2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL11 - 4
Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting
Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools
because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it
should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
ToolNumberNameFunction
MB991454Engine hanger
balancerHolding the engine assembly while the
transmission assembly is removed/installed
Recommended
tools MZ203830
panzai or
MZ203831 safe
vehicle handlingMechanical engine
hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934Engine hanger
A: joint (50) x2
B: joint (90) x2
C: joint (140) x2
D: Foot (standard) x4
E: Foot (short) x4
F: Chain and hook
ASSYSlide bracket (HI)

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 5



O 



O 
Removal procedure
1. Oil feeder control valve connector
2. Oil feeder control valve
3. O-ring
4. Breather hose
• Secondary air control valve
(refer to Section 15-2: Secondary Air
Control System)
5. Centre cover
• Ignition coil
6. O
2sensor connector
7. Crank angle sensor connector8. Connection of the control harness
9. Vacuum hose
10. PCV hose
11.Connection of the radiator upper hose
12. Camshaft position sensor connector
(exhaust side)
13. Camshaft position sensor connector
(inlet side)
14. Connection of the earth cable
15. Rocker cover ASSY
16. Spark plug hole gasket
17. Rocker cover gasket
 
A






N 



M 

ENGINE – CAMSHAFT, VALVE STEM SEAL11 - 6
18. Camshaft position sensor support cover
19. Camshaft position sensor support cover
gasket
20. Camshaft position sensing cylinder
(exhaust side)
21. Camshaft position sensor support
22. Camshaft position sensor support cover
23. Camshaft position sensor support cover
gasket
24. Camshaft position sensing cylinder (inlet
side)
25. Camshaft position sensor support
26. Camshaft sprocket (exhaust side)
27. Camshaft oil seal
28. Camshaft bearing cap front
29. Camshaft bearing cap rear left30. Camshaft bearing cap No. 2
31. Camshaft bearing cap No. 5
32. Camshaft bearing cap No. 3
33. Camshaft bearing cap No. 4
34. Exhaust camshaft
35. Camshaft sprocket cap
36. Washer
37. Camshaft sprocket (inlet side)
38. Camshaft oil seal
39. Camshaft bearing cap front
40. Camshaft bearing cap rear right
41. Camshaft bearing cap No. 2
42. Camshaft bearing cap No. 5
43. Camshaft bearing cap No. 3
44. Camshaft bearing cap No. 4
45. Inlet camshaft
During assembly, apply
engine oil to all sliding
parts.



F 



F 



F 



F 



E 
 
B






H 



G 



F 



F 



F 



F 



F 



F 



E 




L 



J 



K 



J 
 
B






I 



G 



F 



F 

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 7
46. Rocker arm
47. Rush adjuster
48. Oil delivery body
49. Spark plug
50. Valve spring retainer lock51. Valve spring retainer
52. Valve spring
53. Inlet valve stem seal
54. Exhaust valve stem seal



D 
 
C






C 



B 



A 



A 

ENGINE – CAMSHAFT, VALVE STEM SEAL11A-8
Locations for the application of lubricant and seals

Semi-dry sealant:
Three bond 1207D
(around the lip):
Engine oil
Semi-dry sealant: Three bond 1207F
Semi-dry sealant: Three bond 1207F

Semi-dry sealant: Three bond 1207D

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 9
Removal guidelines
 
A


Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.
 
B


Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.
 
C


Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.
Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.
Fitting guidelines



A 
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Indicator marks
Colour of main
body: greyColour of main
body: grey/green
Inlet sideExhaust side
Valve
Valve guide
Valve stem
seal

ENGINE – CAMSHAFT, VALVE STEM SEAL11-10



B 
Fitting the valve spring
Fit the valve spring so that the end of the valve spring which has
the smaller radius is on the rocker arm side.



C 
Fitting the valve spring retainer lock
In the same way as when the valve spring retainer lock was
removed, compress the valve spring using the special tool for
compressing valve springs (MD998772), and fit the valve spring
retainer lock.



D 
Fitting the rush adjuster
Caution
If a rush adjuster is being reused, it must be washed and
inspected before fitting.
(Ref: Engine Service Manual)



E 
Fitting the camshaft
1. Remove any sealant from the cylinder head.
2. Apply engine oil to the camshaft cams and journals.
3. Fit the camshaft to the cylinder head.
Caution
Ensure that the inlet and exhaust sides are not the wrong way
round.



F 
Fitting the camshaft bearing cap No.4, the camshaft
bearing cap No.3, the camshaft bearing cap No.5, the
camshaft bearing cap No.2, the rear camshaft bearing
cap, and the front camshaft bearing cap
1. Set the camshaft dowel pins in the position shown in the
diagram.Rocker arm side
Front of engine

slit
slit
Approx. 4°dowel pins
inlet sideexhaust side