On-Vehicle Service - 2.0l (except Evolution & Sportback) Mitsubishi Lancer Evolution VIII

GENERAL DESCRIPTION

The 4G94 (2.0L) engine is an in-line four-cylinder engine. The cylinder numbers are assigned as 1-2-3-4 from the front of the engine (timing belt side).

This engine's firing order is 1,3,4,2.

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Scheme 336

Scheme 337

Generator Drive Belt Tension Check

< When using scan tool MB991958>

Required Special Tools

1. MB991668: Belt Tension Meter Set
2. MB991958: Scan Tool (MUT-III Sub Assembly MB991824: V.C.I. MB991911: MUT-III Main Harness B

Scheme 338

Scheme 339

1. Connect special tool MB991668 to scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Turn the ignition switch to the "ON" position and select scan tool MB991958 "Belt Tension Measurement" from the menu screen.
4. Hold special tool MB991668 (microphone) near the center of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm (0.4 - 0.8 inch) away from the rear surface of the belt and perpendicular to the belt (within an angle of +/- 15 degree angle). CAUTION: The temperature of the surface of the belt should be as close as possible to underhood temperature. Do not let any contaminants such as water or oil get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
5. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Standard value: < When using scan tool MB991958> Required Special Tools: MB991668: Belt Tension Meter Set MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B

Scheme 340

Scheme 341

Scheme 342

1. Connect special tool MB991668 to scan tool MB991824.
2. Connect scan tool MB991911 to scan tool MB991824.
3. Connect scan tool MB991911 to the data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt Tension" from the menu scan tool MB991824 screen.
5. Hold special tool MB991668 (microphone) near the center of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm (0.4 - 0.8 inch) away from the rear surface of the belt and perpendicular to the belt (within an angle of +/- 15 degree angle). CAUTION: The temperature of the surface of the belt should be as close as possible to underhood temperature. Do not let any contaminants such as water or oil get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
6. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard values. Standard value

< When using the tension gauge>

Use a belt tension gauge to check that the belt tension is within the standard value.

Scheme 343

Standard value

Scheme 344

< Belt deflection check>

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Scheme 345

Standard value

Scheme 346

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Scheme 348

1. Loosen the nut of the generator pivot bolt.
2. Loosen the lock bolt.
3. Turn the adjusting bolt to adjust the belt vibration frequency, belt tension or deflection to the standard value. CAUTION: Check after turning the crankshaft one or more rotations clockwise. Standard value
4. Tighten the lock bolt. Tightening torque: 23 +/- 2 N.m (16 +/- 2 ft-lb
5. Tighten the nut of the generator pivot bolt. Tightening torque: 44 +/- 10 N.m (33 +/- 7 ft-lb)
6. Tighten the adjusting bolt. Tightening torque: 5.0 +/- 1.0 N.m (44 +/- 8 in-lb)

Scheme 349

Check the drive belt tension by the following procedure.

< When using scan tool MB991502 or MB991958>

Required Special Tools

1. MB991502: Scan Tool (MUT-II)
2. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B
3. MB991668: Belt Tension Meter Set

Gently tap the middle of the belt between the pulleys (the location indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Note. Refer to ON-VEHICLE SERVICE for details on the method of measuring the vibration frequency using the scan tool.

< When using a tension gauge>

Use a belt tension gauge to check that the belt tension is within the standard value.

< Belt deflection check>

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value

Scheme 350

If the tension or deflection is outside the standard value, adjust by the following procedure.

Scheme 351

1. Loosen the tension pulley fixing nut A behind the tension pulley.
2. Adjust the belt deflection amount using the adjusting bolt B.
3. Tighten the fixing nut A. Tightening torque: 26 +/- 4 N.m (19 +/- ft-lb) CAUTION: Check after turning the crankshaft one or more rotations clockwise.
4. Check the belt deflection amount and tension, and readjust if necessary.

