Engine Mechanical <2.0l Turbo> - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

The 4B11 (2.0 L) 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 chain side). The firing order is 1-3-4-2.

GENERAL INFORMATION

ENGINE DIAGNOSIS

ENGINE DIAGNOSIS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

SEALANTS AND ADHESIVE

SEALANTS AND ADHESIVE

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB992080 Belt tension meter set MB9912081 Belt tension meter MB992082 Microphone assembly Tool not available Drive belt tension (frequency) measurement MB991958 Scan tool (M.U.T.-III sub assembly) MB991824 Vehicle communication interface (V.C.I.) MB991827 M.U.T.-III USB cable MB991910 M.U.T.-III main harness A (Vehicles with CAN communication system) MB991911 M.U.T.-III main harness B (Vehicles without CAN communication system) MB991914 M.U.T.-III main harness C (for Chrysler models only) MB991825 M.U.T.-III adapter harness MB991826 M.U.T.-III trigger harness MB991824-KIT NOTE: MB991826 M.U.T.-III Trigger Harness is not necessary when pushing V.C.I. ENTER key. CAUTION: For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly. Ignition timing check Curb idle speed check Idle mixture check Erasing the diagnostic trouble code MB992278 Belt tension release wrench Auto-tensioner tension release MB990767 Front hub and flange yoke holder MB990767-01 Holding the crankshaft pulley MD998719 Pin MIT308239 MB992103 Chain tension release bar - Camshaft and camshaft sprocket assembly (exhaust side) removal MD998772 Valve spring compressor General service tool Valve spring compression MB992090 Retainer holder attachment - MB992089 Retainer holder C - MB992085 Valve stem seal pliers - Valve stem seal removal MD998737 Valve stem seal installer MD998737-01 Valve stem seal press-fitting MD998727 Oil pan FIPG cutter MD998727-01 Engine oil pan removal MB991883 Flywheel stopper General service tool Supporting the flywheel MB991448 Bush remover and installer base MB991448-01 Press-fitting the crankshaft front oil seal MB991928 Engine hanger MB991929 Joint (50) x 2 MB991930 Joint (90) x 2 MB991931 Joint (140) x 2 MB991932 Foot (standard) x 4 MB991933 Foot (short) x 2 MB991934 Chain and hook assembly Tool not available Supporting the engine assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453. MB991895 Engine hanger Tool not available MB991454 Engine hanger balancer MZ203827-01

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1. Remove the radiator condenser tank, and move the radiator condenser tank to a place where it does not interfere with the drive belt tension check. CAUTION: Check the drive belt tension after turning the crankshaft clockwise one turn or more.
2. Make sure that the indicator mark on the auto-tensioner is within the area marked with A in the illustration.
3. If the mark is out of the area A, replace the drive belt (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .) NOTE: The drive belt tension adjustment is not necessary as the auto-tensioner is adopted.
4. Install the radiator condenser tank to the original position.

OPERATION CHECK

Required Special Tool

MB992278: Belt tension release wrench

Scheme 12

1. Stop the engine from the idle state.
2. Remove the radiator condenser tank, and move the radiator condenser tank to a place where it does not interfere with the auto-tensioner check.
3. Check that the drive belt is not protruding from the pulley width of the auto-tensioner.
4. Remove the drive belt (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .) WARNING: Always work from above when releasing the tension of the auto-tensioner. When you try to gain access from underneath the vehicle, you will experience difficulty, thus causing the tool to be dropped off. CAUTION: To work at the optimum angle, you must choose a most suitable box-type wrench is applied to the special tool. WARNING: Be sure to set the box-type wrench and the special tool MB992278 to the hexagonal parts securely to prevent the tool from falling off because the tension of the auto-tensioner is high.
5. Install special tool MB992278 and a box-type wrench at the optimum angle.
6. Check that no binding is present by turning the auto-tensioner in the left and right directions.
7. If there are any problems in the procedure 3 or 6, replace the auto-tensioner (Refer to «TIMING CHAIN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) ).
8. Install the drive belt (Refer to «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .)
9. Install the radiator condenser tank to the original position.

FUNCTION CHECK

The auto-tensioner can be checked whether it is in good condition by checking its tension.

