engine MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
July 1998
EVOLUTION-IV
EVOLUTION-V

GENERAL – Models00-2
MODELS

Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
E-CN9ASNDF’97RS4G63 (2,000-DOHC –
16 valves-intercooler
W5M51
(4WD-5M/T)
Electronically
controlledfuel
SRGF’97GSR
16 valves-intercooler
turbo)
(4WD-5M/T)controlled fuel
injection (MPI)

Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
GF-CP9ASNDF’98EVOLUTION-V RS4G63 (2,000-DOHC –
16 valves intercooler
W5M51
(4WD 5M/T)
MPI
SNGF’98EVOLUTION-V
GSR
16 valves-intercooler
turbo)(4WD-5M/T)
Applicable serial numbers
E-CN9A: CN9A – 0000001

GF-CP9A: CP9A – 0000001

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 – Service Specifications / Sealants / Special Tools11-2
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Basic ignition timing5
BTDC ± 3
–
Ignition timing (at idle)Approx. 5
BTDC–
Idle speed rpm850 ± 50–
CO contents %0.6 or less–
HC contents ppm300 or less–
Compression pressure kg/cm2 – rpm11.5 – 250Min. 9.7 – 250
Compression pressure difference of all cylinders kg/cm2–Max. 1.0
Intake manifold vacuum kPa {mmHg}–Min. 55 {410}
Cylinder head bolt shank length mm–99.4
SEALANTS
ItemsSpecified sealants
Rocker coverSemi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g)
Oil panSemi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)
NOTE:
Given in [ ] are MITSUBISHI GENUINE PART numbers.
SPECIAL TOOLS
ToolNumberNameUse
MD998782Valve lifter setReplacing the lash adjuster
MB990767End yoke holderHolding the crankshaft pulley
Holding the camshaft sprocket

ENGINE – Special Tools11-3
Tool UseName Number
MD998719Crankshaft pulley
holder pinHolding the crankshaft pulley
Holding the camshaft sprocket
MD998715Pulley holder pin
MD998713Camshaft oil seal
installerPressfitting the camshaft oil seal
MD998727Oil pan removerRemoving the oil pan
MD998781Flywheel stopperSecuring the flywheel or drive plate
MD998776Crankshaft rear oil
seal installerPressfitting the crankshaft rear oil seal
MB990938Handle
MD998382Crankshaft front oil
seal installerInstalling the crankshaft front oil seal
MD998285Crankshaft front oil
seal guide

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 – 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