IGNITION TIMING CHECK

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

Scheme 352

1. Before checks, set the vehicle in the following conditions: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks. CAUTION: To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Set up a timing light.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 700 r/min.
6. Select scan tool MB991958 MFI actuator test "item number 17."
7. Check that basic ignition timing is within the standard value. Standard value: 5° BTDC +/- 3°
8. If the basic ignition timing is not within the standard value, check the following items: Is the MFI system diagnostic trouble code is output Timing belt cover and crankshaft position sensor installation conditions Crankshaft sensing blade condition CAUTION: If the actuator test is not canceled, the forced drive will continue for 27 minutes. Driving in this state could lead to engine failure.
9. Press the clear key on scan tool MB991958 (select forced-drive stop mode), and cancel the actuator test.
10. Check that the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC NOTE: Ignition timing fluctuates about +/- 7° Before Top Dead Center, even under normal operating condition. NOTE: It is automatically further advanced by about 5° to 10°Before Top Dead Center at higher altitudes.

IDLE MIXTURE CHECK

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

Scheme 353

1. Before checks, set the vehicle in the following conditions: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks. CAUTION: To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Confirm basic ignition timing is within the standard value. Refer to «IGNITION TIMING CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-20l-except-evolution-sportback__ignition-timing-check) . Standard value: 5° BTDC +/- 3°
4. Increase engine speed to 2,500 r/min for 2 minutes.
5. Set the CO/HC tester.
6. Check the CO and HC contents at idle. Standard value: CO contents: 0.5 % or less HC contents: 100 ppm or less
7. If the CO and HC contents do not remain inside the standard value, check the following items: If the MFI system diagnostic trouble code is output Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) Fuel pressure Injector(s) Ignition coil, spark plug cable, spark plug EGR system and EGR valve leak Evaporative emission system Compression pressure NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items.

CURB IDLE SPEED CHECK

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

Scheme 354

1. Before checks, set the vehicle in the following conditions: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks. CAUTION: To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Confirm basic ignition timing is within the standard value. Refer to «IGNITION TIMING CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-20l-except-evolution-sportback__ignition-timing-check) . Standard value: 5° BTDC +/- 3°
4. Start the engine.
5. Run the engine at idle for 2 minutes.
6. Check the idle speed. Select MFI service data item number 22 and take a reading of the idle speed. Curb idle speed: 700 +/- 100 r/min NOTE: The idle speed is controlled automatically by the idle air control system.
7. If the idle speed is outside the standard value, refer to «MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) .

Scheme 355

Scheme 356

1. Before checks, check that the engine oil, starter and battery are normal. Also, set the vehicle to the following conditions: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is not problem for checks.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crankshaft position sensor connector. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection. WARNING: Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury.
5. Cover the spark plug holes with a shop towel etc. Crank the engine for a few seconds to clear debris from a round the spark plug holes. After the engine has been cranked, check for foreign material adhering to the shop towel.
6. Install the compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 200 r/min): 1,618 kPa (234 psi) Minimum limit (at engine speed of 200 r/min): 1,176 kPa (170 psi)
8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: 98 kPa (14 psi)
9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8. If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.
10. Connect the crankshaft position sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the scan to erase the diagnostic trouble codes. NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected. NOTE: If the negative (-) cable has been disconnected from the battery terminal in order to erase the diagnostic trouble code, operate the engine at idle for approximately 10 minutes after restarting.

Scheme 357

1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 - 95°C (176 - 203°F).
2. Connect an engine tachometer.
3. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and connect a vacuum gauge to the ventilation hose.
4. Plug the PCV valve.
5. Start the engine and check that idle speed is within specification. Then check the vacuum gauge reading. Idle speed: 700 +/- 100 r/min Minimum limit: 60 kPa (18 in.Hg)

Scheme 358

1. Remove the timing belt upper cover.
2. Turn the crankshaft clockwise to set the No. 1 cylinder to the top dead compression center. CAUTION: As the purpose of this procedure is to apply the proper amount of tension to the timing belt by means of the cam drive torque, be sure not to rotate the crankshaft counterclockwise.
3. Remove the access cover.
4. Loosen the timing belt tensioner fixing bolt to apply tension to the belt by means of the force of the tensioner spring. CAUTION: Loosen the bolt 1/4 to 1/2 turn. If the belt is loosened more than necessary, the bolt may fall inside the cover.
5. Tighten the timing belt tensioner fixing bolt.
6. Install the access cover.
7. Install the timing belt upper cover.

