2005 MITSUBISHI LANCER EVOLUTION IX check engine

ENGINE – CYLINDER HEAD GASKET
11-17
Removal guidelines



A 
Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn
the bolts 2~3 times in order to loosen them, before removing them
in the numerical order as shown in the diagram.
Fitting guidelines



A 
Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of
the gasket.
Caution
Do not allow any foreign matter to get into the channels for
coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the
holes in the cylinder head gasket match up with the holes in the
cylinder head.



B 
Fitting the cylinder head bolts
1. Check that the length of the body of cylinder head bolts is less
than the maximum permitted. If the length is in excess of the
maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the
bolt, and to the washer.
Front of engine
(engine oil)

ENGINE – CYLINDER HEAD GASKET11-18
3. Use the special wrench for cylinder head bolts (MB991654) to
(loosely) tighten the bolts in the following order.
(1) In the order shown in the diagram, tighten the bolts to
78 ± 2 N•m.
(2) In reverse order to that shown in the diagram, completely loosen
the bolts.
(3) In the order shown in the diagram, tighten the bolts to
20 ± 2 N•m.
(4) Make a paint mark on the top of the cylinder head bolt, and on
the cylinder head, and tighten them to 90° as shown in the
diagram.
(5) Tighten the bolts to 90° as shown in the diagram, and check that
the paint mark on the top of the cylinder head bolt and the paint
mark on the cylinder head are in line.
Caution
1) If a bolt is tightened to an angle of less than 90° it has not
been tightened sufficiently.
2) If the angle of tightening exceeds the regulation level,
remove the bolt and start again from procedure number (1).



C 
Fitting the O-ring/fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that engine oil does not get inside the delivery pipe.
2. Without damaging the O-ring, twist the fuel high pressure hose
to fit it to the delivery pipe, making sure that it is twisted
smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose to the
specified torque.
Tightening torque: 5.0 ± 1.0 N•m.
Front of engine
Procedure number (4)Procedure number (5)
paint markpaint mark

ENGINE – TIMING BELT, TIMING BELT B11-20
TIMING BELT, TIMING BELT B
Removal and fitting
Caution
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.
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Removal and refitting of the LH side cover.
•Checking and adjustment of the tension of the drive belt.
•Removal and refitting of the crankshaft pulley.
•Removal and refitting of the cross member bar.
•Removal and refitting of the front exhaust pipe.
Removal procedure
1. Pressure hose connection
2. Timing belt front upper cover
3. Water pump pulley
4. Idler pulley
5. Drive belt auto-tensioner
6. Timing belt front lower cover•Remove the engine mount bracket
•Adjust the tension of the timing belt

7. Timing belt
8. Tensioner pulley
9. Tensioner arm
10. Auto-tensioner



G 
 
A






F 



E 



D 

ENGINE – TIMING BELT, TIMING BELT B11-22
3. Twist the special tool for adjusting bolts (MD998738) by hand
until it touches the tensioner arm.
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and
then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.
Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
direction (clockwise direction) on the back of the belt.
 
B


Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.
 
C


Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.timing belt tensioner
arm
bolt for fitting the timing belt
tensioner
wire or pin
Crankshaft
sprocket

ENGINE – TIMING BELT, TIMING BELT B
11-23
 
D


Removing timing belt B
Caution
If planning to re-use a timing belt B, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
Fitting guidelines



A 
Fitting timing belt B and the timing belt B tensioner
1. Check that the timing marks for the crankshaft sprocket and the
balancer shaft sprocket are aligned.
2. Fit timing belt B onto the crankshaft sprocket and the balancer
shaft sprocket. Ensure that the side of the belt under tension is
not slack.
3. As a temporary step, fit the timing belt B tensioner pulley so that
its centre is to the upper left of the centre of the mounting bolt,
and so that the flange of the pulley is facing towards the front of
the engine.
4. Adjust the tension of timing belt B.



B 
Adjusting the tension of timing belt B
1. Hold the timing belt B tensioner between fingertips and in the
direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to
timing belt B until the side of the belt under tension becomes
taught. In this condition, tighten the mounting bolt to the
specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m
Caution
When tightening the mounting bolt, ensure that the
tensioner does not turn round with it. If the tensioner turns
with the mounting bolt, it could cause the tension in the belt
to become too high.
timing marks
balancer shaft
sprocket
crankshaft sprocket
side of belt
under tension
timing
marks
centre of the
pulley
centre of the
mounting bolt

ENGINE – TIMING BELT, TIMING BELT B11-24
2.
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
5~7mm
5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3.
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
approx. 100 N
amount of
give
pull lightly with fingertips

ENGINE – TIMING BELT, TIMING BELT B11-26



F 
Fitting the timing belt
1. Check that all the timing marks for the camshaft sprocket, the
crankshaft sprocket and the oil pump sprocket are aligned.
2. After the timing marks for the oil pump sprocket have been
aligned, remove the plug from the cylinder block and insert a
posidrive (+) with a diameter of 8 mm into the plug hole. Check
that more than 60 mm of the shaft of the screwdriver can be
inserted. If the screwdriver strikes the balancer shaft and can
only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one
complete turn, realign the timing marks, and check that more
than 60 mm of the screwdriver can be inserted. Do not remove
the screwdriver until the timing belt has been fitted.
3. Install the timing belt in accordance with the following guidelines
so that the side that is under tension does not get slack.
(1) Fit the timing belt around the crankshaft sprocket first, then
the oil pump sprocket and then fit it around the idler pulley.
(2) Fit the timing belt around the camshaft sprocket (exhaust
side) and hold it in place with a paper clip at the position
shown in the diagram.
timing marks
camshaft
sprocket (inlet
side)
timing
marks
crankshaft
sprocket
camshaft
sprocket
(exhaust
side)
timing
marks
oil pump
sprocket
plug
more than
60 mm
screwdriver
balancer shaft
camshaft
sprocket (inlet
side)
tensioner pulley
crankshaft
sprocket
camshaft
sprocket
(exhaust side)
idler
pulley
oil pump
sprocket
paper
clip

ENGINE – TIMING BELT, TIMING BELT B
11-27
(3) Use a wrench to align the timing marks on the rocker cover and
the camshaft sprocket, and whilst doing so, fit the timing belt
around the camshaft sprocket (inlet side) and hold it in place
with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley.
(5) Remove the two paper clips.
Caution
After the timing belt has been installed, apply some force in
an anti-clockwise direction to the camshaft sprocket and
check once more that all the timing marks are in the correct
position when the side of the belt under tension is taught.
4. Using the special wrench for the tensioner pulley socket
(MD998767), tense the timing belt by turning the tensioner
pulley in the direction shown in the diagram, and temporarily
tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.



G 
Adjusting the tension of the timing belt
1. Remove the rubber plug from the rear cover of the timing belt
and put the special adjusting bolt (MD998738) in position.
Slowly twist the adjusting bolt a little at a time, so that the wire
or pin inserted when fitting the auto-tensioner, only moves a
little.
Caution
There is a possibility that the wire or pin inserted in the
auto-tensioner may break if the adjusting bolt is twisted
with a spanner or a similar tool, so it must be twisted by
hand.
2. Turn the crankshaft a quarter turn in an anti-clockwise direction.
3. Turn the crankshaft in a clockwise direction, realign all the timing
marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had
been temporarily tightened.paper clips