radiator MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 5



O 



O 
Removal procedure
1. Oil feeder control valve connector
2. Oil feeder control valve
3. O-ring
4. Breather hose
• Secondary air control valve
(refer to Section 15-2: Secondary Air
Control System)
5. Centre cover
• Ignition coil
6. O
2sensor connector
7. Crank angle sensor connector8. Connection of the control harness
9. Vacuum hose
10. PCV hose
11.Connection of the radiator upper hose
12. Camshaft position sensor connector
(exhaust side)
13. Camshaft position sensor connector
(inlet side)
14. Connection of the earth cable
15. Rocker cover ASSY
16. Spark plug hole gasket
17. Rocker cover gasket
 
A






N 



M 

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
11-13



K 
Fitting the camshaft position sensing cylinder (inlet
side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



L 
Fitting the camshaft position sensing cylinder (exhaust
side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
Note
Under pressure from the exhaust valve spring, it will turn slightly
in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position
approximately 45° to the exhaust camshaft dowel pin.
3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



M 
Fitting the locker cover assembly
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.
Semi-dry sealant: Three bond 1207D
2. Fit the rocker cover assembly onto the cylinder head.



N 
Connecting the radiator upper hose
1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose. dowel pin
pane
pane (small)
dowel pin approx. 45º
pane (large)
Front of engine
Protrusion
water outlet
fittingindicator marks

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 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 ASSY
11-31
Removal guidelines
 
A


Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, and remove the drive belt.
Caution
If planning to re-use the drive belt, 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.
 
B


Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
 
C



Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
AholeB hole
L-shaped
hex-
agonal
Allen
wrench

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 COOLING – WATER HOSE AND PIPE
14-3
Water hose and pipe
Removal and fitting
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence
•Draining and refilling of the water coolant
•Removal and refitting of the air cleaner ASSY
•Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C
•Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system)
Removal procedure
1. Connection to the radiator upper hose
2. Connection to the radiator lower hose
3. Water temperature gauge unit connector
4. Water temperature sensor connector
5. Water hose
6. Bracket
7. Water outlet fitting and thermostat case
ASSY
8. Thermostat case gasket
9. Connection to the knock sensor harness
clamp
10. O-ring
11. Water hose12. Water hose
13. Connection to the heater hose
14. Water hose
15. Water inlet pipe
16. O-ring
17. Turbocharger water feed pipe
18. Gasket
•Turbocharger ASSY
19. Turbocharger water return pipe
20. Gasket
 
A






B 
 
A






B 



A 




A 



A 

ENGINE COOLING – WATER HOSE AND PIPE14-4
Removal guidelines
 
A


Removing the radiator upper hose and the radiator
lower hose
Mark the radiator hose and the hose clamp with indicator marks
and then remove the radiator hose.
Fitting guidelines



A 
Fitting the O-ring and the water inlet pipe
Fit the O-ring into the groove at the end of the water inlet pipe, and
insert it after moistening with water the places where the O-ring and
the water inlet pipe will be in contact.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.



B 
Connecting the radiator lower hose and the radiator
upper hose
1. Insert the hose as far as the protrusion on the water inlet pipe
and the water outlet fitting.
2. Match up the indicator marks on the radiator hose and the hose
clamp, and fit the radiator hose.
indicator marks
water pump and
thermostat case
O-ring
water inlet pipe
protrusion
water inlet pipe and
water outlet pipe fittingindicator marks

INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER15-8
Exhaust manifold and turbocharger
Removal and fitting
Jobs to be completed before removal and after
fitting
• Removal and refitting of the valence
• Removal and refitting of the radiator
• Removal and refitting of the air intake hose and
air hose A• Removal and refitting of the cross member bar
• Removal and refitting of the front exhaust pipe
• Draining and refilling of the engine oil