On-Vehicle Service - Evolution Mitsubishi Lancer Evolution VIII

GENERAL DESCRIPTION

The 4G63 (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.

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

DRIVE BELT TENSION CHECK

Scheme 791

1. Make sure that the indicator mark is within the area marked with A in the illustration.
2. If the mark is out of the area, replace the drive belt. (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .) NOTE: The drive belt tension check is not necessary as auto-tensioner is adopted.

Scheme 792

1. Turn OFF the engine from the idle state then check to see that the drive belt is not protruding from the pulley width of the auto-tensioner.
2. Remove the drive belt. (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)
3. Securely insert the spindle handle or ratchet handle with a 12.7 mm (1/2-inch) insertion angle into the jig hole of the auto tensioner. Turn the auto-tensioner to the left and right to check and see that there is no threading.
4. If there are any problems in the procedure 1 or 3, replace the auto-tensioner. (Refer to «TIMING BELT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)
5. Install the drive belt. (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)

FUNCTION CHECK

You can verify if the auto-tensioner is defective or not by checking the drive belt tension.

Required Special Tools

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

Scheme 793

Scheme 794

1. Check the drive belt tension. (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__drive-belt-tension-check).)
2. Measure the drive belt tension vibration frequency by the following procedures: CAUTION: To prevent damage to scan tool MB991824, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991824. Connect special tool MB991668 to scan tool MB991824. Connect scan tool MB991911 to scan tool MB991824. Connect scan tool MB991911 to the data link connector. Turn the ignition switch to the "ON" position and select "Belt Tension Measurement" from the menu scan tool MB991824 screen. CAUTION: The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to 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. Hold special tool MB991668 to the middle of the drive belt between the pulleys (at the place indicated by arrow), approximately 10 - 20 mm (0.40 - 0.78 inch) away from the rear surface of the belt so that it is perpendicular to the belt (within an angle of +/- 15 degree). Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger (Scheme 794), and measure that the vibration frequency of the belt is within the standard value. Standard value: 110 - 144 Hz
3. If not within the standard value, replace the auto-tensioner. (Refer to «TIMING BELT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution).)

Scheme 795

1. Check the drive belt tension. (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__drive-belt-tension-check) .)
2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 - 412 N
3. If not within the standard value, replace the auto-tensioner. (Refer to «TIMING BELT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)

IGNITION TIMING CHECK

Required Special Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.I.C.
2. MB991827: USB Cable
3. MB991911: Main Harness B

Scheme 796

1. Before inspection, set vehicle to the following conditions: Engine coolant temperature: 80 - 95°C (176-203°F) Lights and all accessories: OFF Transaxle: Neutral 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 850 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 5° 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 Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.I.C.
2. MB991827: USB Cable
3. MB991911: Main Harness B

Scheme 797

1. Before inspection, set vehicle to the following conditions: Engine coolant temperature: 80-95°C (176-203°F) Lights and all accessories: OFF Transaxle: Neutral 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-evolution__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 Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.I.C.
2. MB991827: USB Cable
3. MB991911: Main Harness B

Scheme 798

1. Before inspection, set vehicle to the following conditions: Engine coolant temperature: 80-95°C (176-203°F) Lights and all accessories: OFF Transaxle: Neutral 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-evolution__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: 850 +/- 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 «SYMPTOM CHARTS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-20l-evolution) .

COMPRESSION PRESSURE CHECK

Required Special Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.I.C.
2. MB991827: USB Cable
3. MB991911: Main Harness B

Scheme 799

Scheme 800

Scheme 801

1. Before inspection, set vehicle to the following conditions: Engine coolant temperature: 80-95°C (176-203°F) Lights and all accessories: OFF Transaxle: Neutral
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 250 r/min): 1,128 kPa (163 psi) Minimum limit (at engine speed of 250 r/min): 951 kPa (138 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 difference 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 tool MB991958 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 802

