check engine MITSUBISHI LANCER EVOLUTION IX 2005 User Guide

ENGINE – TIMING BELT, TIMING BELT B11-20
TIMING BELT, TIMING BELT B
Removal and fitting
Caution
If Brembo brake callipers are being used take care that they are not scratched by other
components or tools because there is a chance that the paint might peel off. In
addition, if any brake fluid gets on the callipers, it should be wiped off immediately.
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Removal and refitting of the LH side cover.
•Checking and adjustment of the tension of the drive belt.
•Removal and refitting of the crankshaft pulley.
•Removal and refitting of the cross member bar.
•Removal and refitting of the front exhaust pipe.
Removal procedure
1. Pressure hose connection
2. Timing belt front upper cover
3. Water pump pulley
4. Idler pulley
5. Drive belt auto-tensioner
6. Timing belt front lower cover•Remove the engine mount bracket
•Adjust the tension of the timing belt

7. Timing belt
8. Tensioner pulley
9. Tensioner arm
10. Auto-tensioner



G 
 
A






F 



E 



D 

ENGINE – TIMING BELT, TIMING BELT B11-22
3. Twist the special tool for adjusting bolts (MD998738) by hand
until it touches the tensioner arm.
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and
then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.
Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
direction (clockwise direction) on the back of the belt.
 
B


Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.
 
C


Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.timing belt tensioner
arm
bolt for fitting the timing belt
tensioner
wire or pin
Crankshaft
sprocket

ENGINE – TIMING BELT, TIMING BELT B
11-23
 
D


Removing timing belt B
Caution
If planning to re-use a timing belt B, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
Fitting guidelines



A 
Fitting timing belt B and the timing belt B tensioner
1. Check that the timing marks for the crankshaft sprocket and the
balancer shaft sprocket are aligned.
2. Fit timing belt B onto the crankshaft sprocket and the balancer
shaft sprocket. Ensure that the side of the belt under tension is
not slack.
3. As a temporary step, fit the timing belt B tensioner pulley so that
its centre is to the upper left of the centre of the mounting bolt,
and so that the flange of the pulley is facing towards the front of
the engine.
4. Adjust the tension of timing belt B.



B 
Adjusting the tension of timing belt B
1. Hold the timing belt B tensioner between fingertips and in the
direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to
timing belt B until the side of the belt under tension becomes
taught. In this condition, tighten the mounting bolt to the
specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m
Caution
When tightening the mounting bolt, ensure that the
tensioner does not turn round with it. If the tensioner turns
with the mounting bolt, it could cause the tension in the belt
to become too high.
timing marks
balancer shaft
sprocket
crankshaft sprocket
side of belt
under tension
timing
marks
centre of the
pulley
centre of the
mounting bolt

ENGINE – TIMING BELT, TIMING BELT B11-24
2.
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
5~7mm
5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3.
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
approx. 100 N
amount of
give
pull lightly with fingertips

ENGINE – TIMING BELT, TIMING BELT B11-26



F 
Fitting the timing belt
1. Check that all the timing marks for the camshaft sprocket, the
crankshaft sprocket and the oil pump sprocket are aligned.
2. After the timing marks for the oil pump sprocket have been
aligned, remove the plug from the cylinder block and insert a
posidrive (+) with a diameter of 8 mm into the plug hole. Check
that more than 60 mm of the shaft of the screwdriver can be
inserted. If the screwdriver strikes the balancer shaft and can
only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one
complete turn, realign the timing marks, and check that more
than 60 mm of the screwdriver can be inserted. Do not remove
the screwdriver until the timing belt has been fitted.
3. Install the timing belt in accordance with the following guidelines
so that the side that is under tension does not get slack.
(1) Fit the timing belt around the crankshaft sprocket first, then
the oil pump sprocket and then fit it around the idler pulley.
(2) Fit the timing belt around the camshaft sprocket (exhaust
side) and hold it in place with a paper clip at the position
shown in the diagram.
timing marks
camshaft
sprocket (inlet
side)
timing
marks
crankshaft
sprocket
camshaft
sprocket
(exhaust
side)
timing
marks
oil pump
sprocket
plug
more than
60 mm
screwdriver
balancer shaft
camshaft
sprocket (inlet
side)
tensioner pulley
crankshaft
sprocket
camshaft
sprocket
(exhaust side)
idler
pulley
oil pump
sprocket
paper
clip

ENGINE – TIMING BELT, TIMING BELT B
11-27
(3) Use a wrench to align the timing marks on the rocker cover and
the camshaft sprocket, and whilst doing so, fit the timing belt
around the camshaft sprocket (inlet side) and hold it in place
with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley.
(5) Remove the two paper clips.
Caution
After the timing belt has been installed, apply some force in
an anti-clockwise direction to the camshaft sprocket and
check once more that all the timing marks are in the correct
position when the side of the belt under tension is taught.
4. Using the special wrench for the tensioner pulley socket
(MD998767), tense the timing belt by turning the tensioner
pulley in the direction shown in the diagram, and temporarily
tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.



G 
Adjusting the tension of the timing belt
1. Remove the rubber plug from the rear cover of the timing belt
and put the special adjusting bolt (MD998738) in position.
Slowly twist the adjusting bolt a little at a time, so that the wire
or pin inserted when fitting the auto-tensioner, only moves a
little.
Caution
There is a possibility that the wire or pin inserted in the
auto-tensioner may break if the adjusting bolt is twisted
with a spanner or a similar tool, so it must be twisted by
hand.
2. Turn the crankshaft a quarter turn in an anti-clockwise direction.
3. Turn the crankshaft in a clockwise direction, realign all the timing
marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had
been temporarily tightened.paper clips

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11.Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the bonnet.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Checking the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.

ENGINE – ENGINE ASSY11-32
 
D


Removing the engine mount bracket & stopper ASSY
1. Support the engine using a garage jack.
2. Remove the special mechanical engine hanger (MZ203830,
MZ203831 or MB991928).
3. Hold the engine ASSY using a chain block.
4. Support the engine oil pan component with the garage jack
through the engine block, so that the weight of the engine is not
taken by the engine mount bracket.
5. Loosen the nuts and bolts and remove the engine mount bracket
and stopper ASSY.
 
E


Removing the engine ASSY
After checking that all of the cables, hoses and harness connectors
etc have been disconnected, slowly hoist the engine using a chain
block and remove the engine from the engine compartment.
Fitting guidelines



A 
Fitting the engine ASSY
Install the engine whilst checking that cables, hoses and harness
connectors etc will not be squashed beneath it.
MZ203830 or MZ203831
slide bracket (HI)

ENGINE – ENGINE ASSY
11-33



B 
Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
(1) (MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2)
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)



C 
Fitting the transfer ASSY and the transmission ASSY
1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).engine sideengine side
engine mount stopper
rear of chassis> front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)

ENGINE – ENGINE ASSY11-34
 
D


Fitting the O-ring and the fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that no engine oil gets inside the deliver pipe.
2. Without damaging the O-ring, fit the fuel high pressure hose to
the delivery pipe by twisting it from left to right. Ensure that the
hose is twisted smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose, to
the specified torque.
Tightening torque: 5.0 ± 1.0 N•m.