< When the vibration frequency is measured: Recommendation >

Required Special Tools

1. MB992080: Belt Tension Meter Set MB992081: Belt Tension Meter MB992082: Microphone Assembly

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1. Check the tension of the drive belt (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .)
2. Check the tension of the drive belt in the following procedures. Connect special tool MB992082 to special tool MB992081 of special tool MB992080. Press the "POWER" button to turn on the power supply. Press number key "1". Check to ensure that "No.01" appears on the upper left of the display and that the following numeric values are displayed for individual items (M, W, and S): M 000.9 g/m W 010.0 mm/R S 0100 mm If numeric values have not been entered (new tool), set them according to the belt specifications as shown below. Once you set them, you do not have to set them again. The settings remain undeleted even after battery replacement. NOTE: This operation is to temporarily set the preset data such as the belt specifications, because if the measurement is taken without input of the belt specifications, conversion to tension value (N) cannot be made, resulting in judgement of error. < Setting procedure > Press down the "MASS" button till the belt mass select display appears. Press the "UP" or "DOWN" button to select "01 1.5GT 0.9" and press the "MEASURE" button to decide it. Check to ensure that "M 000.9 g/m" is displayed. Press the "WIDTH" button to change to the belt width input display. Press number keys 0, 1, 0, and 0 sequentially, and press the "SELECT" button to apply them. Check to ensure that "W 010.0 mm/R" appears on the display. Press the "SPAN" button to change to the span length input display. Press number keys 0, 1, 0, and 0 sequentially, and press the "SELECT" button to apply them. Check to ensure that "S 0100 mm" appears on the display. Press "Hz" button twice to change the display to the frequency display (Hz.) CAUTION: When measuring, make sure that the engine is cold. Measure after turning the crankshaft clockwise one turn or more. 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 MB992080 to the middle of the belt between the pulleys (at the place indicated by arrow) where it does not contact the belt [approximately 10 - 15 mm (0.4 - 0.59 inch) away from the rear surface of the belt] so that it is perpendicular to the belt (within an angle of ± 15 degree angle.) Press the "MEASURE" button. 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: 98 - 124 Hz NOTE: To take the measurement repeatedly, tap the belt again. Press and hold the "POWER" button to turn off the power supply.
3. If not within the standard value, replace the auto-tensioner (Refer to «TIMING CHAIN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .)

Scheme 15

1. Check the tension of the drive belt (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .) CAUTION: When measuring, make sure that the engine is cold. Measure after turning the crankshaft clockwise one turn or more.
2. Use a belt tension gauge in the middle of the belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the belt tension is within the standard value. Standard value: 248 - 400 N (56 - 90 lb)
3. If not within the standard value, replace the auto-tensioner (Refer to «TIMING CHAIN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .)

VALVE CLEARANCE CHECK AND ADJUSTMENT

Refer to 6. INTAKE AND EXHAUST VALVE CLEARANCE

IGNITION TIMING CHECK

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

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1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range NOTE: On 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 the timing light to the power supply line (terminal No. 4) of the ignition coil No. 1.
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 actuator test "item number 11".
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, refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) . 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. Cancel the setting mode of the scan tool MB991958.
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. NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.
11. Remove the timing light. 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.
12. Disconnect scan tool MB991958 from the data link connector.

CURB IDLE SPEED CHECK

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range NOTE: On 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 the timing light to the power supply line (terminal No. 4) of the ignition coil No. 1.
4. Start the engine.
5. Run the engine at idle for 2 minutes.
6. Check the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC NOTE: Ignition timing fluctuates about ±7°, even under normal operating condition. NOTE: It is automatically further advanced by about 5° from 10° Before Top Dead Center at higher altitudes. NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.
7. Check the idle speed. Select item number 2 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.
8. If the idle speed is outside the standard value, refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) .
9. Remove the timing light. 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.
10. Disconnect scan tool MB991958 from the data link connector.

IDLE MIXTURE CHECK

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range NOTE: On 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 the timing light to the power supply line (terminal No. 4) of the ignition coil No. 1.
4. Start the engine and let it run at idle.
5. Check that the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC NOTE: Ignition timing fluctuates about ±7°, even under normal operating condition. NOTE: It is automatically further advanced by about 5° from 10° Before Top Dead Center at higher altitudes. NOTE: Wait till approximately 1 minute passes after the engine started, and check the ignition timing when the engine stabilized.
6. Run the engine and increase the engine speed to 2,000 - 3,000 r/min for 2 minutes.
7. Set the CO, HC tester.
8. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5% or less HC contents: 100 ppm or less
9. If there is a deviation from the standard value, inspect the MFI system (Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) )
10. Remove the CO. HC tester and timing light. 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.
11. Disconnect scan tool MB991958 from the data link connector.

COMPRESSION PRESSURE CHECK

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

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1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range NOTE: On 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.
2. Disconnect the connector of the ignition coil, and then remove all the ignition coils and the spark plugs.
3. Disconnect the all of the injector connectors. 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.
4. Cover the spark plug hole with a shop towel etc., after the engine has been cranked, check that no foreign material is adhering to the shop towel.
5. Set compression gauge to one of the spark plug holes.
6. Cranking the engine with the accelerator pedal fully depressed, measure the compression pressure. Standard value (at engine speed of 200 r/min): 1,090 kPa (158 psi) Limit (at engine speed of 200 r/min): Minimum 750 kPa (109 psi)
7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Maximum 98 kPa (14 psi)
8. 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 from 5 to 7 . 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.
9. Connect the all of the injector connector.
10. Install the spark plugs and ignition coils.
11. Use the scan tool MB991958 to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.
12. Select "Mode $0A" from "Special Function" of Scan tool MB991958. Check whether the permanent-DTC (PDTC) is stored or not. If stored, clear the PDTC. (Refer to «DIAGNOSTIC FUNCTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) )

MANIFOLD VACUUM CHECK

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

Scheme 20

1. Before inspection, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range NOTE: On 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. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. Plug the PCV valve.
4. Start the engine and check that idle speed is approximately 700 r/min.
5. Check the intake manifold vacuum. Limit: Minimum 60 kPa (18 in Hg)
6. Turn off the ignition switch.
7. Remove the vacuum gauge and then connect the ventilation hose to the PCV valve. 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.
8. Disconnect scan tool MB991958 from the data link connector.