LASH ADJUSTER CHECK

If an abnormal nose (chattering noise) is heard by malfunction of the lash adjuster immediately after starting the engine and does not disappear, it might be the lash adjusters. Perform the following check.

Note. An abnormal noise due to malfunction of the lash adjuster is produced immediately after starting the engine and changes with the engine speed, irrespective of the engine load. If the abnormal noise is not produced immediately after starting the engine or does not change with the engine speed, or it changes with the engine load, the lash adjuster is not the cause for the abnormal noise.

Note. When the lash adjuster is malfunctioning, the abnormal noise is rarely eliminated by running the engine at idle speed. However, the abnormal noise may disappear only when seizure is caused by oil sludge in the engine whose oil is not maintained properly.

1. Start the engine.
2. Check if the abnormal noise produced immediately after starting the engine changes with the change in the engine speed. If the abnormal noise is not produced immediately after starting the engine or it does not change with the engine speed, the lash adjuster is not the cause for the noise. Therefore, investigate other cause. The abnormal noise is probably caused by some other parts than the engine proper if it does not change with the engine speed. (In this case, the lash adjuster is in good condition.)
3. With the engine idling, change the engine load (shift from N to D range, for example) to make sure that there is no change in the level of abnormal noise. If there is a change in the level of abnormal noise, suspect a tapping noise due to worn crankshaft bearing or connecting rod bearing. (In this case, the lash adjuster is in good condition.)
4. After completion of warm-up, run the engine at idle to check for abnormal noise. If the noise is reduced or disappears, clean the lash adjuster. Refer to INSPECTION under «ROCKER ARMS AND CAMSHAFT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#overhaul-24l-sportback) . It is suspected that the noise is due to collapse of the lash adjuster. If there is no change in the level of the abnormal noise, proceed to step 5.
5. Run the engine to bleed the lash adjuster system. Refer to INSPECTION under «ROCKER ARMS AND CAMSHAFT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#overhaul-24l-sportback) .
6. If the abnormal noise does not disappear after air bleeding operation, clean the lash adjuster. Refer to INSPECTION under «ROCKER ARMS AND CAMSHAFT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#overhaul-24l-sportback) .

Bleeding lash adjuster system

Note. Parking the vehicle on a grade for a long time may drain oil from the lash adjuster, causing air to enter the high pressure chamber when starting the engine.

Note. After parking for many hours, oil may drain from the oil passage and take time before oil is supplied to the lash adjuster, causing air to enter the high pressure chamber.

Note. In the above cases, abnormal noise can be eliminated by bleeding the lash adjuster system.

Scheme 359

Scheme 360

Scheme 361

1. Check engine oil. Add or change oil as required. NOTE: If the engine oil level is low, air is sucked from the oil screen, causing air to enter the oil passage. NOTE: If the engine oil level is higher than specification, oil may be stirred by the crankshaft, causing oil to be mixed with air creating aerated (foaming) oil. NOTE: If oil is deteriorated, air is not easily separated from oil, increasing the quantity of air contained in oil. NOTE: If air mixed with oil enters the high pressure chamber inside the lash adjuster from the above causes, air in the high pressure chamber is compressed excessively while the valve is being opened, resulting in an abnormal noise when the valve closes. This is the same phenomenon as that observed when the valve clearance has become excessive. The lash adjuster can resume normal function when air entered the lash adjuster is removed.
2. Idle the engine for one to three minutes to warm it up.
3. Repeat the operation pattern (Scheme 362), at no load to check for abnormal noise. (Usually the abnormal noise is eliminated after repetition of the operation 10 to 30 times. If, however, no change is observed in the level of abnormal noise after repeating the operation more than 30 times, suspect that the abnormal noise is due to some other factors.)
4. After elimination of abnormal noise, repeat the operation shown in left figure five more times.
5. Run the engine at idle for one to three minutes to make sure that the abnormal noise has been eliminated.

