belt MITSUBISHI LANCER EVOLUTION VI 1999 User Guide

ENGINE – Timing Belt11-20
GTIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
(3) Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
(4) Move the tensioner “B” in the direction of arrow while
lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B”. When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.
(5) Check to ensure that timing marks on sprockets and front
case are in alignment.
(6) Press with index finger the center of span on the tension
side of timing belt “B”. The bolt must deflect 5 – 7 mm.
HCRANKSHAFT BOLT TIGHTENING
(1) Using the special tool, hold the flywheel or drive plate.
(2) Install the crankshaft pulley in position.
Timing
marks
Timing
marks
(on front
case)

ENGINE – Timing Belt11-21
IOIL PUMP SPROCKET INSTALLATION
(1) Insert a Phillips screwdriver (shank diameter 8 mm shaft)
through the plug hole on the left side of the cylinder
block to block the left counterbalance shaft.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces
of the nuts.
(4) Tighten the nuts to the specified torque.
JAUTO TENSIONER INSTALLATION
(1) If the auto tensioner rod is in its fully extended position,
reset it as follows.
(2) Clamp the auto-tensioner in the vise with soft jaws.
(3) Push in the rod little by little with the vise until the set
hole A in the rod is aligned with the hole B in the cylinder.
(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.
(6) Install the auto tensioner to front case and tighten to
the specified torque.
Caution
Leave the wire installed in the auto tensioner.
KTENSIONER PULLEY INSTALLATION
Install the tensioner pulley in such direction that its two small
holes are arranged vertically.
6EN0564
A
B
6EN1323
Small holes

ENGINE – Timing Belt11-22
LTIMING BELT INSTALLATION
(1) Place the exhaust side camshaft sprocket in a position
where its timing mark is one tooth offset from the timing
mark on the rocker cover in the counterclockwise direction.
NOTE
Even if the timing marks on the sprocket and the rocker
cover are brought into alignment, the exhaust camshaft
is forced back by the valve spring tension. It is stabilized
at a position one tooth before the timing mark.
(2) Align the timing mark on the intake side camshaft sprocket
with that on the rocker cover.
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
(3) Place the timing mark on the crankshaft sprocket one
tooth this side from the mated timing mark as in the case
of the camshaft sprocket.
(4) Align the timing mark on oil pump sprocket with its mating
mark.
(5) Remove the plug on cylinder block and insert a Phillips
screwdriver (shank diameter 8 mm) through the hole
(Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 – 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
screwdriver can be inserted 60 mm or more. Keep the
screwdriver inserted until installation of timing belt is
finished.
Timing mark
Timing mark
6EN1327
Oil pump
sprocket
timing marks
Screwdriver
6EN1026
Plug

ENGINE – Timing Belt11-23
(6) Remove the Phillips screwdriver. Place the oil pump
sprocket in a position where its timing mark is one tooth
offset from the mated timing mark in the counterclockwise
direction.
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
(8) Turn the intake side camshaft sprocket as shown to a
position where its timing mark is one tooth offset from
the mated timing mark in the counterclockwise direction.
Then, fit the timing belt over the sprocket and secure
it with a paper clip.
NOTE
The intake camshaft will be turned a little clockwise by
the valve spring tension and stabilized in position even
if the belt is clipped at one tooth offset position.
(9) Check to ensure that the timing marks on the intake
camshaft sprocket side are in alignment when the exhaust
camshaft sprocket is turned clockwise to align the timing
marks.
NOTE
The timing belt span between the intake and exhaust
sprockets will have 17 cogs.
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
Timing mark
6EN1327
Timing mark
Crankshaft
sprocketOil pump
sprocket

ENGINE – Timing Belt11-24
(11) Fit the timing belt over the tensioner pulley.
NOTE
When fitting the timing belt over the tensioner pulley,
turn the intake side camshaft sprocket a little
counterclockwise, as this will facilitate the work.
(12)Turn the crankshaft pulley a little in the illustrated direction
to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft
sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
(14)Using the special tool, turn the tensioner pulley in the
illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
lightly.
NOTE
There must be no slack in the timing belt between the
intake and exhaust camshafts.
(15)Turn the crankshaft to align the timing mark with the mark
for No. 1 cylinder top dead center in the compression
stroke.
(16)Set the special tool as shown and screw it in up to the
position where the wire inserted in the auto-tensioner
when installing it can be moved lightly.
Crankshaft
sprocket
MD998767
MD998738