TIMING CHAIN ELONGATION VISUAL CHECK

Note. When the timing chain elongates more than the specified length, the diagnostic trouble code No. P0012, variable valve timing (VVT) advanced-angle value abnormal, is set. Unless the diagnostic trouble code No. P0012, therefore, is set, the visual check is unnecessary. After the following diagnostic trouble codes are repaired, it is necessary to delete the learning value of the timing chain elongation. At that time, perform the visual check. DTC P0016: Crankshaft/Camshaft (intake) Position Sensor Phase Problem DTC P0017: Crankshaft/Camshaft (exhaust) Position Sensor Phase Problem

Note. Unless the work using the following scan tool MB991958 is correctly carried out due to the malfunction of ECM, carry out the check whether or not the diagnostic trouble code exists. Storing the learning value regarding the amount of timing chain elongation before the ECM replacement Writing the learning value into the new ECM after the ECM replacement

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1. Remove all the ignition coils.
2. Remove the cylinder head cover.
3. Remove the upper chain guide. CAUTION: Always rotate the crankshaft clockwise.
4. Rotating the crankshaft clockwise, align the timing mark of camshaft sprocket with the point on the upper plane of cylinder head shown in the illustration. As a result of this, the No. 1 cylinder is positioned at the compression TDC.
5. Look at the inside of timing chain case with one eye in the direction of arrow shown in the illustration. Fix the eye line at the point where the top axis line of the chain elongation indicator at the front side of timing chain case is overlapped with that of the chain elongation indicator at the reverse side of timing chain case.
6. Check the end top point "A" of timing chain cross section surface and the point of chain elongation indicator which is fixed in Step 5 . When the end top point "A" of timing chain is positioned at the left-hand side of chain elongation indicator, it is unnecessary to replace the timing chain because the timing chain is within the specified length. When the end top point "A" of timing chain is positioned at the right-hand side of chain elongation indicator, it is necessary to replace the timing chain because the timing chain elongates more than the specified length. NOTE: If the timing chain is extended more than the specified value, the oil pump chain could possibly be extended, too. The oil pump chain, therefore, must be replaced when the timing chain is replaced.
7. Install the upper chain guide. CAUTION: Completely clean the old FIPG remaining in the clearance between the mating parts.
8. After completely removing the liquid gasket adhering on the timing chain case, cylinder block and cylinder head, degrease them with white gasoline. CAUTION: Install the cylinder head cover within 3 minutes of applying the liquid gasket.
9. Apply a 4 mm diameter bead of liquid gasket to the point shown in the illustration. Specified sealant: THREE BOND 1217G or equivalent
10. Installing the cylinder head cover, tighten the tightening bolt according to the following procedures. Temporarily tighten the tightening bolt in the order shown in the illustration. Tightening torque: 3.0 ± 1.0 N.m Tighten the tightening bolt to the specified torque in the order shown in the illustration. Tightening torque: 5.5 ± 0.5 N.m
11. Install the ignition coil.
12. Use the scan tool MB991958 to select the timing chain maintenance. Initialize the learning value. Refer to «TIMING CHAIN MAINTENANCE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution__timing-chain-maintenance-20-l) . NOTE: Carry out the initialization even if the amount of timing chain elongation is normal. As a result of this, it is necessary to replace the timing chain before the timing chain interferes with the other components when the next warning lamp illuminates or the diagnostic trouble code No. P0012 is set.

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Required Special Tools

1. MB992278: Belt Tension Release Wrench
2. MB990767: Front Hub and Flange Yoke Holder
3. MD998719: Pin

<< A >> DRIVE BELT REMOVAL

Since the serpentine drive system with the auto-tensioner is used, the following operations will be required.

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1. Install special tool MB992278 and a box-type wrench at the optimum angle.
2. Rotate the pulley bolt of the auto-tensioner counterclockwise.
3. Insert the L-shaped hexagon wrench into the auto-tensioner hole to fix the auto-tensioner.
4. Remove the drive belt.

Scheme 29

1. Hold the crankshaft drive sprocket with special tools MB990767 and MD998719.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft pulley center bolt and crankshaft pulley washer.

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1. Wipe off the dirt on the crankshaft and crankshaft pulley as shown in the figure using a rag.
2. Wipe off the dirt on the crankshaft sprocket, crankshaft and crankshaft pulley as shown in the figure using a rag, and then degrease them. NOTE: Degrease them to prevent drop in the friction coefficient of the pressed area, which is caused by oil adhesion.
3. Install the crankshaft pulley.
4. Wipe off the dirt on the crankshaft pulley washer and crankshaft pulley center bolt as shown in the figure using a rag.
5. Apply an adequate and minimum amount of engine oil to the threads of the crankshaft pulley center bolt and lower area of the flange.
6. Hold the crankshaft pulley with special tools MB990767 and MD998719 in the same manner as removal.
7. Tighten the crankshaft pulley center bolt according to the following procedure. Tighten the crankshaft pulley center bolt to the specified torque. Tightening torque: 250 N.m (184 ft-lb) Loosen the crankshaft pulley center bolt fully. Tighten the crankshaft pulley center bolt again to the specified torque. Tightening torque: 110 N.m (81 ft-lb) As shown in part "A" in the illustration, apply the paint mark to the crankshaft pulley on the extended line of the corner adjacent to the one of the crankshaft pulley center bolt corners. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the crankshaft pulley center bolt to start from the beginning again according to the procedure. Tighten the crankshaft pulley center bolt by 60 degrees angle once more. Make sure the paint mark of crankshaft pulley center bolt is aligned with the paint mark of crankshaft pulley as shown in part "B" in the illustration

