. Crankshaft rear oil seal

ENGINE – Crankshaft Oil Seal11-16
REMOVAL SERVICE POINT
AFLYWHEEL ASSEMBLY REMOVAL
Use the special tool to secure the flywheel assembly and
remove the bolts.
INSTALLATION SERVICE POINTS
ACRANKSHAFT REAR OIL SEAL INSTALLATION
(1) Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
(2) Install the oil seal with the special tool as far as the
chamfered position of the oil seal case as shown in the
illustration.
BFLYWHEEL ASSEMBLY INSTALLATION
Use the special tool to hold the flywheel in the same manner
as removal, and install the bolt. Tighten the bolts to the
specification.
Tightening torque: 127 – 137 Nm {13.0 – 14.0 kgf
m}
CCRANKSHAFT FRONT OIL SEAL INSTALLATION
Apply a small amount of engine oil to the entire circumference
of the oil seal lip.
Pressfit the oil seal until it is flush with the chamfered end
of the oil pump case.
MD998781
Crankshaft
rear oil seal
MB990938
MB998776Crankshaft
Crankshaft
MD998382
Oil seal
MD998285
(Lubricate outer
circumference with oil)

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 Gasket11-18
10 mm
10 mm
10 mm
Semi-drying sealant:
THREEBOND 1207D
29
9 {0.9}
Unit: Nm {kgf
m}
3.4 {0.35}
30 {3.1} 22 {2.2}
9 {0.9}
30 {3.1}
32
33
28
2725
26
2430 23
2122
31
78 → 0 → 20 → +90
→ +90

{8.0 → 0 → 2.0 → +90
→ +90
}
22
22
23
10 mm 10 mm
Removal steps
21. PCV hose connection
22. Rocker cover
23. Semi-circular packing
24. Starter
25. Oil return pipe
C26. Oil return pipe gasket
27. Vacuum tank/solenoid valve/vacuum
hose assembly28. Intake manifold stay
29. Heater hose connection
30. Alternator brace stay mounting bolt
AB31. Cylinder head bolt
32. Cylinder head assembly
A33. Cylinder head gasket