Engine Mechanical <2.4l> - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

The 4B12 (2.4 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 or drive plate MD998718 Crankshaft rear oil seal installer MD998718-01 Press-fitting the crankshaft rear oil seal MB991448 Bush remover and installer base MB991448-01 Press-fitting the crankshaft front oil seal MB991614 Angle gauge - Balancer shaft and oil pump module installation 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 MB991527 Hanger Tool not available MB992201 Engine hanger plate - MB991454 Engine hanger balancer MZ203827-01

Scheme 227

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Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

1. Remove the radiator condenser tank mounting bolt, and move the radiator condenser tank to a place where it does not interfere with the drive belt tension check (Refer to «RADIATOR»(/mitsubishi/lancer-evolution/x-2007-2016/remont/cooling-system-mechanical/#engine-cooling-except-lancer-evolution) ). 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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution__removal-and-installation) .) 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 (Refer to «RADIATOR»(/mitsubishi/lancer-evolution/x-2007-2016/remont/cooling-system-mechanical/#engine-cooling-except-lancer-evolution) ).

OPERATION CHECK

Required Special Tool

MB992278: Belt tension release wrench

Scheme 240

1. Stop the engine from the idle state.
2. Remove the radiator condenser tank mounting bolt, and move the radiator condenser tank to a place where it does not interfere with the auto-tensioner check (Refer to «RADIATOR»(/mitsubishi/lancer-evolution/x-2007-2016/remont/cooling-system-mechanical/#engine-cooling-except-lancer-evolution) ).
3. Check that the drive belt are not protruding from the pulley width of drive belt auto-tensioner.
4. Remove the drive belt (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution__removal-and-installation) ). 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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) ).
8. Install the drive belt (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution__removal-and-installation) .)
9. Install the radiator condenser tank to the original position (Refer to «RADIATOR»(/mitsubishi/lancer-evolution/x-2007-2016/remont/cooling-system-mechanical/#engine-cooling-except-lancer-evolution) ).

FUNCTION CHECK

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

Required Special Tools

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

Scheme 241

Scheme 242

1. Check the tension of the drive belt (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-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 (Scheme 230) 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. 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: 102 - 129 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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution).)

Scheme 243

1. Check the tension of the drive belt (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-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

Scheme 244

Scheme 245

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: Neutral (P range on vehicles with CVT) 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. 3) of the ignition coil No. 1.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 650 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, check the following items: Diagnostic output Timing chain 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. 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: The 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.
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: Neutral (P range on vehicles with CVT) 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. 3) 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: The 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: 650 ± 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-24l-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: Neutral (P range on vehicles with CVT) 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. 3) 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: The 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-24l-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

Scheme 246

Scheme 247

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: Neutral (P range on vehicles with CVT) 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. Turn the ignition switch to the "LOCK" (OFF) position.
3. Disconnect the connector of the ignition coil, and then remove all the ignition coils and the spark plugs.
4. 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.
5. 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.
6. Set compression gauge to one of the spark plug holes.
7. Cranking the engine with the accelerator pedal fully depressed, measure the compression pressure. Standard value (at engine speed of 200 r/min): 1,440 kPa (209 psi) Limit (at engine speed of 200 r/min): Minimum 1,000 kPa (145 psi)
8. 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)
9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps from 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 all of the injector connectors.
11. Install the spark plugs and ignition coils.
12. Use the scan tool MB991958 to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.
13. 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-24l-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 248

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: Neutral (P range on vehicles with CVT) 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 650 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.

Scheme 249

Required Special Tools

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

<< A >> RADIATOR CONDENSER TANK ASSEMBLY REMOVAL

Remove the radiator condenser tank assembly mounting bolt, and move the radiator condenser tank assembly to a place where it does not interfere with the drive belt removal and installation.

<< B >> DRIVE BELT REMOVAL

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

Scheme 250

Scheme 251

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 252

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

Scheme 253

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 to the specified torque. Tightening torque: 210 N.m (155 ft-lb)

Scheme 254

Scheme 255

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 256

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 257

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

Scheme 258

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.)