REMOVAL AND INSTALLATION

Scheme 362

Scheme 363

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991527: Hanger
3. MB991895: Engine Hanger
4. MB991928: Engine Hanger

<< A>> POWER STEERING OIL PUMP AND BRACE ASSEMBLY REMOVAL

Remove the power steering oil pump and brace assembly from the engine with the hose attached.

Note. Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<< B>> A/C COMPRESSOR REMOVAL

Remove the compressor from the compressor bracket with the hose still attached.

Note. Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<< C>> RADIATOR UPPER HOSE/RADIATOR LOWER HOSE REMOVAL

After alignment marks are made on radiator hoses and hose clamps, remove hoses.

<< D>> TRANSAXLE ASSEMBLY REMOVAL

< M/T>: Refer to TRANSAXLE ASSEMBLY .

< A/T >: Refer to TRANSAXLE ASSEMBLY .

Scheme 364

Scheme 365

Scheme 366

1. Support the engine with a floor jack.
2. Remove the following special tool. < Special tool MB991895 is used> Remove special tool MB991895. < Special tool MB991928 is used> Remove special tool MB991928.
3. Hold the engine assembly with a chain block, etc.
4. Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine front mounting bracket.
5. Loosen the engine front mounting bracket mounting nuts and bolts, and remove the engine front mounting bracket.

<< F>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, use the chain block to slowly lift the engine assembly upward from the engine compartment.

>> A << ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

Scheme 367

Scheme 368

Scheme 369

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to support the engine. < Special tool MB991895 is used> Set special tool MB991895. Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/automatic-trans/#diagnosis-24l-except-evolution-sportback) (A/T) or «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-trans/#on-vehicle-service-evolution) (M/T). < Special tool MB991928 is used> Set special tool MB991928. Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/automatic-trans/#diagnosis-24l-except-evolution-sportback) (A/T) or «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-trans/#on-vehicle-service-evolution) (M/T).

>> C << O-RING/FUEL HIGH-PRESSURE INSTALLATION

Scheme 370

1. Apply a small amount of new engine oil to the O-ring.
2. While turning the fuel high-pressure hose to the right and left, slide it into the fuel rail. Be careful not to damage the O-ring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably binding. Disconnect the fuel high-pressure hose and check the O-ring for damage. Replace if necessary.
4. Re-insert the fuel rail and confirm the hose turns smoothly.

>> D << RADIATOR LOWER HOSE/RADIATOR UPPER HOSE INSTALLATION

1. Slide the hose onto the water inlet fitting and thermostat case.
2. Align the marks on the radiator hose and hose clamp made during removal when installing.

Scheme 371

Required Special Tools

1. MB990767: End Yoke Holder
2. MD998719: Crankshaft Pulley Holder.

<< A>> CRANKSHAFT PULLEY REMOVAL

Use special tools MD998719 and MB990767 to remove the crankshaft pulley.

Scheme 372

>> A << CRANKSHAFT PULLEY INSTALLATION

1. Clean the tapped holes on crankshaft to eliminate oil fouled, etc.
2. Apply engine oil at the contact surfaces and threads on crankshaft bolts.
3. Use the same special tool as in the removal procedure to retain crankshaft pulley, and tighten crankshaft bolts to the specified torque.

