1998 MITSUBISHI LANCER EVOLUTION IV service

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
July 1998
EVOLUTION-IV
EVOLUTION-V

11-1
ENGINE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SEALANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ADJUSTMENTS 4 . . . . . . . . . . . . . . . . .
1. Drive Belt Tension Check 4 . . . . . . . . . . . . . . .
2. Auto Tensioner Check 5 . . . . . . . . . . . . . . . . . . .
3. Lash Adjuster Check 5 . . . . . . . . . . . . . . . . . . . .
4. Lash Adjuster Replacement 7 . . . . . . . . . . . . . .
5. Ignition Timing Check 7 . . . . . . . . . . . . . . . . . . .
6. Idle Speed Check and Idle Mixture Check 7
7. Compression Pressure Check 7 . . . . . . . . . . . .
8. Manifold Vacuum Check 8 . . . . . . . . . . . . . . . . .
CRANKSHAFT PULLEY 9. . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT
OIL SEAL 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL 15 . . . . . . . . . . . . . .
CYLINDER HEAD GASKET 17 . . . . . . . . . . . .
TIMING BE LT . . . . . . . . . . . . . . 21 . . . .
ENGINE ASSEMB LY 32
. . . . . . . . . . . . . . . . . . .

ENGINE – Service Specifications / Sealants / Special Tools11-2
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Basic ignition timing5
BTDC ± 3
–
Ignition timing (at idle)Approx. 5
BTDC–
Idle speed rpm850 ± 50–
CO contents %0.6 or less–
HC contents ppm300 or less–
Compression pressure kg/cm2 – rpm11.5 – 250Min. 9.7 – 250
Compression pressure difference of all cylinders kg/cm2–Max. 1.0
Intake manifold vacuum kPa {mmHg}–Min. 55 {410}
Cylinder head bolt shank length mm–99.4
SEALANTS
ItemsSpecified sealants
Rocker coverSemi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g)
Oil panSemi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)
NOTE:
Given in [ ] are MITSUBISHI GENUINE PART numbers.
SPECIAL TOOLS
ToolNumberNameUse
MD998782Valve lifter setReplacing the lash adjuster
MB990767End yoke holderHolding the crankshaft pulley
Holding the camshaft sprocket

ENGINE – Crankshaft Pulley11-9
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
Under Cover RemovalPost-installation Operation
Drive Belt Tension Adjustment (Refer to P.11-4.)
Under Cover Installation
1
2
25 {2.5}
Unit: Nm {kgf
m}
Removal steps
A1. Drive belt
2. Crankshaft pulley
REMOVAL SERVICE POINT
ADRIVE BELT REMOVAL
(1) Align the hole in the auto tensioner bracket with that
in the arm and insert a screwdriver into the holes.
(2) Remove the drive belt.
Phillips
screwdriver
Hole in arm
Auto tensioner
Hole in bracket

ENGINE – Camshaft and Camshaft Oil Seal11-11
Grease and adhesive application points
Timing belt side
Semi-drying sealant: THREEBOND 1207D
Lip 10 mm
10 mm10 mm
Semi-drying sealant:
THREEBOND 1207FEngine oil
Semi-drying sealant: THREEBOND 1207DTiming belt side
26
φ 3 mm
REMOVAL SERVICE POINT
ACAMSHAFT SPROCKET REMOVAL
INSTALLATION SERVICE POINTS
ACAMSHAFT INSTALLATION
(1) Apply engine oil to the cams and journals of the camshaft.
(2) Mount the camshaft on the cylinder head.
Caution
Make sure that the camshaft has a unique orientation
for installation, the intake side and exhaust side. The
exhaust camshaft has a slit in the rear end face.
MB990767
MD998719
Camshaft sprocket side
Camshaft (exhaust side)Slit

ENGINE – Oil Pan11-14
REMOVAL SERVICE POINT
AOIL PAN REMOVAL
INSTALLATION SERVICE POINTS
ADRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
BOIL RETURN PIPE GASKET INSTALLATION
Install the gasket with the printed portion toward the oil pan.
MD998727MD998727
Drain plug gasket
Oil pan side
GasketPrinted portion

ENGINE – Crankshaft Oil Seal11-16
REMOVAL SERVICE POINT
AFLYWHEEL ASSEMBLY REMOVAL
Use the special tool to secure the flywheel assembly and
remove the bolts.
INSTALLATION SERVICE POINTS
ACRANKSHAFT REAR OIL SEAL INSTALLATION
(1) Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
(2) Install the oil seal with the special tool as far as the
chamfered position of the oil seal case as shown in the
illustration.
BFLYWHEEL ASSEMBLY INSTALLATION
Use the special tool to hold the flywheel in the same manner
as removal, and install the bolt. Tighten the bolts to the
specification.
Tightening torque: 127 – 137 Nm {13.0 – 14.0 kgf
m}
CCRANKSHAFT FRONT OIL SEAL INSTALLATION
Apply a small amount of engine oil to the entire circumference
of the oil seal lip.
Pressfit the oil seal until it is flush with the chamfered end
of the oil pump case.
MD998781
Crankshaft
rear oil seal
MB990938
MB998776Crankshaft
Crankshaft
MD998382
Oil seal
MD998285
(Lubricate outer
circumference with oil)

ENGINE – Cylinder Head Gasket11-19
REMOVAL SERVICE POINT
ACYLINDER HEAD BOLT REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
INSTALLATION SERVICE POINTS
ACYLINDER HEAD GASKET INSTALLATION
(1) Wipe off all oil and grease from the gasket mounting
surface.
(2) Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.
BCYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 99.4 mm
(2) Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
Intake sideMB991654
Exhaust sideFront of engine
Cylinder head bolt
Washer
(Engine
oil)
Cylinder
head A