2005 MITSUBISHI LANCER EVOLUTION IX belt

ENGINE ELECTRICAL – CHARGING SYSTEM
16-3
Removal guidelines
 
A



Removing the delivery pipe, the injector, and the fuel
pressure regulator ASSY
Loosen the bolts holding it in place, slightly dislodge all of the
components and make space for the alternator to be removed.
 
B


Removing the drive belt
The following procedures are necessary because a serpentine drive
system with auto-tensioner has been installed.
1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and
turn the auto-tensioner in an anti-clockwise direction until it
reaches the stopper.
2. Align the A hole and the B hole, hold them in place by inserting
an L-shaped hexagonal Allen Key, and remove the drive belt.
Caution
If planning to re-use the drive belt, 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.
 
C


Removing the alternator
Push the whole engine up using a garage jack, and remove the
alternator from above.
AholeB hole
L-shaped
hexagonal
Allen
wrench

Service Manual
4G6
FOREWORD
This manual contains information about the 4G6
DOHC engine. It only covers those points that are
different from the service manuals listed below.
Therefore, this manual should be used in conjunction
with the following manuals.
• 4G6 DOHC engine Service Manual (No. 1039G46)
• 4G6 DOHC engine Service Manual Supplement
(No.1039G63)
This manual is based on the engine specifications as of
March 2005. Please note that some engine details may
not match those given in this manual due to
subsequent changes in engine specifications. The units
shown in this manual are the standard international
SI units.
(However, conventional units are used for some figures
taken from existing documents)
If you have any opinions, requests or queries regarding
this manual, please write them down on the “Servicing
Comment Form” on the last page, and fax them to us.
March 2005
Mitsubishi Motor Corporation
This manual is printed on recycled paper.
CONTENTS
General Information . . . . . . . . . . . . . . . 4
Servicing Specification Values . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator / Ignition system . . . . . . . . . 8
Timing belt . . . . . . . . . . . . . . . . . . . . . 10
Fuel system . . . . . . . . . . . . . . . . . . . . . 13
Secondary air system /
inlet manifold . . . . . . . . . . . . . . . . . . . 15
Exhaust manifold . . . . . . . . . . . . . . . . 16
Water pump / Water hose . . . . . . . . . 17
Rocker arm / Cam shaft . . . . . . . . . . . 18
Oil pump / Sump . . . . . . . . . . . . . . . . . 21
Pistons / Connecting rods . . . . . . . . . 22
Crank shaft / Cylinder block . . . . . . . 25
Turbocharger. . . . . . . . . . . . . . . . . . . . 27
DOHC
ENGINE

54G6 – TIGHTENING TORQUES
Tightening Torques
Par tTightening Torque Nm
Alternator, ignition system
Oil level gauge guide bolt13 ± 1
Water pump pulley bolt8.8 ± 1.0
Auto tension bolt (washer)44 ± 10
Auto tension bolt (flange)24 ± 4
Alternator bracket bolt (flange)24 ± 4
Alternator bracket bolt (washer M8 x 22)22 ± 4
Alternator bracket bolt (washer M8 x 32)20 ± 2
Alternator nut44 ± 10
Crankshaft pulley bolt25 ± 4
Centre cover holt3.0 ± 0.5
Ignition coil bolt10 ± 2
Spark plug25 ± 5
Timing belt
Timing belt cover bolt (flange)11 ± 1
Timing belt cover bolt (washer)9.0 ± 1.0
Power steering pump bracket bolt49 ± 9
Connector bracket bolt11 ± 1
Locker cover bolt3.5 ± 0.5
Plug cap32 ± 2
Tensioner pulley bolt48 ± 5
Tensioner arm bolt21 ± 4
Auto tensioner bolt23 ± 3
Idler pulley bolt35 ± 6
Crank angle sensor bolt8.8 ± 1.0
Oil pump sprocket nut54 ± 5
Crankshaft holt167
Tensioner B bolt19 ± 3
Counterbalance shaft sprocket bolt45 ± 3
Engine support bracket bolt49 ± 5
V.V.T. sprocket bolt65 ± 5
Camshaft sprocket bolt88 ± 10
Fuel system
Throttle body bolt19 ± 3
Cover bolt12 ± 1
Fuel pressure regulator bolt8.8 ± 2.0
Delivery pipe and injector bolt11 ± 1
Vacuum hose and pipe bolt11 ± 1
Solenoid valve assembly bolt9.0 ± 1.0
Vacuum tank bracket bolt9.0 ± 1.0
Secondary air system / Intake manifold
Exhaust manifold heat protector bolt20 ± 3
Air pipe assembly

104G6 – TIMING BELT
Timing Belt
Removal and Installation
Note :
NEVER disassemble the V.V.T. sprocket.
Removal Sequence
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering pump bracket4. Breather hose
5. PCV hose
6. PCV valve
7. PCV valve gasket
8. Oil filler cap

114G6 – TIMING BELT
9. Connector bracket
10. Rocker cover
11.Rocker cover gasket A
12. Rocker cover gasket B
13. Semi-circular packing
14. Plug cap
15. Timing belt
16. Tensioner pulley
17. Tensioner arm
18. Auto tensioner
19. Idler pulley
20. Crank angle sensor
21. Oil pump sprocket
22. Crankshaft bolt
23. Crankshaft sprocket
24. Crankshaft sensing blade
25. Tensioner B26. Timing belt B
27. Counterbalance shaft sprocket
28. Spacer
29. Crankshaft sprocket B
30. Crankshaft key
31. Engine support bracket
32. V.V.T. sprocket bolt
33. V.V.T. sprocket
34. Camshaft sprocket bolt
35. Camshaft sprocket
36. Timing belt rear right cover
37. Timing belt rear left upper cover
38. Timing belt rear left lower cover
Removal Service Point
Removal of plug cap
Hold hexagonal section of camshaft with wrench, and loosen plug cap.
Removal of V.V.T. sprocket bolt
Hold hexagonal section of camshaft with wrench, and loosen V.V.T.
sprocket bolt.
Installation Service Point
Installation of V.V.T. sprocket bolt / V.V.T.
sprocket
1. Apply the minimum suitable coating of engine oil to the following
points:
• Whole circumference of end of camshaft
• Inserted part of V.V.T. sprocket (full circumference; inner
& outer sides)
• Bolt seating of V.V.T. sprocket bolt
2. Install the V.V.T. sprocket.
V. V. T.
sprocket
boltV.V.T. sprocket
Camshaft

* A


* B 
B
*
A
*
A
*

* * 1


* * 1


* * 1


* * 1

* * 1

* * 1

* * 1


* * 1 
* 1
* 
* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* A


* B


* A

124G6 – TIMING BELT
3. Push the V.V.T. sprocket firmly to the end and, holding the
hexagonal part of the camshaft with a wrench, check that the V.V.T.
sprocket does not rotate.
4. Hold the hexagonal section of the camshaft with a wrench and
tighten the V.V.T. sprocket bolt to the specified torque of 65 ±5 N-m.
5. Hold the hexagonal section of the camshaft with a wrench and
check that the V.V.T. sprocket does not rotate.
Note :
This check shows that the V.V.T. sprocket is locked at the maximum
delay angle by the interior pin.
Installation of plug cap
Note :
The washer must not be reused.
1. Install the washer on the plug cap.
2. Hold the hexagonal section of the camshaft with a wrench and
tighten the plug cap to the specified torque of 32±2 N-m.
B
*

264G6 – CRANKSHAFT / CYLINDER BLOCK
Installation Service Point
Installation of crankshaft bearings
1. Using the table below, select a bearing of the correct size
corresponding to the diameter of the crankshaft journal.
(Selecting a bearing : Example)
If the identifier on the crankshaft journal is 0, and the identifier on the
cylinder block bearing is 1, then a bearing with identification mark 1
should be chosen.
If the identifier on the crankshaft is difficult to make out, measure the
diameter of the journal and choose the bearing that corresponds to the
measured diameter.
Crankshaft journal diameter
Identification mark Journal
diameter (mm)Cylinder
block bearingCrankshaft
bearing
00
11
056.994~57.000
22
00
11
156.988~56.994
22
00
11
256.982~56.988
22
2. Install grooved bearing on cylinder block side.
3. Install bearing without oil groove on bearing cap side.
Position of crankshaft journal diameter identification marks
Timing belt
Cylinder block bearing hole diameter
identification mark
Cylinder
bore size
mark
Position of crankshaft bearing size
identification mark
Identification mark
Groove
Lower bearingUpper bearing
A
*

Related Documentation
Cautionary Note regarding servicing of vehicles fitted with SRS airbags and/or seatbelts
with pre-tensioner systems.
Warnings:
1. Incorrect inspection or servicing of a component part of the SRS airbag system or seatbelt pre-tensioner system,
or a part relating to these systems, may cause accidental operation (deployment) of the SRS airbag or seatbelt
pre-tensioners, or may cause these systems to be disabled, leading in either case the risk of serious injury.
2. If parts may be affected by heat during painting operations, then those parts must be removed in advance. This
applies to the SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors, and pre-tensioner seatbelts.
• 93ºC or above : SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front
impact sensors, side impact sensors
•90ºC or above : Pre-tensioner seatbelts
3. The component parts of the SRS airbag system or seatbelt pre-tensioner system, and parts relating to these
systems, must always be inspected and serviced by a Mitsubishi dealer.
4. Service personnel must read the relevant service manuals (particularly, Section 52B – SRS Airbags) carefully and
thoroughly, before inspecting or servicing the component parts of the SRS airbag system or seatbelt pre-
tensioner system, and parts relating to these systems.