1. Before inspection, 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
2. Connect an engine tachometer.
3. Attach a tee-fitting joint to the vacuum hose between the fuel pressure solenoid and the intake manifold plenum, and connect a vacuum gauge.
4. Start the engine and check that idle speed is within specification. Then check the vacuum gauge reading. Idle speed: 850 +/- 100 r/min Minimum limit: 51 kPa (15 in Hg)

LASH ADJUSTER CHECK

If an abnormal noise (chattering noise) is heard because of a malfunctioning lash adjuster immediately after starting the engine and does not disappear, suspect 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 causes. 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 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»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#engine-overhaul-20l-evolution) .) 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 «BLEEDING LASH ADJUSTER SYSTEM»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__bleeding-lash-adjuster-system) .)
6. If the abnormal noise does not disappear after air bleeding operation, clean the lash adjuster (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#engine-overhaul-20l-evolution) .)

WHEN USING A TENSION GAUGE

1. Check the drive belt tension. (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution__drive-belt-tension-check) .)
2. Use a belt tension gauge in the middle of the belt between the pulleys (at the place indicated by the arrow) to measure that the belt tension is within the standard value. Standard value: 245 - 412 N
3. If not within the standard value, replace the auto-tensioner. (Refer to «TIMING BELT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)

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 803

Scheme 804

Scheme 805

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, shown in illustration, 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 illustration 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 806

Scheme 807

Scheme 808

Required Special Tools

1. MB991453: Engine Hanger Assembly
2. MB991454: Engine Hanger Balancer
3. MB991895: Engine Hanger
4. MB991928: Engine Hanger
5. MZ203827: Engine Lifter

<< A >> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.

Scheme 809

Scheme 810

1. Securely insert the spindle handle or ratchet handle with a 12.7 mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper. CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.

<< B >> POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY/A/C COMPRESSOR AND CLUTCH ASSEMBLY < VEHICLE WITH A/C > REMOVAL

With the hose installed, remove the power steering oil pump assembly, and A/C compressor and clutch assembly from the bracket.

Note. Secure the removed power steering oil pump assembly, and A/C compressor and clutch assembly with cord or rope at a position where they will not interfere with the removal of the engine assembly.

Scheme 811

1. Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools MZ203827, MB991895 or MB991928.
2. Remove the transaxle assembly. (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-trans/#on-vehicle-service-evolution) .)

Scheme 812

Scheme 813

Scheme 814

Scheme 815

1. Support the engine with a garage jack.
2. Remove the following special tool. < Engine lifter (special tool MZ203827) is used > Remove special tool MZ203827. < Engine hanger (special tool MB991895) is used > Remove special tool MB991895. < Engine hanger (special tool MB991928) is used > Remove the base hanger and the following tool. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930)
3. Hold the engine assembly with a chain block, etc.
4. Place a garage jack against the engine oil pan with a place 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 bolt. Remove the engine front mounting bracket and cushion stopper assembly.

<< E >> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove 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 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

1. Arrow marks on the engine front mounting cushion stopper should face the direction shown in illustration. NOTE: Disregard F and R stamped as a shared part.
2. Place a garage jack against the engine oil pan with a piece of wood in between. Install the engine front mounting bracket and cushion stoppers while adjusting the position of the engine.
3. Support the engine assembly with a garage jack.
4. Remove the chain block.
5. Use the following special tool as during removal to support the engine. < Engine lifter (special tool MZ203827) is used > Set special tool MZ203827. < Engine hanger (special tool MB991895) is used > Set special tool MB991895. < Engine hanger (special tool MB991928) is used > Set the following parts to the base hanger. Slide bracket (HI) Foot (standard) (MB991932) Joint (90) (MB991930) Set special tool MB991928.

Scheme 822

1. Install the transaxle assembly. (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-trans/#on-vehicle-service-evolution) .)
2. Remove from the car the 2 bolts, to assemble the radiator support upper insulator.

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

1. Apply a small amount of new engine oil to the O-ring.
2. Turning the fuel high-pressure hose to the right and left, install it to the fuel rail, being 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 being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, reinsert it to the fuel rail and check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 +/- 1.0 N.m (44 +/- 9 in-lb)

Scheme 823

The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.