Scheme 259

Scheme 260

Scheme 261

Scheme 262

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 252).) 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 252) ), and the spread timing chain tension side guide can be held ("C" in (Scheme 252).)
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 263

<< 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 264

Scheme 265

Scheme 266

Scheme 267

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/CAMSHAFT REMOVAL

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

Scheme 268

<< 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.

<< I >> 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.

Scheme 269

Scheme 270

1. Use a monkey wrench to secure the hexagon part of the camshaft in the same manner as removal.
2. Apply an adequate and minimum amount of engine oil to the camshaft and camshaft sprocket as shown in the figure.
3. Install the camshaft sprocket to the camshaft.
4. Apply an adequate and minimum amount of engine oil to the camshaft sprocket mounting bolt.
5. Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 59 ± 5 N.m (44 ± 3 ft-lb)

Scheme 271

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 272

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 273

Scheme 274

Scheme 275

Scheme 276

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 265).) 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 265) ) and spread and hold the timing chain tension side guide ("C" in (Scheme 265).)
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 265) ) 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 277

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 267) ). 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 267) ). 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 278

Scheme 279

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 280

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 281

Scheme 282

Scheme 283

1. Temporarily install the engine oil pan which was removed at the timing chain removal (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-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 284

Scheme 285

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 286

>> A << VALVE STEM SEAL INSTALLATION

Scheme 287

Scheme 288

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 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.

Scheme 289

>> C << 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.

>> D << 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)

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

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 283) ). 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 283) ). Tightening torque: 30 ± 2 N.m (22 ± 1 ft-lb)
3. Install special tool MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) ).
4. Remove the garage jack which supports the engine and transaxle assembly.
5. Remove the engine oil pan installed temporarily.

Scheme 290

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 291

Scheme 292

Scheme 293

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 from 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 294

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. Within three minutes, 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 295

>> C << 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 296

INSPECTION

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

Scheme 297

Required Special Tools

1. MB991883: Flywheel Stopper
2. MD998718: Crankshaft Rear Oil Seal Installer
3. MB991448: Bush Remover And Installer Base

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

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

Fix the drive plate using special tool MB991883, and loosen the drive plate bolts .

Scheme 298

Scheme 299

1. Apply a small amount of engine oil to the entire inner diameter of the crankshaft rear oil seal lip.
2. Using special tool MD998718, press in the crankshaft rear oil seal up to the cylinder block end surface.

Scheme 300

Scheme 301

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

Scheme 302

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 303

Scheme 304

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 305

Scheme 306

Scheme 307

1. Remove the stopper of the fuel high-pressure hose.
2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure. NOTE: If the retainer is released, install it securely after removing 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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-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 ASSEMBLY REMOVAL

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

Scheme 308

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

Scheme 309

Scheme 310

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 311

Scheme 312

1. Replace cylinder head bolts with a 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

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

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 102 ). 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 102 ). Tightening torque: 30 ± 2 N.m (22 ± 1 ft-lb)
3. Install special tool MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) ).
4. Remove the garage jack which supports the engine and transaxle assembly.
5. Remove the engine oil pan installed temporarily.

>> F << FUEL HIGH-PRESSURE HOSE CONNECTION

Scheme 313

>> G << 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 314

Scheme 315

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 316

Required Special Tools

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

<< A >> CRANKSHAFT PULLEY REMOVAL

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

<< B >> 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.

<< C >> ENGINE AND TRANSAXLE ASSEMBLY HOLDING

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

Scheme 317

Scheme 318

1. 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. 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 the engine hanger, and set it to special tool MB991895 to support the engine and transaxle assembly.

<< D >> TIMING CHAIN CASE ASSEMBLY REMOVAL

Scheme 319

Scheme 320

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 321

Scheme 322

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 323

Scheme 324

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 325

Scheme 326

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 327

Scheme 328

Scheme 329

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" 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 SPECIFICATIONS 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 330

Required Special Tool

1. MB991614: Angle Gauge

<< A >> TIMING CHAIN TENSIONER REMOVAL

Scheme 331

1. Press the balancer timing chain against the timing chain tensioner, compress the plunger of the timing chain tensioner and insert hard wire (piano wire, etc.) or L-shaped hexagon wrench [1.5 mm (0.05 inch)] to fix the plunger of the timing chain tensioner.
2. Remove the timing chain tensioner.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

