check oil MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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 – CAMSHAFT, VALVE STEM SEAL
11 - 9
Removal guidelines
 
A


Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.
 
B


Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.
 
C


Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.
Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.
Fitting guidelines



A 
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Indicator marks
Colour of main
body: greyColour of main
body: grey/green
Inlet sideExhaust side
Valve
Valve guide
Valve stem
seal

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 11
2. Because camshaft bearing caps Nos. 2~5 are the same shape,
check the identification marks on them so that the bearing cap
number and the inlet and exhaust sides are not mistaken. Then
fit them in the direction shown in the diagram.
Identification marks (stamped on the front bearing cap, and on
bearing cap Nos. 2~5).
I: inlet side
E: exhaust side
3. Apply sealant at the 8 places shown in the diagram of the top
view of the cylinder head.
Semi-dry sealant: Three bond 1207D
4. Fit the rear camshaft bearing cap in the direction indicated by
the front mark.
5. In just the same way as for bearing caps Nos. 2~5, check the
identification marks on the front camshaft bearing cap so that
the exhaust side and the inlet side are not mistaken.
6. Tighten the bearing cap mounting bolts gradually, 2~3 turns at a
time, to the specified torque.
Tightening torque: 20 ± 1 N•m
7. Check that the rocker arm has been fitted correctly.
Note
Completely wipe away any sealant that has been squeezed out.



G 
Fitting the camshaft oil seal
1. Apply engine oil around the entire circumference of the oil seal
lip.
2. Insert the oil seal using the special tool for installing the
camshaft oil seal (MD998713), as shown in the diagram.
Front of
engine
bearing cap No.
mark indicating
inlet side or
exhaust side
Front of engine

Front
of
engine
Front
of
engine
front mark

front mark
camshaft oil seal
(engine oil)

ENGINE – CAMSHAFT, VALVE STEM SEAL11-12



H 
Fitting the camshaft sprocket (inlet side)
1. Apply engine oil to the edges of the camshaft, and to the parts
of the camshaft sprocket which will make contact with the
camshaft.
2. Match up the camshaft dowel pins with the dowel pin holes in
the camshaft sprocket, and fit the camshaft into the camshaft
sprocket.
3. Hold the hexagonal part of the camshaft with a wrench, and
check that the camshaft sprocket cannot be twisted.
Note
This operation is necessary because it is impossible to check by
looking whether the camshaft dowel pins are inserted into the
dowel pin holes in the camshaft sprocket.
4. Apply engine oil to the screw thread and the underside of the
camshaft sprocket mounting bolt, and in the same way as when
the camshaft sprocket was removed, hold the camshaft in place
using a wrench and tighten the bolt to the specified torque.
Tightening torque: 65 ± 5 N•m



I 
Fitting the camshaft sprocket (exhaust side)
In the same way as when the camshaft sprocket was removed,
hold the hexagonal part of the camshaft with a wrench and
tighten the bolt to the specified torque.
Tightening torque: 89 ± 9 N•m



J 
Fitting the camshaft position sensor support
1. Remove any sealant from the camshaft position sensor support.
2. As shown in the diagram, apply sealant to the flange of the
camshaft position sensor support, and then fit it to the cylinder
head.
Semi-dry sealant: Three bond 1207F
3. Tighten the mounting bolts for the camshaft position sensor
support to the specified torque.
Tightening torque: 14 ± 1 N•m
Front of
engine(engine oil)
(engine oil)
camshaft
sprocket
camshaft
sprocket
Front of
engine

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 – CYLINDER HEAD GASKET
11-17
Removal guidelines



A 
Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn
the bolts 2~3 times in order to loosen them, before removing them
in the numerical order as shown in the diagram.
Fitting guidelines



A 
Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of
the gasket.
Caution
Do not allow any foreign matter to get into the channels for
coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the
holes in the cylinder head gasket match up with the holes in the
cylinder head.



B 
Fitting the cylinder head bolts
1. Check that the length of the body of cylinder head bolts is less
than the maximum permitted. If the length is in excess of the
maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the
bolt, and to the washer.
Front of engine
(engine oil)

ENGINE – CYLINDER HEAD GASKET11-18
3. Use the special wrench for cylinder head bolts (MB991654) to
(loosely) tighten the bolts in the following order.
(1) In the order shown in the diagram, tighten the bolts to
78 ± 2 N•m.
(2) In reverse order to that shown in the diagram, completely loosen
the bolts.
(3) In the order shown in the diagram, tighten the bolts to
20 ± 2 N•m.
(4) Make a paint mark on the top of the cylinder head bolt, and on
the cylinder head, and tighten them to 90° as shown in the
diagram.
(5) Tighten the bolts to 90° as shown in the diagram, and check that
the paint mark on the top of the cylinder head bolt and the paint
mark on the cylinder head are in line.
Caution
1) If a bolt is tightened to an angle of less than 90° it has not
been tightened sufficiently.
2) If the angle of tightening exceeds the regulation level,
remove the bolt and start again from procedure number (1).



C 
Fitting the O-ring/fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that engine oil does not get inside the delivery pipe.
2. Without damaging the O-ring, twist the fuel high pressure hose
to fit it to the delivery pipe, making sure that it 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.
Front of engine
Procedure number (4)Procedure number (5)
paint markpaint mark

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 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, 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.