Scheme 824

Scheme 825

1. Securely insert the spindle handle or ratchet handle with a 12.7 mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper. CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.

Scheme 826

Scheme 827

Scheme 828

Required Special Tools

1. MD998713: Camshaft Oil Seal Installer
2. MD998737: Valve Stem Seal Installer
3. MD998772: Valve Spring Compressor

<< A >> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

Scheme 829

Scheme 830

1. Hold the hexagon part of the camshaft with a wrench.
2. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket.

<< C >> VALVE SPRING RETAINER LOCKS REMOVAL

Use special tool MD998772 to compress the valve spring, remove the valve spring retainer locks.

Scheme 831

Scheme 832

Scheme 833

1. Apply a small amount of engine oil to the valve stem seals. CAUTION: Valve stem seals cannot be reused. The special tool MD998737 must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide.
2. Use special tool MD998737 to fill a new valve stem seal in the valve guide using the valve stem area as a guide. NOTE: Check the valve stem seal color to identify the inlet side or exhaust side.

>> B << VALVE SPRINGS INSTALLATION

The small end of the valve spring should face the rocker arm.

Scheme 834

>> C << VALVE SPRING RETAINER LOCKS INSTALLATION

Use special tool MD998772 to compress the valve spring in the same manner as removal.

Scheme 835

>> D << ROCKER ARM LASH ADJUSTERS INSTALLATION

Scheme 836

1. Remove sealant remained on the cylinder head.
2. Apply engine oil to the cam and the journal of the camshaft. CAUTION: Do not install wrong camshaft on the side of inlet or exhaust. The exhaust camshaft has a slit at the rear surface.
3. Install the camshaft to the cylinder head.

Scheme 837

Scheme 838

Scheme 839

Scheme 840

1. Set the dowel pin of the camshaft to the position (Scheme 838)
2. Since the shape of camshaft bearing caps number 2-5 is identical, check the identification marks so that the bearing cap No., inlet side, or exhaust side is installed in the direction shown in the illustration. Identification mark (engraved on the front and bearing caps number 2-5) I: Inlet side E: Exhaust side
3. Apply sealant to the positions (6 areas) of the upper side of the cylinder head (Scheme 840) Specified sealant: 3M™ AAD Part No. 8672, 3M™ AAD Part No. 8679/8678 or equivalent
4. Position the camshaft bearing caps, rear in the direction as shown in the illustration for installation.
5. Check the identification marks on the camshaft bearing caps, front so that inlet side and exhaust side is installed in the same way as that of bearing caps number 2-5.
6. Tighten the bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque. Tightening torque: 20 +/- 1 N.m (14 +/- 0.5 ft-lb)
7. Ensure that the rocker arms are installed properly. NOTE: Remove an excess sealant completely.

Scheme 841

1. Apply engine oil to the entire inner diameter of the oil seal lip.
2. Use special tool MD998713 to press-fit the oil seals.

Scheme 842

1. Hold the hexagon part of the camshaft with a wrench in the same manner as removal.
2. Tighten the camshaft sprocket mounting bolts to the specified torque. Tightening torque: 89 +/- 9 N.m (65 +/- 7 ft-lb)

Scheme 843

1. Remove sealant from the camshaft position sensor support and cylinder head surfaces.
2. Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: 3M™ AAD Part No. 8672, 3M™ AAD Part No. 8679/8678 or equivalent NOTE: Install the camshaft position sensor support within 15 minutes after applying liquid gasket.
3. Install the camshaft position sensor support to the cylinder head. CAUTION: Wait at least one hour. Never start the engine or let engine oil or coolant touch the adhesion surface during that time.
4. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 +/- 1 N.m (120 +/- 13 in-lb)

