belt MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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W
ARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
W arning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fi\
tted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitt\
ed seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensio\
ner fitted seatbelts and the clock spring, should be removed if there is a chance o\
f them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be rem\
oved.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-\
SRS air bags) has been carefully studied.

ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS
11 - 1
SECTION 11
ENGINE
CONTENTS
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
Servicing standards
General .......................................................1
Servicing standards .................................1
Sealants .....................................................1
Special tools ..............................................2
Engine tuning .............................................4
1. Checking of revolutions when idling ................4
2. Checking compression pressure.......................4
Camshaft, valve stem seals .....................4
Cylinder head gaskets.............................14
Timing belt, timing belt B ........................20
Engine ASSY ............................................28





Sealants

Note
The code inside the brackets ( ) is the actual product number.

ENGINE – SPECIAL TOOLS11 - 2
Special tools
ToolNumber NameFunction
MB991502MUT-II Sub
ASSYChecking and adjusting the tension in
timing belt B
Note
If a MUT-III main harness A is
connected to a vehicle not fitted with
CAN, there is a chance that a pulse
signal will be entered in the simulated
vehicle speed line, when the MUT-III is
activated. Therefore, use a MUT-III main
harness B with vehicles not fitted with
CAN.
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826MUT-III Sub ASSY
A: Vehicle
Communication
Interface (VCI)
B: USB cable
C: MUT-III Main
harness A
(For vehicles
fitted with CAN)
D: MUT-III Main
harness B
(For vehicles
not fitted with
CAN)
E: Adaptor
F: Trigger harness
MB991668
A: MB991969
B: MB991670Belt tension meter
set
A: Tension meter
cartridge
B: Mic ASSY• Checking the tension in the drive belt.
(Use in conjunction with VCI)
• Checking the tension in the balancer
timing belt.
Adjusting (Use in conjunction with VCI)
MD998772Valve spring
compressorCompression of the valve spring.
DO NOT USE

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL11 - 4
Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting
Caution
1. 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.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
ToolNumberNameFunction
MB991454Engine hanger
balancerHolding the engine assembly while the
transmission assembly is removed/installed
Recommended
tools MZ203830
panzai or
MZ203831 safe
vehicle handlingMechanical engine
hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934Engine hanger
A: joint (50) x2
B: joint (90) x2
C: joint (140) x2
D: Foot (standard) x4
E: Foot (short) x4
F: Chain and hook
ASSYSlide bracket (HI)

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14



O 
Fitting the O-ring/oil feeder control valve
Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
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 strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Check 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.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape

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 B
11-21
10. Power steering oil pressure switch connector
11.Heat protector
12. Power steering oil pump ASSY
13. Power steering oil pump bracket
14. Idler pulley
15. Crank angle sensor16. Crankshaft sprocket
17. Crankshaft sensing blade
•Adjust the tension of the timing belt B

18. Timing belt B tensioner
19. Timing belt B
Removal guidelines
 
A


Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all
the timing marks until the No.1 cylinder is in the compressor top
dead centre position.
Caution
Turn the crankshaft in the normal way.
2. Remove the rubber plug from the rear cover of the timing belt,
and prepare the special tool for adjusting bolts (MD998738).
 
C






C 



C 



B 



A 
 
D






A 


B


(engine oil)
Timing marks
Timing belt
valence

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