2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

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

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11.Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
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 bonnet.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Checking 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.

ENGINE – ENGINE ASSY
11-29
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 connector
10. Injector connector11.Exhaust cam position sensor connector
12. Inlet cam position sensor connector
13. Water temperature gauge unit connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Alternator connector and terminal
17. Secondary air control solenoid valve
connector
18. Engine oil pressure switch connector
19. Drive belt
 
A

ENGINE – ENGINE ASSY11-30
Caution
Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is
being supported by the chassis.
20. Vacuum tank, solenoid valve, vacuum
pipe and hose ASSY
21. Brake booster vacuum hose connection
22. Purge hose connection
23. Power steering oil pressure switch
connector
24. Heat protector
25. Power steering oil pump
26. A/C compressor connector

27. A/C compressor A/C>28. Heater hose connection
29. Fuel return hose connection
30. Fuel high pressure hose connection
31. O-ring
•Transfer ASSY, transmission ASSY
32. Engine mount bracket & stopper ASSY
33. Engine ASSY
 
B


 
B






D 



D 
 
C






C 
 
D






B 
 
E






A 
(engine oil)

ENGINE – ENGINE ASSY
11-31
Removal guidelines
 
A


Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, 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.
 
B


Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
 
C



Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
AholeB hole
L-shaped
hex-
agonal
Allen
wrench

ENGINE – ENGINE ASSY11-32
 
D


Removing the engine mount bracket & stopper ASSY
1. Support the engine using a garage jack.
2. Remove the special mechanical engine hanger (MZ203830,
MZ203831 or MB991928).
3. Hold the engine ASSY using a chain block.
4. Support the engine oil pan component with the garage jack
through the engine block, so that the weight of the engine is not
taken by the engine mount bracket.
5. Loosen the nuts and bolts and remove the engine mount bracket
and stopper ASSY.
 
E


Removing the engine ASSY
After checking that all of the cables, hoses and harness connectors
etc have been disconnected, slowly hoist the engine using a chain
block and remove the engine from the engine compartment.
Fitting guidelines



A 
Fitting the engine ASSY
Install the engine whilst checking that cables, hoses and harness
connectors etc will not be squashed beneath it.
MZ203830 or MZ203831
slide bracket (HI)

ENGINE – ENGINE ASSY
11-33



B 
Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
(1) (MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2)
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)



C 
Fitting the transfer ASSY and the transmission ASSY
1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).engine sideengine side
engine mount stopper
rear of chassis> front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)

ENGINE – ENGINE ASSY11-34
 
D


Fitting the O-ring and the fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that no engine oil gets inside the deliver pipe.
2. Without damaging the O-ring, fit the fuel high pressure hose to
the delivery pipe by twisting it from left to right. Ensure that the
hose 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.