Scheme 844

1. Set the dowel pin of the exhaust camshaft to the position (number 1 cylinder at compression TDC) (Scheme 845) NOTE: Use the force of the exhaust valve spring to rotate counterclockwise.
2. Install the vane (small) of the camshaft position sensing cylinder at an angle of approximately 45 degrees to the position of the dowel pin of the exhaust camshaft.
3. Tighten the camshaft position sensing cylinder mounting bolts to the specified torque. Tightening torque: 22 +/- 4 N.m (16 +/- 3 ft-lb)

Scheme 845

1. Remove old sealant remnants from the rocker cover.
2. Apply sealant to the positions (4 areas) of the lower side of the rocker cover as shown in the illustration. Specified sealant: 3M™ AAD Part No. 8672, 3M™ AAD Part No. 8679/8678 or equivalent
3. Install the rocker cover gasket to the rocker cover.

>> L << CAMSHAFT END SEAL INSTALLATION

Apply sealant to the positions of the camshaft end seal as shown in the illustration and install to the cylinder head.

Scheme 846

1. Specified sealant: 3M™ AAD Part No. 8672, 3M™ AAD Part No. 8679/8678 or equivalent

Scheme 847

1. Apply sealant to the positions of the rocker cover gasket (6 areas) as shown in the illustration. Specified sealant: 3M™ AAD Part No. 8672, 3M™ AAD Part No. 8679/8678 or equivalent
2. Install the rocker cover to the cylinder head.
3. Tighten the rocker cover mounting bolts to the specified torque. Tightening torque: 3.5 +/- 0.5 N.m (31 +/- 4 in-lb)

Scheme 848

1. Insert each hose until it contacts the projection on the water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then secure the radiator hose.

Scheme 849

Required Special Tool

1. MD998727: Oil Pan Remover

Scheme 850

1. Remove the engine oil pan mounting bolts. CAUTION: Do this slowly to avoid deformation of the engine oil pan flange.
2. Remove the engine oil pan using special tool MD998727.

Scheme 851

Scheme 852

1. Remove old sealant from the engine oil pan and cylinder block surfaces.
2. Apply a bead of the sealant to the cylinder block mating surface of the engine oil pan as shown in illustration. Specified sealant: 3M™ AAD Part No. 8672, 8704, 3M™ AAD Part No. 8679/8678 or equivalent NOTE: Install the engine oil pan within 15 minutes after applying sealant.
3. Assemble the engine oil pan to the cylinder block. CAUTION: Wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during this time.
4. Tighten the engine oil pan mounting bolts to the specified torque. Be careful when installing, as the oil pan mounting bolts (indicated in the illustration) have different lengths from the other bolts. Tightening torque: 9.0 +/- 3.0 N.m (80 +/- 26 in-lb)

>> B << ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Replace the gasket with a new gasket. Install the new gasket in the direction (Scheme 854)

Scheme 853

>> C << OIL RETURN TUBE GASKET INSTALLATION

The oil return tube gasket should be replaced with a new one. Set the convex part to the position (Scheme 855)for installation.

Note. There is no specific direction indicated for installing the turbocharger side of the oil return tube gasket.

Scheme 854

INSPECTION

1. Check the engine oil pan for cracks.
2. Check the engine oil pan sealant-coated surface for damage and deformation.

Scheme 855

Required Special Tools

1. MB990938: Installer Bar
2. MD998285: Crankshaft Front Oil Seal Guide
3. MD998375: Crankshaft Front Oil Seal Installer
4. MD998776: Crankshaft Rear Oil Seal Installer
5. MD998781: Flywheel Stopper

Scheme 856

1. Use special tool MD998781 to secure the flywheel.
2. Remove the flywheel mounting bolts.

Scheme 857

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
2. Use special tools MB990938 and MD998776 to press-fit the oil seal.

Scheme 858

1. Use special tool MD998781 to secure the flywheel in the same manner as removal.
2. Tighten the flywheel mounting bolts to the specified torque. Tightening torque: 132 +/- 5 N.m (98 +/- 3 ft-lb)

Scheme 859

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer diameter of special tool MD998285 and install it to the crankshaft.
3. Use special tool MD998375 to press-fit the oil seal.