1. When installing the new balancer shaft and oil pump module, apply oil to the oil pump in the balancer shaft and oil pump module and the balancer shaft bearing as follows. Clean the inside of the removed engine oil pan, and put the balancer shaft and oil pump module into the engine oil pan with its oil inlet port facing up. Pour new engine oil until two-thirds of the balancer shaft and oil pump module is soaked. Fill the new engine oil [approximately 50 cm 3 (3.05 cu. in.)] into the balancer shaft and oil pump module from the oil inlet port. Turn the balancer shaft sprocket of the balancer shaft and oil pump module clockwise four rotations or more to apply the engine oil to the entire area of the oil pump and the balancer shaft bearing.
2. With the link marks (orange or blue) of balancer timing chain aligned with the timing marks of balancer sprocket and crankshaft sprocket, install the balancer shaft and oil pump module together with the balancer timing chain and crankshaft sprocket as one unit to the cylinder block. At this time, securely bring the balancer shaft and oil pump module into contact with the rudder frame mounting area.
3. Apply an adequate and minimum amount of engine oil to the threads and bearing surfaces of the balancer shaft and oil pump module mounting bolts.
4. Tighten the balancer shaft and oil pump module mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 20 N.m (15 ft-lb)
5. Retighten the balancer shaft and oil pump module mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 44 N.m (33 ft-lb)
6. Loosen each balancer shaft and oil pump module mounting bolts fully in the reverse sequence to that shown in illustration.
7. Tighten the balancer shaft and oil pump module mounting bolts again to the specified torque in the order of number shown in the figure. Tightening torque: 20 N.m (15 ft-lb)
8. After tightening to the specified torque, tighten the balancer shaft and oil pump module mounting bolts to 135 degrees angle, using special tool MB991614, in the order of number shown in the figure.

>> B << TIMING CHAIN TENSIONER INSTALLATION

1. 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 balancer timing chain.

Scheme 337

Required Special Tool

1. MB991614: Angle Gauge

<< A >> BALANCER SHAFT AND OIL PUMP MODULE REMOVAL

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

1. Turn the crankshaft clockwise to align the timing mark of the balancer shaft sprocket with the timing mark of the balancer shaft and oil pump module, and set the number 1 cylinder or number 4 cylinder to the top dead center of compression.
2. Put paint mark on the balancer shaft sprocket timing mark and balancer timing chain. CAUTION: Securely install the plunger of the timing chain tensioner. Otherwise, it may pop out.
3. Press the balancer timing chain against the timing chain tensioner, compress the plunger of the timing chain tensioner and insert L-shaped hard wire (piano wire, etc.) or L-shaped hexagon wrench [1.5 mm (0.05 inch)] to the plunger fixing hole of the timing chain tensioner from under the timing chain case, and fix the plunger of the timing chain tensioner.
4. Use a wrench to remove the mounting bolt at the lower side of the balancer timing chain guide shown in the figure so that the balancer timing chain guide is unrestricted.
5. Support the balancer shaft and oil pump module with a hand, and remove the balancer shaft and oil pump module mounting bolts.
6. Remove the balancer shaft and oil pump module from the rudder frame with the balancer timing chain attached, and move it to the center of the engine.
7. Remove the balancer timing chain from the balancer shaft and oil pump module, and remove the balancer shaft and oil pump module. CAUTION: When the tooth jump of the balancer timing chain from the crankshaft sprocket occurs, the timing between the balancer shaft and the oil pump module becomes off, resulting in the abnormal engine vibration. Be sure that the tooth jump will not occur.
8. After the balancer shaft and oil pump module is removed, using a cable band, tie the balancer timing chain at the protrusion of the rudder frame to prevent the tooth jump of balancer timing chain from the crankshaft sprocket.