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1. Install the drive belt to each pulleys as shown in the figure. WARNING: Always work from above when releasing the tension of the auto-tensioner. When you try to gain access from underneath the vehicle, you will experience difficulty, thus causing the tool to be dropped off. CAUTION: To work at the optimum angle, you must choose a most suitable box-type wrench is applied to the special tool. WARNING: Be sure to set the box-type wrench and the special tool MB992278 to the hexagonal parts securely to prevent the tool from falling off because the tension of the auto-tensioner is high.
2. Install special tool MB992278 and a box-type wrench at the optimum angle.
3. Rotate the auto-tensioner counterclockwise and remove the L-shaped hexagon wrench fixing the auto-tensioner.
4. Apply tension to the drive belt while slowly turning the auto-tensioner clockwise.

Scheme 34

Required Special Tool

1. MB992103: Chain Tension Release Bar

<< A >> ROCKER COVER ASSEMBLY REMOVAL

Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

Scheme 35

<< B >> NUMBER 1 CYLINDER COMPRESSION TOP DEAD CENTER SETTING

Scheme 36

1. Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the number 1 cylinder to the top dead center of compression. At this time, check that the crankshaft pulley timing mark is in the 0-degree angle position of the ignition timing indicator of the timing chain case assembly.
2. Put paint marks on both the camshaft sprocket and timing chain at the position of camshaft sprocket timing chain mating mark (circular hole.)

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1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case assembly, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state. NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock. CAUTION: When inserting special tool MB992103 into the timing chain case assembly inside, pay attention to the position of the timing chain to avoid damage to the timing chain and timing chain tension side guide. Do not insert the special tool MB992103 beyond its insertion guideline. If unlocking the timing chain tensioner is insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool MB992103.
2. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly ("A" in (Scheme 31).) NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the timing chain, according to the special tool MB992103 top shape. The special tool MB992103 can be inserted smoothly to the position where the special tool MB992103 insertion guide line aligns with the timing chain case assembly top surface ("B" in (Scheme 31) ), and the spread timing chain tension side guide can be held ("C" in (Scheme 31).)
3. With the special tool MB992103 inserted up to the insertion guide line, press the special tool MB992103 against the intake side camshaft sprocket and spread and hold the timing chain tension side guide.
4. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner. CAUTION: The timing chain may snag on by other parts. After sagging the timing chain, never rotate the crankshaft.
5. With the timing chain tension side guide spread, hook the special tool MB992103 over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the timing chain between the camshaft sprockets.

<< D >> FRONT CAMSHAFT BEARING CAP REMOVAL

Loosen the front camshaft bearing cap mounting bolts in the order of number shown in the figure, and remove the front camshaft bearing cap.

Scheme 41

<< E >> OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. Raise slightly the transaxle side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the timing chain, and remove from the cam bearing.
2. Remove the timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transaxle.
3. Remove special tool MB992103 inserted into the timing chain case assembly. CAUTION: The timing chain may snag on other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.
4. After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the timing chain with a rope to prevent the timing chain from falling into the timing chain case assembly.

<< G >> CAMSHAFT SPROCKET BOLT/CAMSHAFT SPROCKET/CAMSHAFT REMOVAL

Hold the hexagon part of the camshaft with a monkey wrench. Loosen the camshaft sprocket bolt and remove the camshaft sprocket from the camshaft.

Scheme 46

<< H >> POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. With the hose installed, remove the power steering oil pump assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of oil feed control valve.

<< B >> OIL FEEDER CONTROL VALVE REMOVAL

>> A << O-RING/OIL FEEDER CONTROL VALVE INSTALLATION

Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.

>> B << CAMSHAFT/CAMSHAFT SPROCKET/CAMSHAFT SPROCKET BOLT INSTALLATION

Install the camshaft and camshaft sprocket assembly as follows.

Scheme 47

Scheme 48

1. Check that the knock pin is set to the right overhead position.
2. An adequate and minimum amount of engine oil to the outer of the camshaft edge and the entire insertion area around camshaft sprocket assembly.
3. Set the knock pin hole of camshaft sprocket assembly to the right overhead position, and slowly insert it into the camshaft assembly to the specified position.
4. Install the camshaft sprocket to the camshaft.
5. Apply an adequate and minimum amount of engine oil to the thread of the camshaft sprocket bolt and the lower area of the flange.
6. Clamp the hexagon part of the camshaft and fix it in the same manner as removal.
7. Tighten the camshaft sprocket bolt to the specified torque. Tightening torque: 85 ± 5 N.m (63 ± 4 ft-lb)

Scheme 49

1. Align the intake side paint mark of the timing chain which was put at removal with the paint mark of the intake side camshaft sprocket, and install the camshaft sprocket to the timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake side) to the cylinder head.