Scheme 373

Required Special Tools

1. MB990767: End Yoke Holder
2. MD998713: Camshaft Oil Seal Installer
3. MD998719: Crankshaft Pulley Holder Pin

<< A>> CAMSHAFT SPROCKET REMOVAL

Scheme 374

Scheme 375

Scheme 376

1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that No.1 cylinder is at TDC on the compression stroke.
2. Secure the camshaft sprocket and the timing belt with tie-wraps to prevent slippage between the camshaft sprocket and the timing belt.
3. Use the special tools MB990767 and MD998719 to stop the camshaft sprocket from turning. CAUTION: Do not turn the crankshaft after the camshaft sprocket is removed.
4. Remove the camshaft sprocket.

<< B>> ROCKER ARM AND SHAFT ASSEMBLY REMOVAL

Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached.

Scheme 377

Scheme 378

1. Apply engine oil to the camshaft oil seal lip.
2. Use special tool MD998713 to install the camshaft oil seal.

>> B << CAMSHAFT SPROCKET INSTALLATION

Use special tools MD998719 and MB990767 in the same way as during removal to install the camshaft sprocket.

Scheme 379

Scheme 380

<< A>> LOWER OIL PAN REMOVAL

Use a wood block and hammer tapping against the lower oil pan to loosen it (Scheme 382)

Scheme 381

<< B>> UPPER OIL PAN REMOVAL

When individual mounting bolts are remove, insert a pry bar into the gap (Scheme 383) between upper oil pan and cylinder block, and pry off upper oil pan.

Scheme 382

Scheme 383

Scheme 384

Scheme 385

1. With scraper or wire brush, etc., remove residual gasket sealant from the attached on upper oil pan and cylinder block.
2. Apply sealant on the mounting surface of upper oil pan without any gap as indicated in the figure, and install oil pan on cylinder block. Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No. 8679/8678 or equivalent
3. Using the letter symbols in the table below, install the upper oil pan using the correct bolt. Refer to «Fastener Tightening Specifications»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-20l-except-evolution-sportback)

Scheme 386

Scheme 387

1. With scraper or wire brush, etc., remove residual gasket sealant from the attached on lower oil pan.
2. Apply sealant on the mounting surface of lower oil pan without any gap as indicated in the figure, and install lower oil pan to the upper oil pan. Specified sealant: 3M™ AAD Part No.8672, 8704, 3M™ AAD Part No.8679/8678 or equivalent
3. According to the sequence specified in the figure, tighten mounting bolts of lower oil pan to the specified torque.

>> C << DRAIN PLUG GASKET INSTALLATION

Gasket should be replaced with a new one, and install it in the direction specified in the figure.

Specified torque: 39 +/- 5 N.m (29 +/- 3 ft-lb)

Scheme 388

Scheme 389

Required Special Tools

1. MD998717: Crankshaft Front Oil Seal Installer

Scheme 390

1. Apply a small amount of engine oil to the oil seal lip and then insert.
2. Using special tool MD998717, tap the oil seal into the front case.

Scheme 391

1. Remove oil and lubricant from the mounting surfaces on crankshaft, crankshaft spacer, crankshaft sensing blade and crankshaft sprocket.
2. Assemble spring pin, crankshaft sensing blade and crankshaft spacer together. Install crankshaft sprocket assembly onto the crankshaft.

Scheme 392

Required Special Tools

1. MD998718: Crankshaft Rear Oil Seal Installer
2. MD998781: Flywheel Stopper

<< A>> FLYWHEEL BOLT < M/T >/DRIVE PLATE BOLT < A/T > REMOVAL

Use the special tool MD998781 to secure the flywheel or drive plate, and remove the bolts.

Scheme 393

Scheme 394

1. Apply a small amount of engine oil to the entire circumference of the oil seal lip.
2. Use special tool MD998718 to tap in the oil seal as shown in the illustration.

>> B << DRIVE PLATE BOLT < A/T >/FLYWHEEL BOLT < M/T > INSTALLATION

Use the special tool MD998781 to hold the flywheel or drive plate in the same manner as removal. Then install the bolts.