Scheme 344

1. When installing the new balancer shaft and oil pump module, apply engine oil to the oil pump in the balancer shaft and oil pump module and the balancer shaft bearing as follows. Clean the inside of the removed engine oil pan, and put the balancer shaft and oil pump module into the engine oil pan with its oil inlet port facing up. Pour new engine oil until two-thirds of the balancer shaft and oil pump module is soaked. Fill the new engine oil [approximately 50 cm 3 (3.05 cu. in.)] into the balancer shaft and oil pump module from the oil inlet port. Turn the balancer shaft sprocket of the balancer shaft and oil pump module clockwise four rotations or more to apply the engine oil to the entire area of the oil pump and the balancer shaft bearing.
2. Remove the cable band installed to prevent the tooth jump of the balancer timing chain from the crankshaft sprocket from the balancer timing chain.
3. Regarding the prevention of the tooth jump of the balancer timing chain, install the balancer shaft sprocket to the balancer timing chain with aligning the paint mark of the balancer shaft sprocket (the timing mark of the new balancer shaft and oil pump module) with that of the balancer timing chain.
4. With the paint mark of the balancer timing chain aligned with that of the balancer sprocket (the timing mark of the new balancer shaft and oil pump module), install the balancer shaft and oil pump module to the rudder frame. Securely bring the balancer shaft and oil pump module into contact with the rudder frame mounting area.
5. Apply an adequate and minimum amount of engine oil to the threads and bearing surfaces of the balancer shaft and oil pump module mounting bolts.
6. Tighten the balancer shaft and oil pump module mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 20 N.m (15 ft-lb)
7. Retighten the balancer shaft and oil pump module mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 44 N.m (33 ft-lb)
8. Loosen each balancer shaft and oil pump module mounting bolts fully in the reverse sequence to that shown in illustration.
9. Tighten the balancer shaft and oil pump module mounting bolts again to the specified torque in the order of number shown in the figure. Tightening torque: 20 N.m (15 ft-lb)
10. After tightening to the specified torque, tighten the balancer shaft and oil pump module mounting bolts to 135 degrees angle, using special tool MB991614, in the order of number shown in the figure.
11. Tighten the mounting bolt of the lower side of the balancer timing chain guide with the standard torque. Tightening torque: 10 ± 2 N.m (89 ± 17 in-lb)
12. Remove the plunger of the timing chain tensioner using the L-shaped hard wire (piano wire, etc.) or L-shaped hexagon wrench [1.5 mm (0.05 inch).]

Scheme 345

Scheme 346

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991527: Hanger
3. MB991895: Engine Hanger
4. MB991928: Engine Hanger
5. MB992201: Engine Hanger Plate

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 >> FUEL HIGH-PRESSURE HOSE DISCONNECTION

1. Remove the stopper of the fuel high-pressure hose.
2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure. NOTE: If the retainer is released, install it securely after removing the fuel high-pressure hose.

<< C >> POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. Remove the power steering oil pump assembly together with the hose 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 engine assembly.

<< D >> 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.

Scheme 347

1. Install the front end upper bar bolts to the position as shown in the figure.
2. Remove the transaxle assembly (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-trans/#manual-transaxle-on-vehicle-service-except-lancer-evolution) ) or (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-on-vehicle-service-except-lancer-evolution) )

<< F >> ENGINE MOUNTING INSULATOR REMOVAL

Scheme 348

Scheme 349

Scheme 350

1. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.
2. Remove the special tool for holding the engine assembly, which has been set when the transaxle assembly is removed. MB991928 or MB991895 MB991527 MB992201
3. Operate a garage jack so that the engine weight is not applied to the engine mounting insulator, and remove the engine mounting insulator.

Scheme 351

1. Mount the special tool MB991454 to the power steering oil pump bracket and the engine hanger, and set the chain block.
2. After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the engine assembly slowly with the chain block 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.

>> B << ENGINE MOUNTING INSULATOR INSTALLATION

1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting insulator while adjusting the position of the engine assembly.
2. Remove special tool MB991454.
3. Secure the special tool for holding the engine assembly, which will be used when the transaxle assembly is installed (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-trans/#manual-transaxle-on-vehicle-service-except-lancer-evolution) ) or (Refer to «TRANSAXLE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-on-vehicle-service-except-lancer-evolution) ) . MB991928 or MB991895 MB991527 MB992201

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)

>> D << FUEL HIGH-PRESSURE HOSE CONNECTION

>> E << 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:
• RADIATOR
• 6. INTAKE AND EXHAUST VALVE CLEARANCE
• SYMPTOM CHART
• INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE
• TRANSAXLE ASSEMBLY
• TRANSAXLE ASSEMBLY
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION