Mechanical - Lancer Evolution: Other Mitsubishi Lancer X

SEALANTS

SEALANTS SPECIFICATION

DRIVE BELT TENSION CHECK

1. Remove the radiator condenser tank. (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ). 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»(ref-289376-S30714563292008063000000) ). NOTE: The drive belt tension check is not necessary as the auto-tensioner is adopted.
4. Install the radiator condenser tank. (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ).

Scheme 76

1. Stop the engine from the idle state.
2. Remove the radiator condenser tank. (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ).
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»(ref-289376-S30714563292008063000000) ).
5. Rotate the pulley bolt of the auto-tensioner clockwise and counterclockwise with an offset wrench [45°, a long offset wrench (5/8 x 11/16 inches) recommended] to check for binding.
6. If there are any problems in the procedure 3 or 5, replace the auto-tensioner. (Refer to «TIMING CHAIN»(ref-289376-S35593109372008063000000) ).
7. Install the drive belt. (Refer to «CRANKSHAFT PULLEY»(ref-289376-S30714563292008063000000) ).
8. Install the radiator condenser tank. (Refer to «RADIATOR»(ref-289378-S01895578722008063000000) ).

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: Mic Assembly

Scheme 77

Scheme 78

1. Check the tension of the drive belt. (Refer to «ON-VEHICLE SERVICE»(ref-289376-S33084051282008063000000) ).
2. Check the tension of the drive belt in the following procedures. Connect special tool microphone assembly (MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080). Press the "POWER" button to turn on the power supply. Press the numeral key of "1" and check that "No. 1" appears on the upper left of the display. 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 "Hz" button twice to change the display to the frequency display (Hz). CAUTION: The temperature of the surface of the belt should be as close to normal temperature as possible. Do not allow any contaminants such as water or oil to get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running. Hold special tool 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). 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»(ref-289376-S35593109372008063000000) ).

< When using a tension gauge >

Scheme 79

1. Check the tension of the drive belt. (Refer to «ON-VEHICLE SERVICE»(ref-289376-S33084051282008063000000) ).
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»(ref-289376-S35593109372008063000000) ).

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 80

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 TC-SST) 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»(ref-289380-S32060888702008063000000) . 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: Neutral (P range on vehicles with TC-SST) 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»(ref-289380-S32060888702008063000000) .
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 TC-SST) 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 2,500 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»(ref-289380-S32060888702008063000000) )
10. 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.
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 81

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 TC-SST) 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. Remove all of the ignition coils and 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. Crank the engine with the throttle valve fully open and 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 650 kPa (95 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 100 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.

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

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 TC-SST) 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 diagnosis code No. P0012, variable valve timing (VVT) advanced-angle value abnormal, is output. Unless the diagnosis code No. P0012, therefore, is output, the visual check is unnecessary.

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 diagnosis 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

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

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.
7. Install the upper chain guide. CAUTION: Completely clean the old FIPG remaining in the clearance between the mating parts. Install the cylinder head cover within 3 minutes of applying the liquid gasket.
8. Apply a 4 mm diameter bead of liquid gasket to the point shown in the illustration. Liquid gasket: THREE BOND 1217G or equivalent product.
9. 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
10. Install the ignition coil.
11. Use the scan tool MB991958 to select the timing chain maintenance. Initialize the learning value. Refer to «TIMING CHAIN MAINTENANCE»(ref-289379-S11700470332008063000000) . 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 diagnosis code No. P0012 is output.

Scheme 87

Required Special Tools

1. MB990767: Front Hub and Flange End Yoke Holder
2. MD998719: Pin

B: CYLINDER NO. 1 COMPRESSION TOP DEAD CENTER SETTING

Scheme 88

1. Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the cylinder No. 1 to the top dead center of compression. At this time, check that the crankshaft pulley timing mark is in the 0-degree 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 89

Scheme 90

Scheme 91

1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case, 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 beyond its insertion guideline. If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special tool forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool.
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 (Figure A). NOTE: With the timing chain tensioner unlocked, insert the special tool along the tension side of the timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guide line aligns with the timing chain case assembly top surface (Figure B), and the spread timing chain tension side guide can be held (Figure C).
3. With the special tool inserted up to the insertion guide line, press the special tool 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 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.

F: FUEL HIGH-PRESSURE HOSE CONNECTION

Scheme 92

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 93

Required Special Tools

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