Scheme 50

1. Install the camshaft bearing caps to the cylinder head. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

>> E << CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure. FRONT CAMSHAFT BEARING CAP SPECIFICATION Front camshaft bearing cap Camshaft bearing identification mark Identification mark Journal diameter mm (in) 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3
2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case assembly, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner. NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock. CAUTION: When inserting special tool MB992103 into the timing chain case assembly, pay attention to the position of the timing chain to avoid damage to the timing chain and timing chain tension side guide. Do not insert the special tool MB992103 beyond its insertion guideline. If unlocking the timing chain tensioner is insufficient, the special tool MB992103 cannot be inserted to the insertion guideline. Do not insert the special tool MB992103 forcibly, follow Step 2 again to unlock the timing chain tensioner and insert the special tool MB992103.
3. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly ("A" in (Scheme 45).) NOTE: With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the timing chain, according to the special tool MB992103 top shape. The special tool MB992103 can be inserted smoothly to the position where the special tool MB992103 insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.
4. With the special tool inserted up to the insertion guide line, press the special tool MB992103 against the intake side camshaft sprocket ("B" in (Scheme 45) ) and spread and hold the timing chain tension side guide ("C" in (Scheme 45).)
5. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.
6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the timing chain ("D" in (Scheme 45) ) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the timing chain. CAUTION: When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
7. Align the exhaust side paint mark of the timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the timing chain to the camshaft sprocket.
8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.
9. Remove the special tool MB992103 inserted into the timing chain case assembly inside.

>> F << FRONT CAMSHAFT BEARING CAP INSTALLATION

Scheme 55

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap mounting bolts to the specified torque in the order of (1 in (Scheme 47).) Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap mounting bolts again to the specified torque in the order (2 in (Scheme 47).) Tightening torque: 30 ± 2 N.m (22 ± 1 ft-lb)
3. After the front camshaft bearing cap installation, check that the paint markings of the camshaft sprocket and the timing chain and the timing mark of the crankshaft pulley and the 0-degree angle position of ignition timing indicator are aligned respectively.

Scheme 56

Scheme 57

1. Wipe off the sealant on the mating surface of the rocker cover assembly and cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied. CAUTION: After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
2. Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head. Specified sealant: ThreeBond 1227D or equivalent NOTE: Install the rocker cover assembly immediately after applying sealant.
3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 3.0 ± 1.0 N.m (27 ± 8 in-lb)
4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 5.5 ± 0.5 N.m (49 ± 4 in-lb)

REMOVAL AND INSTALLATION

Scheme 58

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991895: Engine Hanger
3. MB991928: Engine Hanger
4. MD998772: Valve Spring Compressor
5. MB992089: Retainer Holder C
6. MB992090: Retainer Holder Attachment
7. MB992085: Valve Stem Seal Pliers
8. MD998737: Valve Stem Seal Installer

Scheme 59

Scheme 60

1. Temporarily install the engine oil pan which was removed at the timing chain removal (Refer to «OIL PAN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .) CAUTION: When supporting the engine and transaxle assembly with a garage jack, be careful not to deform the engine oil pan.
2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transaxle assembly.
3. Remove special tool MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed. CAUTION: Be careful not to drop the camshaft bearing.
4. Loosen the front camshaft bearing cap mounting bolts in the order of number shown in the figure, and remove the front camshaft bearing cap.

<< B >> OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the camshaft bearing caps mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<< C >> VALVE TAPPET REMOVAL

Remove all of the valve tappets by hand.

Scheme 61

Scheme 62

1. Screw in special tool MB992090 to special tool MD998772 and assemble special tool MB992089. CAUTION: When removing the valve spring retainer lock, leave the piston of the cylinder in the TDC (Top Dead Center) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.
2. Install special tool MD998772 (with special tools MB992090 and MB992089 attached) to the cylinder head and compress the valve spring. Then, remove the valve spring retainer lock.

<< E >> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to grip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

Scheme 63

>> A << VALVE STEM SEAL INSTALLATION

Scheme 64

Scheme 65

1. Apply a small amount of engine oil to the press-fit part and lip part of the new valve stem seal.
2. Use special tool MD998737 to press-fit a new valve stem seal in the valve guide using the valve stem area as a guide.

>> B << VALVE SPRING INSTALLATION

Install the valve spring so that the painted side faces toward the camshaft.

Scheme 66

>> C << VALVE SPRING RETAINER LOCK INSTALLATION

In the same manner as removal, use special tool MD998772 (with special tools MB992090 and MB992089 attached) to compress the valve spring, and install the valve spring retainer lock.

>> D << VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets. CAUTION: Do not use pliers or other tools to install the valve tappets. Always install them by hand. Be sure to install the valve tappets in the same position as before.
2. Install the valve tappet to the cylinder head.

>> E << THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION

1. Install the camshaft bearing caps to the cylinder head. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

>> F << CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.

