2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

ENGINE – CYLINDER HEAD GASKET
11-19



D 
Fitting the oil return pipe gasket
Replace the gasket with a new one, and fit it to the protruded part
shown in the diagram.
Note:
For the oil return pipe gasket on the turbocharger side, there is no
direction for slotting it in.



E 
Fitting the eyebolts
Caution
When tightening the eyebolts, hold the oil pipe joint in place
with a spanner so that it does not turn round as the eyebolts
are tightened.
Protrusion

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 B
11-21
10. Power steering oil pressure switch connector
11.Heat protector
12. Power steering oil pump ASSY
13. Power steering oil pump bracket
14. Idler pulley
15. Crank angle sensor16. Crankshaft sprocket
17. Crankshaft sensing blade
•Adjust the tension of the timing belt B

18. Timing belt B tensioner
19. Timing belt B
Removal guidelines
 
A


Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all
the timing marks until the No.1 cylinder is in the compressor top
dead centre position.
Caution
Turn the crankshaft in the normal way.
2. Remove the rubber plug from the rear cover of the timing belt,
and prepare the special tool for adjusting bolts (MD998738).
 
C






C 



C 



B 



A 
 
D






A 


B


(engine oil)
Timing marks
Timing belt
valence

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 B
11-25



C 
Fitting the crankshaft sensing blade and the
crankshaft sprocket
1. Clean, and remove any grease from the crankshaft sensing
blade, the crankshaft sprocket, and the surface of the crankshaft
to which the crankshaft sprocket will be fitted.
2. Fit the crankshaft sensing blade and the crankshaft sprocket in
the direction shown in the diagram.
3. Clean the screw hole in the crankshaft.
4. Place the washer with the larger surface side in the direction as
shown in the diagram, and fit it to the crankshaft bolt.
5. Apply a small quantity of engine oil to the top and to the screw
thread parts of the crankshaft bolt.
6. In the same way as when it was removed, hold the crankshaft
sprocket using the special tool, and tighten the crankshaft bolt to
the specified torque.
Tightening torque: 167 N·m



D 
Fitting the auto-tensioner
1. If the auto-tensioner rod remains in an extended state, install it
using the following procedure.
(1) Using a press or a vice, slowly compress the auto-
tensioner rod and align the rod with setting hole A and the
tensioner cylinder with setting hole B.
Caution
If the speed of compression is too fast, there is a
chance that the rod may break, so carry out this
operation slowly.
(2) Insert a wire or pin into the aligned holes.
Note
If a brand new or a replacement auto-tensioner is being
used, use a pin to set the auto-tensioner in place.
2. Fit the auto-tensioner into the engine and tighten the mounting
bolt to the specified torque. Do not remove the wire or pin until
the tension of the timing belt has been adjusted.
Tightening torque: 23 ± 3 N·m



E 
Fitting the tensioner pulley
As a temporary step, fit the tensioner pulley as shown in the
diagram.
Front of engine
washer
crankshaft sprocket
clean
here
crankshaft
crankshaft boltcrankshaft
sensing
blade
remove
grease
wire or pin
tensioner pulley holes

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