Scheme 860

1. Clean or degrease the front case, the crankshaft and the crankshaft balancer shaft drive sprocket as shown in illustration. NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket in the direction shown in the illustration.

Scheme 861

Scheme 862

Scheme 863

Required Special Tool

1. MB991654: Cylinder Head Bolt Wrench (12)

<< A >> CYLINDER HEAD BOLTS REMOVAL

Using special tool MB991654, loosen the cylinder head bolts in two or three steps in the order shown in the illustration.

Note. If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it by using a magnet.

Scheme 864

>> A << CYLINDER HEAD GASKET INSTALLATION

Scheme 865

1. Install the gasket on the cylinder head and cylinder block.
2. Assemble to the cylinder block so the cylinder head gasket identification mark "63" is at the top surface and on the exhaust side.

Scheme 866

Scheme 867

Scheme 868

1. Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one. Limit (A): 99.4 mm (3.91 inches)
2. Apply a small amount of engine oil to the thread of the bolts and to the washers.
3. Use special tool MB991654 to tighten the cylinder head bolts as follows: Tighten the cylinder head bolts to 78 +/- 2 N.m (58 +/- 1 ft-lb) in the order shown in illustration. Loosen the bolts fully in the reverse order of that shown in illustration. Tighten the cylinder head bolts to 20 +/- 2 N.m (15 +/- 1 ft-lb) in the order shown in illustration.
4. Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown in illustration. CAUTION: The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle.
5. Tighten the bolt an additional 90 degree angle as shown in illustration. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned.
6. If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.

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

1. Apply a small amount of new engine oil to the O-ring.
2. Turning the fuel high-pressure hose to the right and left, install it onto the fuel rail, while being 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 being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, reinsert it to the fuel rail and check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting bolts to the specified torque. Tightening torque: 5.0 +/- 1.0 N.m (44 +/- 9 in-lb)

>> D << OIL RETURN TUBE GASKET INSTALLATION

The oil return tube gasket should be replaced with a new one. Set the convex part to the position shown in the illustration.

Note. There is no specific direction indicated for installing the turbocharger side of the oil return tube gasket.

Scheme 869

Scheme 870

Scheme 871

Required Special Tools

1. MB991367: Special Spanner
2. MB991385: Pin
3. MD998738: Adjusting Bolt
4. MD998767: Tensioner Wrench

<< A >> VALVE TIMING BELT REMOVAL

Scheme 872

Scheme 873

Scheme 874

Scheme 875

Scheme 876

1. Turn the crankshaft clockwise, align each timing mark to set number 1 cylinder to TDC of its compression stroke.
2. Remove the timing belt under cover rubber plug and then set the special tool MD998738. CAUTION: The special tool MD998738 can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool MD998738 may bend.
3. Screw in the special tool MD998738 until it comes in contact with the timing belt tensioner arm.
4. Gradually screw in the special tool MD998738. Then align the timing belt tensioner adjuster rod set hole A with the timing belt tensioner adjustor cylinder set hole B.
5. Insert a wire, etc. in the set hole. CAUTION: For reinstallation of the valve timing belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk.
6. After removal of adjusting bolt special tool MD998738, loosen the timing belt tensioner pulley mounting bolt and remove the valve timing belt.

<< B >> POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY REMOVAL

With the hose installed, remove the power steering oil pump assembly from the bracket.

Note. Secure the removed power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the balance timing belt.

Scheme 877

1. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft camshaft drive sprocket.

<< D >> BALANCER TIMING BELT REMOVAL

Scheme 878

Scheme 879

1. Ensure that the crankshaft balancershaft drive sprocket timing marks and balancershaft sprocket timing marks are aligned.
2. Install the balancer timing belt on the crankshaft balancershaft drive sprocket and balancershaft sprocket. There should be no slack on the tension side.
3. Assemble and temporarily fix the center of the pulley of the balancer timing belt tensioner so that it is at the top left from the center of the assembling bolt, and the pulley flange is at the front-side of the engine.
4. Adjust the balancer timing belt tension.