ENGINE – Timing Belt11-25
(17)Loosen the retaining bolt of the tensioner pulley.
Caution
Loosening the retaining bolt can cause the intake
and exhaust camshafts to turn, resulting in slackened
timing belt. Use care that the timing belt does not
come off the sprockets at this time.
(18)Pull up the slack of the timing belt by turning the tensioner
in illustrated direction using the special tool and a torque
wrench (0 – 5 Nm).
(19)From this position, turn back the tensioner until the torque
wrench reading becomes 3.5 Nm, then secure it by
tightening the retaining bolt.
(20)Remove the special tool attached in step (16).
(21)Rotate the crankshaft clockwise 2 turns. Then, leave it
intact 15 minutes.
(22)Check to see that the wire inserted when installing the
auto-tensioner can be pulled out lightly. If it can be pulled
out lightly, the timing belt is being tensioned properly.
If so, remove the wire. In addition, check that the rod
protrusion from the auto-tensioner meets the standard
value, which is also an indication of properly tensioned
timing belt.
Standard value: 3.8 – 4.5 mm
(23)If the wire cannot be removed with a light force, repeat
steps (16) through (21) until the proper belt tensioner
is obtained.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
(2) Cracks on rubber back.
(3) Cracks or peeling of canvas.
(4) Cracks on rib root.
(5) Cracks on belt sides.
MD998767

ENGINE – Timing Belt11-26
(6) Abnormal wear of belt sides. The sides are normal if
they are sharp as if cut by a knife.
(7) Abnormal wear on teeth.
(8) Missing tooth.
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace
as necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(4) Press the rod with a force of 98 to 196 N and measure
its protrusion.
(5) If the measured value is 1 mm or more shorter than the
value obtained in step (3), replace the auto tensioner.
12 mm
98 to 196 N
Movement

ENGINE – Exhaust Manifold11-32
INSTALLATION SERVICE POINTS
AEXHAUST MANIFOLD INSTALLATION
Tighten the exhaust manifold mounting nuts to the specified
torque in the sequence given in the illustration.
BGASKET / OIL RETURN GASKET INSTALLATION
EVOLUTION IV AND V
Install the gasket with the silicon-printed side toward the oil
pan and with the tabbed end directed as shown.
EVOLUTION VI
(1) Install the gasket with the tabbed end directed as shown.
(2) Apply sealant to both sides of the oil return pipe gasket
and leave it for 20 minutes to dry before installing. Tighten
the mounting bolts to the specified torque.
Specified sealant:
3M
TM AAD Part No. 8731 or equivalent
NOTE
If mounting bolts with head mark 7 have been used,
be sure to replace them with bolts having head mark
10.
1234 5 6
789
Timing belt side
Oil pan
Oil return
pipe gasket Silicon print
Timing belt side
Oil pan
Oil return
pipe gasket
Oil pan
Oil return
pipe
Gasket

ENGINE – Rocker Arms and Camshaft11-38
INSTALLATION SERVICE POINTS
ALASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto rocker arm without allowing diesel
fuel to spill out.
BCAMSHAFT INSTALLATION
(1) Apply engine oil to the journals and cams of the camshafts.
Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
(2) Install the crankshaft sprocket B or spacer and flange
to one end of the crankshaft, and turn the crankshaft
until the timing marks are lined up, setting No. 1 cylinder
to the TDC.
(3) Set the camshafts so that their dowel pins are positioned
at top.
CBEARING CAP INSTALLATION
(1) According to the identification mark stamped on the top
of each bearing cap, install the caps to the cylinder head.
Only “L” or “R” is stamped on front bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing caps. Rear
bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(2) Tighten the bearing caps in the order shown two to three
times by torquing progressively.
Tighten to the specification in the final sequence.
(3) Check to ensure that the rocker arm is positioned correctly
on the lash adjuster and valve stem end.
Camshaft sprocket side
Slit
Intake side
camshaft
Dowel pin
Cam number
Symbol identifying
intake or exhaust
Timing belt side

ENGINE – Cylinder Head and Valves11-46
BVALVE SPRING INSTALLATION
Direct the valve spring end with identification color toward
the spring retainer.
CRETAINER LOCK INSTALLATION
The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and damage,
the stem seal.
DCYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm
(2) Apply engine oil to the bolt threads and to the washers.
(3) Using the special tool (MB991654) and according to the
tightening sequence, tighten the bolts to the specified
torque.
Tightening torque: 78 Nm
(4) Loosen all bolts fully.
(5) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
MD998772
MD998735
6EN0782
Shank length
Timing belt side