FRONT CAMSHAFT BEARING CAP SPECIFICATION

Scheme 67

>> G << FRONT CAMSHAFT BEARING CAP INSTALLATION

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap mounting bolts to the specified torque in the order (1 in (Scheme 62).) Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap mounting bolts again to the specified torque in the order (2 in (Scheme 62).) Tightening torque: 30 ± 2 N.m (22 ± 1 ft-lb)
3. Install special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed (Refer to «TIMING CHAIN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) ).
4. Remove the garage jack which supports the engine and transaxle assembly.
5. Remove the engine oil pan installed temporarily.

Scheme 68

Required Special Tool

1. MD998727: Oil Pan FIPG Cutter

<< A >> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine oil pan.

Scheme 69

Scheme 70

Scheme 71

1. Remove the engine oil pan mounting bolts. CAUTION: Do not forcibly drive in special tool MD998727 to avoid damage to the engine oil pan seal surface of cylinder block assembly.
2. Insert special tool MD998727 to the engine oil pan removal groove of the cylinder block assembly.
3. Lightly tap the special tool MD998727 with a hammer to slide the engine oil pan seal surface, cut off the liquid gasket, and remove the engine oil pan.

Scheme 72

1. Remove all the traces of sealant adhering to the engine oil pan and cylinder block assembly using a remover or others. Then, degrease them.
2. Apply the sealant without any gap to the mating surface of engine oil pan as shown in the figure, and install the engine oil pan to the cylinder block assembly. Specified sealant: ThreeBond 1227D or equivalent NOTE: Install the engine oil pan immediately after applying sealant. CAUTION: After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
3. Tighten the engine oil pan mounting bolts to the specified torque. Tightening torque: M6: 10 ± 2 N.m (89 ± 17 in-lb) M8: 29 ± 2 N.m (22 ± 1 ft-lb)

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

Replace the engine oil pan drain plug gasket with a new one. Install the new engine oil pan drain plug gasket in the direction shown in the illustration.

Scheme 73

INSPECTION

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

Scheme 74

Required Special Tools

1. MB991883: Flywheel Stopper
2. MB991448: Bush Remover And Installer Base

<< A >> FLYWHEEL BOLT REMOVAL

Fix the flywheel using special tool MB991883, and loosen the flywheel bolts.

Scheme 75

Scheme 76

1. Remove all the traces of sealant adhering to the cylinder block and ladder frame using a remover or others. Then, degrease them using.
2. Apply the sealant without any gap to the cylinder block and ladder frame as shown in the figure, and install the crankshaft rear oil seal case assembly. Specified sealant: ThreeBond 1227D or equivalent NOTE: Install the crankshaft rear oil seal case assembly immediately after applying sealant.
3. Apply a small amount of engine oil to the entire inner diameter of the crankshaft rear oil seal lip, and install the crankshaft rear oil seal case assembly. CAUTION: After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
4. Tighten the crankshaft rear oil seal case assembly mounting bolts to the specified torque. Tightening torque: 10 ± 2 N.m (89 ± 17 in-lb)

Scheme 77

Scheme 78

1. Remove the sealant, the engine oil, and other adhering materials from the flywheel bolt threads, crankshaft tapped hole, and flywheel.
2. Install the flywheel and flywheel hub to the crankshaft.
3. Use special tool MB991883 to secure the flywheel in the same manner as removal.
4. Apply a small amount of engine oil to the screw holes of the crankshaft and the bearing surface of the flywheel bolts.
5. Apply sealant to the thread of the flywheel bolts. Specified sealant: ThreeBond 1324
6. Tighten the flywheel bolts to temporary torque in the order shown in the illustration. Tightening torque: 40 N.m (30 ft-lb)
7. Tighten the flywheel bolts to specified torque in the order shown in the illustration. Tightening torque: 130 N.m (96 ft-lb)

Scheme 79

1. Apply a small amount of engine oil to the entire inner diameter of the crankshaft front oil seal lip. CAUTION: When installing the crankshaft front oil seal, be careful to avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

Scheme 80

Scheme 81

Required Special Tools

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

<< A >> RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp as shown in illustration to install them in the original position. Then, remove them.

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Follow the steps below to unlock the fuel high-pressure hose connector. Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel high-pressure hose connector. CAUTION: When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees angle to push up the retainer and unlock the fuel high-pressure hose connector.
2. Disconnect the fuel high-pressure hose.

<< C >> FRONT CAMSHAFT BEARING CAP REMOVAL

1. Temporarily install the engine oil pan which was removed at the timing chain removal (Refer to «OIL PAN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) .) CAUTION: When supporting the engine and transaxle assembly with a garage jack, be careful not to deform the engine oil pan.
2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transaxle assembly.
3. Remove special tool MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed. CAUTION: Be careful not to drop the camshaft bearing.
4. Loosen the front camshaft bearing cap mounting bolts in the order of number shown in the figure, and remove the front camshaft bearing cap.

<< D >> OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<< E >> CYLINDER HEAD BOLT/CYLINDER HEAD BOLT WASHER/CYLINDER HEAD BOLT AND WASHER ASSEMBLY REMOVAL

Loosen and remove the cylinder head bolts in two or three steps in the order of number shown in the figure.