>> B << BALANCER TIMING BELT TENSION ADJUSTMENT

Scheme 880

Scheme 881

Scheme 882

1. With your fingers, lift the balancer timing belt tensioner in the direction of the arrow. (Scheme 881) Apply pressure of [3.0 +/- 0.4 N.m (26 +/- 4 in-lb)] to the balancer timing belt. Tighten the assembling bolt to the standard torque. Then, fix the balancer timing belt tensioner. Tightening torque: 19 +/- 3 N.m (14 +/- 2 ft-lb)
2. Turn the crankshaft clockwise two turns to set number 1 cylinder to TDC of its compression stroke and check that the sprocket timing marks are aligned.
3. Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as shown in illustration, then inspect whether the belt deflection is within the standard value. Standard value: At adjustment: 5-7 mm (0.20-0.27 inch) At replacement: 5-7 mm (0.20-0.27 inch)
4. If not within the standard value, adjust the belt tension again.

Scheme 883

Scheme 884

1. Clean or degrease the crankshaft, the crankshaft angle sensing blade, the crankshaft camshaft drive sprocket and crankshaft pulley washer as shown in illustration. NOTE: Also clean the degreased surfaces.
2. Install the crankshaft angle sensing blade and crankshaft camshaft drive sprocket in the direction shown in illustration.
3. Place the larger chamfer side of the crankshaft pulley washer in the direction shown in illustration and then assemble on the crankshaft pulley center bolt.
4. Apply some engine oil to the crankshaft pulley center bolt bearing surface and screw.
5. Hold the crankshaft camshaft drive sprocket with special tools MB991367 and MB991385 in the same manner as removal.
6. Tighten the crankshaft pulley center bolts to the specified torque. Tightening torque: 167 N.m (123 ft-lb)

Scheme 885

Scheme 886

1. Install according to the following procedures when the timing belt tensioner adjuster rod is fully extended. CAUTION: If the compression is too fast, the procedure may damage the rod. Slowly compress the timing belt tensioner adjuster rod using a press or vice, then align the set hole A of the rod with set hole B of the timing belt tensioner adjuster cylinder. Insert a wire into the aligned set hole. NOTE: When replacing the timing belt tensioner adjuster with new parts, the timing belt tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the engine, then tighten the assembling bolt to the standard torque. Do not remove the wire or pin until the tension of the valve timing belt is adjusted. Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

>> E << TIMING BELT TENSIONER PULLEY INSTALLATION

Temporarily tighten the timing belt tensioner pulley as shown in illustration.

Scheme 887

Scheme 888

Scheme 889

Scheme 890

Scheme 891

Scheme 892

Scheme 893

Scheme 894

Scheme 895

1. Align the timing marks on the camshaft sprocket, crankshaft camshaft drive sprocket and engine oil pump sprocket.
2. After aligning the timing marks of the engine oil pump sprocket, remove the cylinder block plug and insert a Phillips screw driver with a shaft diameter of 8 mm (0.31 inch) through the plug hole to check that the shaft of the screw driver can be inserted for 60 mm (2.36 inches) or more. If the screw driver makes contact with the balancer shaft and can be inserted for only 20-25 mm (0.79-0.98 inch), turn the engine oil pump sprocket for one round and align timing marks again to check that screw driver can be inserted for 60 mm or more. Do not take the screw driver out before completing installation of the valve timing belt.
3. Install the valve timing belt as follows: Pass the valve timing belt around the crankshaft camshaft drive sprocket, the engine oil pump sprocket and the timing belt idler pulley in that order. Pass the valve timing belt around the exhaust-side camshaft sprocket, and hold the valve timing belt with paper clamps. Use two wrenches to align the timing mark on the rocker cover with that on the camshaft sprocket. Pass the valve timing belt around the inlet-side camshaft sprocket. Hold the valve timing belt with paper clamps. Pass the valve timing belt around the timing belt tensioner pulley. CAUTION: Install the valve timing belt then apply reverse rotation (counterclockwise rotation) pressure to the camshaft sprocket. Recheck to see that each timing mark is aligned while the tension side of the belt is tight. Remove the two paper clamps.
4. Turn the timing belt tensioner in the direction shown in illustration using special tool MD998767 to apply tension to the valve timing belt. Then pre-tighten the timing belt tensioner pulley.
5. Check that the timing marks are aligned.
6. Remove the Phillips screw driver inserted in Step 2 above, then assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified torque. Tightening torque: 30 +/- 3 N.m (23 +/- 2 ft-lb)
8. Adjust the valve timing belt tension.

