1998 MITSUBISHI LANCER EVOLUTION IV engine

ENGINE – Timing Belt11-23

ETIMING BELT “B” REMOVAL
Make an arrow mark on the back of the timing belt indicating
the direction of rotation so it may be reassembled in the
same direction if it is to be reused.

FCOUNTERBALANCE SHAFT SPROCKET
REMOVAL

GCRANKSHAFT SPROCKET “B” REMOVAL
If it is difficult to remove the sprocket, use the special tool.

HCAMSHAFT SPROCKET BOLT LOOSENING
Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
6EN1322

ENGINE – Timing Belt11-24
(2) Cracks on rubber back.
(3) Cracks of canvas.
(4) Cracks on rib root.
(5) Cracks on belt sides.
(6) Abnormal wear of belt sides.
NOTE
The sides are normal if they are sharp as if cut by a
knife.
(7) Abnormal wear on teeth.
Initial stage:
Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white, and
unclear canvas texture)
Final stage:
Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
(8) Missing tooth.
AUTO TENSIONER
(1) Check the auto tensioner for possible leaks and replace
as necessary.
(2) Check the rod end for wear or damage and replace as
necessary.
(3) Measure the rod protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 12 mm
(4) Press the rod with a force of 98 – 196 N {10 – 20 kgf}
and measure its protrusion. If it is out of specification,
replace the auto tensioner.
Standard value: 1 mm or lessCracks
Cracks
on sides Cracks
Cracks on rib root Peeling of
canvas
Tooth missing
12 mm
6EN1033
98 to 196 N {10 to 20 kgf}
Movement

ENGINE – Timing Belt11-25
INSTALLATION SERVICE POINTS
A
CAMSHAFT SPROCKET BOLT TIGHTENING
Using a wrench, hold the camshaft at its hexagon and tighten
the bolt to the specification.
Caution
Locking the camshaft sprocket with a tool damages the
sprocket.
B
ENGINE SUPPORT BRACKET LEFT
INSTALLATION
Coat the bolts illustrated with sealant before tightening.
Specified sealant: THREEBOND 1207F or equivalent
C
SEALANT APPLICATION ON SEMI-CIRCULAR
PACKING
Apply sealant to the areas indicated in the illustration.
Specified sealant: THREEBOND 1212D or equivalent
Apply sealant
Apply
sealant 10 mm
10 mm
Cylinder head Semi-circular
packing

ENGINE – Timing Belt11-26
D
SEALANT APPLICATION ON ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Specified sealant: THREEBOND 1212D or equivalent
Apply sealant
10 mm
10 mm 10 mm
10 mm
Apply sealant
Apply sealant
E
SPACER INSTALLATION
(1) Apply very thin coat of oil to the outer periphery of the
spacer (oil seal contacting surface).
(2) Install the spacer with the chamfered end toward the
oil seal. Mounting in the reverse direction can damage
the oil seal lip.
F
COUNTERBALANCE SHAFT SPROCKET
INSTALLATION
G
TIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
SpacerOil seal
Chamfer
Timing
marks Timing
marks

ENGINE – T iming Belt 11-27
(3) Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
(4) Move the tensioner “B” in the direction of arrow while
lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B” . When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.
 H
CRANKSHAFT BOLT TIGHTENING
 I
OIL PUMP SPROCKET INSTALLATION
(1) Block the counterbalance shaft in the same way as at the disassembly to prevent it from turning.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces
of the flange nuts.
(4) Tighten the flange nuts to the specified torque.
 J
AUTO TENSIONER INSTALLATION
(1) If the auto tensioner rod is in its fully extended position, reset it as follows.
a. Clamp the auto-tensioner in the vise with soft jaws.
b. Push in the rod little by little with the vise until the
set hole A in the rod is aligned with the hole B in
the cylinder.
Tensioner “B”
Timing belt “B”
Tension side
of timing belt
Center of
tensioner
pulley
Center
of bolt
6EN0564
6AE0049
A
B

ENGINE – Timing Belt11-28
c. Insert a wire (1.4 mm in diameter) into the set holes.
d. Unclamp the auto tensioner from the vise.
(2) Install the auto tensioner. Leave the wire installed in the
auto tensioner until the timing belt is installed.
 K
TENSIONER PULLEY INSTALLATION
Install the tensioner pulley as shown in the illustration.
 L
TIMING BELT INSTALLATION
(1) Place the exhaust side camshaft sprocket in a position where its timing mark is one tooth offset from the timing
mark on the rocker cover in the counterclockwise direction.
NOTE
Even if the timing marks on the sprocket and the rocker
cover are brought into alignment, the exhaust camshaft
is forced back by the valve spring tension. It is stabilized
at a position one tooth before the timing mark.
(2) Align the timing mark on the intake side camshaft sprocket with that on the rocker cover.
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
(3) Place the timing mark on the crankshaft sprocket one tooth this side from the mated timing mark as in the case
of the camshaft sprocket.
6AE0050
6EN1323
Holes in
tensioner
pulley
Timing marks
Timing marks

ENGINE – T iming Belt 11-29
(4) Align the timing mark on the oil pump sprocket with its
mating mark.
(5) Remove the plug on the left side of the cylinder block
and insert a Phillips screwdriver (shank diameter 8 mm)
through the hole.
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 – 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
screwdriver can be inserted 60 mm or more.
(6) Remove the Phillips screwdriver. Place the oil pump sprocket in a position where its timing mark is one tooth
offset from the mated timing mark in the counterclockwise
direction.
(7) Fit the timing belt over the exhaust side camshaft sprocket, and secure it at the illustrated position using a paper
clip.
(8) Turn the intake side camshaft sprocket as shown to a position where its timing mark is one tooth offset from
the mated timing mark in the counterclockwise direction.
Then, fit the timing belt over the sprocket and secure
it with a paper clip.
NOTE
The intake camshaft will be turned a little clockwise by
the valve spring tension and stabilized in position even
if the belt is clipped at one tooth offset position.
(9) Check to ensure that the timing marks on the intake camshaft sprocket side are in alignment when the exhaust
camshaft sprocket is turned clockwise to align the timing
marks.
NOTE
The timing belt span between the intake and exhaust
sprockets will have 17 cogs.
Screwdriver
Plug
Timing marks
6EN1327
Timing marks

ENGINE – Timing Belt11-30
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
(11) Fit the timing belt over the tensioner pulley. NOTE
When fitting the timing belt over the tensioner pulley,
turn the intake side camshaft sprocket a little
counterclockwise, as this will facilitate the work.
(12)Turn the crankshaft pulley a little in the illustrated direction to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
(14)Using the special tool, turn the tensioner pulley in the illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
lightly.
NOTE
There must be no slack in the timing belt between the
intake and exhaust camshafts.
(15)Turn the crankshaft to align the timing mark with the mark for No. 1 cylinder top dead center in the compression
stroke.
(16)Set the special tool as shown and screw it in up to the position where the wire inserted in the auto-tensioner
when installing it can be moved lightly.
Crankshaft
sprocket Oil pump
sprocket
Camshaft
sprocket
Crankshaft
sprocket
MD998767
MD998738