Scheme 86

>> A << CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION

Scheme 87

Scheme 88

1. Remove the sealant and grease on the top surface of cylinder block and on the bottom surface of the cylinder head. Then, degrease the sealant application surface.
2. Apply the sealant to the top surface of cylinder block as shown in the figure. Specified sealant: ThreeBond 1217G or equivalent
3. Install the cylinder head gasket to the cylinder block. NOTE: Install the cylinder head gasket immediately after the application of sealant. When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
4. Apply the sealant to the top surface of cylinder head gasket as shown in the figure. Specified sealant: ThreeBond 1217G or equivalent CAUTION: After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
5. Install the cylinder head assembly to the cylinder block.

Scheme 89

Scheme 90

1. Replace the cylinder head bolt and washer with new ones.
2. For two cylinder head bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the cylinder head bolts.
3. Apply a small amount of engine oil to the cylinder head bolt threads and the washers.
4. Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method.) Tighten the cylinder head bolts to the specified torque in the order of number shown in the figure. Tightening torque: 35 ± 2 N.m (26 ± 1 ft-lb) CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the cylinder head bolt to start from the beginning again according to the procedure. Apply paint marks to the head of cylinder head bolt and the cylinder head. Tighten the cylinder head bolt to 90 degrees angle in the tightening order. Additionally tighten to 90 degrees angle, and check that the paint mark on the cylinder head bolt is aligned with the paint mark on the cylinder head.

>> C << CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY INSTALLATION

When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.

FRONT CAMSHAFT BEARING CAP SPECIFICATION

>> D << THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION

1. Install the camshaft bearing caps to the cylinder heads. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

>> E << FRONT CAMSHAFT BEARING CAP INSTALLATION

Scheme 91

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap mounting bolts to the specified torque in the order (1 in see scheme 109.) Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap mounting bolts again to the specified torque in the order (2 in see scheme 109.) Tightening torque: 30 ± 2 N.m (22 ± 1 ft-lb)
3. Install special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed (Refer to «TIMING CHAIN»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) ).
4. Remove the garage jack which supports the engine and transaxle assembly.
5. Remove the engine oil pan installed temporarily.

>> F << O-RING INSTALLATION

Fit the O-ring in the water pump inlet pipe groove, wet the O-ring circumference or the pipe mounting area inner wall, and then insert the O-ring.

Scheme 92

>> G << FUEL HIGH-PRESSURE HOSE CONNECTION

Scheme 93

1. Securely insert the fuel rail stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel rail.
2. Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel rail.

Scheme 94

1. Insert radiator hose as far as the projection of the water inlet fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

Scheme 95

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991895: Engine Hanger
3. MB991928: Engine Hanger
4. MB991448: Bush Remover and Installer Base

<< A >> POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. With the hose installed, remove the power steering oil pump assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of timing chain.

<< B >> ENGINE AND TRANSAXLE ASSEMBLY HOLDING

Install a special tool for holding the engine and transaxle assembly.

Scheme 96

Scheme 97

Scheme 98

1. < Special tool MB991928 is used > Assemble the special tool MB991928. Set the following parts on the base hanger. Slide bracket (HI) Foot x 4 (standard) (MB991932) Joint x 2 (90) (MB991930) Set the foot of the special tool as shown in the figure. NOTE: Slide the slide bracket (HI) to adjust the engine hanger balance. Mount special tool MB991454 to the power steering oil pump bracket and engine hanger, and set it to special tool MB991928 to support the engine and transaxle assembly.
2. < Special tool MB991895 is used > Set the foot of special tool MB991895 as shown in the figure. NOTE: Slide the foot to adjust the engine hanger balance. Mount special tool MB991454 to the power steering oil pump bracket and engine hanger, and set it to special tool MB991895 to support the engine and transaxle assembly.

<< C >> CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water pump pulley mounting bolts before removal of the drive belt.

<< D >> AUTO-TENSIONER REMOVAL

Loosen the mounting bolt of generator assembly lower part, and remove the mounting bolt of generator assembly upper part. Slide the generator assembly, and remove the auto-tensioner.

Scheme 99

<< E >> TIMING CHAIN CASE ASSEMBLY REMOVAL

Scheme 100

Scheme 101

1. After removing the timing chain case assembly mounting bolts, slightly pry the boss of the timing chain case assembly shown in the figure using a flat-tipped screwdriver, and remove the timing chain case assembly from the cylinder head and cylinder block.
2. If the sealant cannot be peeled off easily, insert a wooden hammer shank into the timing chain case assembly inside as shown in the figure, pry slightly, and remove the timing chain case assembly from the cylinder head and cylinder block.

Scheme 102

Scheme 103

1. Temporarily install the crankshaft pulley to the crankshaft. CAUTION: Never turn the crankshaft counterclockwise.
2. Turn the crankshaft clockwise to align the sprocket timing marks as shown in the figure and set the number 1 cylinder to the top dead center of compression stroke. NOTE: At this time, it is not necessary that the link plate (orange or blue) of the timing chain always aligns with each sprocket timing mark.
3. Remove the crankshaft pulley installed temporarily.
4. Using a flat-tipped precision screwdriver, release the ratchet of timing chain tensioner.
5. Compress the plunger of timing chain tensioner and insert hard wire (such as piano wire) or the L-shaped hexagon wrench [1.5 mm (0.05 inch)] to fix the plunger of the timing chain tensioner.
6. Remove the timing chain tensioner.

