2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 11
2. Because camshaft bearing caps Nos. 2~5 are the same shape,
check the identification marks on them so that the bearing cap
number and the inlet and exhaust sides are not mistaken. Then
fit them in the direction shown in the diagram.
Identification marks (stamped on the front bearing cap, and on
bearing cap Nos. 2~5).
I: inlet side
E: exhaust side
3. Apply sealant at the 8 places shown in the diagram of the top
view of the cylinder head.
Semi-dry sealant: Three bond 1207D
4. Fit the rear camshaft bearing cap in the direction indicated by
the front mark.
5. In just the same way as for bearing caps Nos. 2~5, check the
identification marks on the front camshaft bearing cap so that
the exhaust side and the inlet side are not mistaken.
6. Tighten the bearing cap mounting bolts gradually, 2~3 turns at a
time, to the specified torque.
Tightening torque: 20 ± 1 N•m
7. Check that the rocker arm has been fitted correctly.
Note
Completely wipe away any sealant that has been squeezed out.



G 
Fitting the camshaft oil seal
1. Apply engine oil around the entire circumference of the oil seal
lip.
2. Insert the oil seal using the special tool for installing the
camshaft oil seal (MD998713), as shown in the diagram.
Front of
engine
bearing cap No.
mark indicating
inlet side or
exhaust side
Front of engine

Front
of
engine
Front
of
engine
front mark

front mark
camshaft oil seal
(engine oil)

ENGINE – CAMSHAFT, VALVE STEM SEAL11-12



H 
Fitting the camshaft sprocket (inlet side)
1. Apply engine oil to the edges of the camshaft, and to the parts
of the camshaft sprocket which will make contact with the
camshaft.
2. Match up the camshaft dowel pins with the dowel pin holes in
the camshaft sprocket, and fit the camshaft into the camshaft
sprocket.
3. Hold the hexagonal part of the camshaft with a wrench, and
check that the camshaft sprocket cannot be twisted.
Note
This operation is necessary because it is impossible to check by
looking whether the camshaft dowel pins are inserted into the
dowel pin holes in the camshaft sprocket.
4. Apply engine oil to the screw thread and the underside of the
camshaft sprocket mounting bolt, and in the same way as when
the camshaft sprocket was removed, hold the camshaft in place
using a wrench and tighten the bolt to the specified torque.
Tightening torque: 65 ± 5 N•m



I 
Fitting the camshaft sprocket (exhaust side)
In the same way as when the camshaft sprocket was removed,
hold the hexagonal part of the camshaft with a wrench and
tighten the bolt to the specified torque.
Tightening torque: 89 ± 9 N•m



J 
Fitting the camshaft position sensor support
1. Remove any sealant from the camshaft position sensor support.
2. As shown in the diagram, apply sealant to the flange of the
camshaft position sensor support, and then fit it to the cylinder
head.
Semi-dry sealant: Three bond 1207F
3. Tighten the mounting bolts for the camshaft position sensor
support to the specified torque.
Tightening torque: 14 ± 1 N•m
Front of
engine(engine oil)
(engine oil)
camshaft
sprocket
camshaft
sprocket
Front of
engine

ENGINE – CAMSHAFT, VALVE STEM SEAL
11-13



K 
Fitting the camshaft position sensing cylinder (inlet
side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



L 
Fitting the camshaft position sensing cylinder (exhaust
side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
Note
Under pressure from the exhaust valve spring, it will turn slightly
in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position
approximately 45° to the exhaust camshaft dowel pin.
3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m



M 
Fitting the locker cover assembly
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.
Semi-dry sealant: Three bond 1207D
2. Fit the rocker cover assembly onto the cylinder head.



N 
Connecting the radiator upper hose
1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose. dowel pin
pane
pane (small)
dowel pin approx. 45º
pane (large)
Front of engine
Protrusion
water outlet
fittingindicator marks

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14



O 
Fitting the O-ring/oil feeder control valve
Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Check the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape

ENGINE – CYLINDER HEAD GASKET
11-15
Removal procedure
1. Ignition coil connector
2. O
2sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position sensor connector
10. Injector connector
11.Exhaust camshaft position sensor
connector12. Inlet camshaft position sensor
connector
13. Water temperature gauge unit
connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Secondary air control solenoid valve
connector
17. Vacuum tank, solenoid valve, vacuum
pipe and hose assembly
18. Brake booster vacuum hose connection
19. Oil level gauge and guide assembly
20. O-ring
21. Purge hose connection
(engine oil)

ENGINE – CYLINDER HEAD GASKET11-16
22. Alternator bracket connection
23. Inlet manifold stay
24. Eye bolt
25. Gasket
26. Eye bolt
27. Gasket
28. Oil feeder control valve pipe
29. Filter
30. Oil pipe joint
31. Gasket
32. Oil return pipe gasket
33. Oil return pipe
34. Oil return pipe gasket35. Oil return pipe gasket
36. Exhaust fitting bracket
•Water outlet fitting and thermostat case
assembly (Refer to Section 14: Water hose
pipe)
37. Water hose connection
38. Heater hose connection
39. Fuel return hose connection
40. Fuel high pressure hose connection
41. O-ring
42. Cylinder head bolt
43. Cylinder head assembly
44. Cylinder head gasket
(when
cool)
(engine oil)
(engine oil)



E 




D 




C 



C 
 
A






B 



A 

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