Scheme 395

Scheme 396

Scheme 397

Required Special Tools

1. MB991653: Cylinder Head Bolt Wrench
2. MB990767: End Yoke Holder
3. MD998719: Crankshaft Pulley Holder Pin

Scheme 398

Scheme 399

Scheme 400

1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that number 1 cylinder is at TDC on the compression stroke.
2. Secure the camshaft sprocket and the timing belt with tie-wraps to prevent slippage between the camshaft sprocket and the timing belt.
3. Use special tools MB990767 to stop the camshaft sprocket from turning. CAUTION: Do not turn the crankshaft after the camshaft sprocket is removed.
4. Remove the camshaft sprocket.

<< B>> CYLINDER HEAD BOLTS REMOVAL

Using special tool MB991653, loosen the bolts in two or three steps in the order of the numbers shown in the illustration, then remove the bolts. Remove the cylinder head assembly.

Scheme 401

>> A << CYLINDER HEAD GASKET INSTALLATION

1. Wipe off all oil and grease from the gasket mounting surface.
2. Match the shapes of the cylinder head holes with their respective cylinder head gasket holes.

Scheme 402

Scheme 403

Scheme 404

Scheme 405

1. Before installing the cylinder head bolts, check if length (A) is within limits. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt. CAUTION: Always tighten cylinder head bolts at a 90 degree angle. If it is less than 90 degree angle, the bolt will loosen. If it is more than 90 degree angle, remove the head bolt and repeat the procedure from step 1.
3. Using special tool MB991653, tighten the bolts by the following procedure.

>> C << CAMSHAFT SPROCKET INSTALLATION

Use special tools MD998719 and MB990767 in the same way as during removal to install the camshaft sprocket.

Scheme 406

>> D << O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

Scheme 407

1. Apply a small amount of new engine oil to the O-ring.
2. While turning the fuel high-pressure hose to the right and left, slide it into the fuel rail. Be careful not to damage the O-ring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably binding. Disconnect the fuel high-pressure hose and check the O-ring for damage.
4. Re-insert the fuel rail and confirm the hose turns smoothly.

Scheme 408

<< A>> TIMING BELT REMOVAL

Scheme 409

Scheme 410

1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the number 1 cylinder at compression top dead center.
2. Loosen the tension pulley fixing bolt. CAUTION: If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.
3. Place a screwdriver against the tensioner pulley and pry it fully back in the direction of the arrow.
4. Temporarily tighten the tensioner pulley bolt.
5. Remove the timing belt.

>> A << TIMING BELT INSTALLATION

Scheme 411

1. With the timing belt tensioner pulley bolt loosened, use a screwdriver to pry the tensioner pulley as close to the engine mount as possible. Then temporarily tighten tensioner bolt.
2. Align each of the camshaft and crankshaft sprocket timing marks.
3. Install the timing belt in the following order, while making sure that the tension side of the belt is not loose. Crankshaft sprocket Water pump sprocket Camshaft sprocket Tensioner pulley

Scheme 412

Scheme 413

1. Initially loosen the fixing bolt of the tensioner pulley fixed to the engine mount side by 1/4-1/2 turn, and use the force of the tensioner spring to apply tension to the belt. CAUTION: As the purpose of this procedure is to apply the proper amount of tension to the tension side of the timing belt by using the cam driving torque, turn the crankshaft only by the amount given below. Be sure not to turn the crankshaft in the opposite direction (counter clockwise).
2. Turn the crankshaft in the proper rotation direction (clockwise) for two rotations, and recheck to be sure that the timing marks on each sprocket are aligned.
3. After checking to be sure that no belt teeth in the section marked with A are lifted up and that the teeth in each sprocket are engaged, secure the tensioner pulley.

>> C << FLANGE INSTALLATION

Install the flange as shown in the illustration.

Scheme 414

FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

Scheme 415

Scheme 416

Scheme 417

NOTES

See also:
• MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• ROCKER ARMS AND CAMSHAFT
• TRANSAXLE ASSEMBLY
• TRANSAXLE ASSEMBLY
• ON-VEHICLE SERVICE
• IGNITION TIMING CHECK