belt MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

11-1
ENGINE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SEALANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ADJUSTMENTS 4 . . . . . . . . . . . . . . . . .
1. Drive Belt Tension Check 4 . . . . . . . . . . . . . . .
2. Auto Tensioner Check 5 . . . . . . . . . . . . . . . . . . .
3. Lash Adjuster Check 5 . . . . . . . . . . . . . . . . . . . .
4. Lash Adjuster Replacement 7 . . . . . . . . . . . . . .
5. Ignition Timing Check 7 . . . . . . . . . . . . . . . . . . .
6. Idle Speed Check and Idle Mixture Check 7
7. Compression Pressure Check 7 . . . . . . . . . . . .
8. Manifold Vacuum Check 8 . . . . . . . . . . . . . . . . .
CRANKSHAFT PULLEY 9. . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT
OIL SEAL 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL 15 . . . . . . . . . . . . . .
CYLINDER HEAD GASKET 17 . . . . . . . . . . . .
TIMING BE LT . . . . . . . . . . . . . . 21 . . . .
ENGINE ASSEMB LY 32
. . . . . . . . . . . . . . . . . . .

ENGINE – Special Tools / Engine Adjustments11-4
Tool UseName Number
MB991654Cylinder head bolt
wrenchRemoving and reinstalling the cylinder head
bolt
MD998767Tensioner pulley
socket wrenchTiming belt tension adjustment
Recommended
tool MZ203826
by Anzen
Jidosha or
MZ203827 by
BanzaiEngine lifterSupporting the engine assembly during
removal and installation of the transmission
MD991453Engine hanger
assembly
ENGINE ADJUSTMENTS
1. DRIVE BELT TENSION CHECK
NOTE
Use of the auto tensioner eliminates the need for belt tension
adjustment. Check that the indicator mark on the auto
tensioner is in the range of A shown.
If it is outside the specified range (i.e., in range of B shown),
replace the drive belt.
(For the removal and installation of the drive belt, refer to
P.11-9.)
Auto tensioner
Indicator mark
AB

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 – 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 – 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 – 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 – Timing Belt11-21
TIMING BELT
REMOVAL AND INSTALLATION
1
2
3
4 56
7
8
910
11 1213
14 15
16 171821
22
23
242526
27
28
20
19
11 {1.1}
11 {1.1} 11 {1.1}
88 {9.0}
49 {5.0}
9 {0.9}
48 {4.9}54 {5.5}49 {5.0} 118 {12.0}
9 {0.9}3.5 {0.35}
49 {5.0}
45 {4.6}
19 {1.9}30 {3.1} 24 {2.4}24 {2.4}
Unit: Nm {kgf
m}
Removal steps
1. Front upper cover
2. Front center cover
3. Front lower cover
4. Bracket

AL
5. Timing belt
K
6. Tensioner pulley
7. Tensioner arm
J
8. Auto tensioner
9. Idle pulley
10. Crankshaft position sensor

BI
11. Oil pump sprocket

CH
12. Crankshaft bolt

D13. Crankshaft sprocket
14. Sensing blade15. Tensioner B

EG
16. Timing belt B

FF
17. Counterbalance shaft sprocket
E
18. Spacer

G19. Crankshaft sprocket B
20. Crankshaft key
D
21. Rocker cover
C
22. Semi-circular packing
B
23. Engine support bracket

HA
24. Camshaft sprocket bolt
25. Camshaft sprocket
26. Timing belt rear right cover
27. Timing belt rear left upper cover
28. Timing belt rear left lower cover