Scheme 896

Scheme 897

Scheme 898

Scheme 899

Scheme 900

Scheme 901

Scheme 902

1. Set special tool MD998738 when removing the valve timing belt. CAUTION: Always screw in special tool MD998738 by hand. Use of a spanner or other tools may damage the wire or pin inserted in the timing belt tensioner adjuster.
2. Gradually screw in special tool MD998738 until the wire or pin inserted in the timing belt tensioner adjuster lightly moves.
3. Turn the crankshaft 1/4 turn counterclockwise.
4. Turn the crankshaft in the clockwise direction until you align each timing mark to set number 1 cylinder to TDC of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting bolt. CAUTION: When tightening the mounting bolts, ensure that the timing belt tensioner pulley does not rotate with the bolts. Allowing it to rotate with the bolts can cause deficient tension of the belt.
6. With special tool MD998767 and torque wrench, apply tension torque [3.5 N.m (31 in-lb)], and tighten the timing belt tensioner pulley mounting bolt to the specified torque. Tightening torque: 48 +/- 5 N.m (36 +/- 3 ft-lb)
7. Remove wire or pin inserted to timing belt tensioner.
8. Remove the special tool MD998738, and install the rubber plug to the timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and leave it for about 15 minutes.
10. Insert wire or pin removed in Step 7 again, and ensure that it can be pulled out easily. When wire or pin can be easily removed, appropriate tension is applied on timing belt. In this case, remove wire or pin. If the projection of timing belt tensioner adjuster rod is within the standard value, appropriate tension is applied. Standard value (A): 3.8-4.5 mm (0.15-0.17 inch)
11. If wire or pin cannot be easily pulled out, repeat Step 1 through Step 9 to reach proper valve timing belt tension. CAUTION: Always check the tightening torque of the crankshaft pulley center bolt when turning the crankshaft pulley center bolt counterclockwise. Retighten if it is loose.
12. Check again that the timing marks on sprockets are aligned.

Scheme 903

1. Check for oil leak from seal, and replace it if leak is detected.
2. Check for wear or damage at the top of the rod. Replace it, if required.
3. Hold the timing belt tensioner adjuster by hand, and press the top end of the rod onto the metal (e.g. cylinder block) under a pressure of 98-196 N (22-44 pounds) to measure the movement of the rod. Standard value: Within 1 mm (0.039 inch) A: Length when it is free (not pressed) B: Length when it is pressed A-B: Movement
4. If the measured value is out of the standard value, replace the timing belt tensioner adjuster.

BALANCER TIMING BELT TENSION CHECK

Check the balancer timing belt tension as follows

Scheme 904

1. Apply a pressure of approximately 100 N (22 pounds) at the center (arrow area) between the sprocket as shown in illustration, then inspect whether the deflection is within the standard value. Standard value: 5-10 mm (0.20-0.39 inch)
2. If not within the standard value, adjust the belt tension (Refer to «TIMING BELT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical/#on-vehicle-service-evolution) .)

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Scheme 905

Scheme 906

See also:
• SYMPTOM CHARTS
• INSPECTION
• TRANSAXLE ASSEMBLY
• CRANKSHAFT PULLEY
• DRIVE BELT TENSION CHECK
• IGNITION TIMING CHECK
• BLEEDING LASH ADJUSTER SYSTEM