Scheme 104

Scheme 105

1. Set the timing marks of the camshaft sprockets and the crankshaft sprocket as shown in the figure.
2. Align each sprocket timing chain mating marks with the link plate (orange or blue) of timing chain to avoid slack of the timing chain tension side, and install the timing chain to the sprockets.

Scheme 106

Scheme 107

1. Check that the sprocket timing chain mating marks align with the link plates (orange or blue) of the timing chain, and install the timing chain tensioner to the cylinder block.
2. Remove the hard wire or L-shaped hexagon wrench fixing the plunger of the timing chain tensioner to apply tension to the timing chain.

>> C << CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire inner diameter of the crankshaft front oil seal lip. CAUTION: When installing the crankshaft front oil seal, be careful to avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

>> D << TIMING CHAIN CASE ASSEMBLY INSTALLATION

Scheme 108

Scheme 109

Scheme 110

1. Completely remove the liquid gasket adhered to the timing chain case assembly, cylinder block and cylinder head, and then degrease using the volatile degreasing agent.
2. Remove all the sealant adhering to the gasket between the cylinder head and cylinder block (three-surface aligned part). Then, degrease the surfaces with the volatile degreasing agent.
3. As for the three-surface aligned part above, the engine oil oozes from the cylinder head gasket. Thus, quickly apply the sealant to it after degreasing. Specified sealant: ThreeBond 1217G or equivalent
4. To the timing chain case assembly installation surface, apply the sealant without a gap. However, overlap the sealant at the "D" part shown in the figure. Specified sealant: ThreeBond 1217G or equivalent NOTE: Install the timing chain case assembly immediately after applying sealant. CAUTION: If the sealant contacts any other part during installation of the timing chain case assembly, apply sealant again before installing the timing chain case assembly. After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
5. Install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.
6. Insert the bolts to the timing chain case assembly as shown in illustration, and tighten them to the specified torque. TIMING CHAIN CASE ASSEMBLY BOLT SPECIFICATION Name Symbol Quantity Size mm (D x L) Flange bolt A 6 M6 x 25 B 6 M8 x 30 Bolt C 1 M6 x 25 NOTE: D: Nominal diameter, L: Nominal length Tightening torque: A, C: 10 ± 2 N.m (89 ± 17 in-lb) B: 24 ± 4 N.m (18 ± 2 ft-lb)

>> E << WATER PUMP PULLEY INSTALLATION

Temporarily tighten the water pump pulley mounting bolts. Then, tighten them to the specified torque after the installation of drive belt.

Tightening torque: 9.0 ± 1.0 N.m (80 ± 9 in-lb)

Scheme 111

Required Special Tools

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

Make mating marks on the radiator hose and the hose clamp as shown in illustration to install them in the original position. Then, remove them.

<< B >> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where it will not interfere with the removal and installation of engine assembly.

<< C >> ENGINE MOUNTING BRACKET/ENGINE ASSEMBLY REMOVAL

Scheme 112

Scheme 113

Scheme 114

1. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.
2. Remove special tool MB991928 or MB991895 which was installed for supporting the engine assembly when the transaxle assembly was removed (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#twin-clutch-sportronic-shift-transmission-tc-sst-on-vehicle-service-except-lancer-evolution) .)
3. Set special tool MB991454 to the engine hanger and the power steering oil pump bracket.
4. Hold the engine assembly with a chain block.
5. Place a garage jack against the engine oil pan with a piece of wood in between, and remove the engine mounting bracket while adjusting the position of the engine.
6. After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, raise the vehicle slowly with a lift, and remove the engine assembly downwards from the engine compartment.

>> A << ENGINE ASSEMBLY/ENGINE MOUNTING BRACKET INSTALLATION

1. Place the engine assembly below the lifted vehicle.
2. Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.
3. Set special tool MB991454 and a chain block to the engine assembly. CAUTION: When supporting the engine assembly with a garage jack, be careful not to deform the engine oil pan.
4. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting bracket while adjusting the position of the engine.
5. Remove the chain block.
6. Install special tool MB991928 or MB991895 which is used during installation of transaxle assembly to hold the engine assembly (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#twin-clutch-sportronic-shift-transmission-tc-sst-on-vehicle-service-except-lancer-evolution) .)
7. Remove the garage jack.

>> B << A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N.m (17 ± 4 ft-lb)

Scheme 115

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

1. Insert radiator hose as far as the projection of the water inlet fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

See also:
• 6. INTAKE AND EXHAUST VALVE CLEARANCE
• SYMPTOM CHART
• TIMING CHAIN MAINTENANCE
• INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE
• SERVICE PRECAUTIONS
• STEERING WHEEL SENSOR CALIBRATION
• TRANSAXLE ASSEMBLY
• CRANKSHAFT PULLEY