2005 MITSUBISHI LANCER EVOLUTION IX oil pan

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

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 B11-22
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withdrawn, and this may lead to problems with twisting and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 – 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)

INTAKE & EXHAUST – EXHAUST MANIFOLD15-9
Removal procedure
1. Exhaust manifold heat protector
2. Air pipe ASSY connection
3. O
2sensor
4. Turbocharger heat protector
5. Turbocharger water feed pipe connection
6. Gasket
7. Water hose connection
8. Oil feed pipe
9. Gasket
10. Starter
11.Oil return pipe
12. Oil return pipe gasket (turbocharger side)
13. Oil return pipe gasket (oil pan side)14. Vacuum hose connection
15. Air outlet fitting
16. Air outlet fitting gasket
17. Exhaust fitting bracket
18. Turbocharger and exhaust fitting ASSY
19. Turbocharger ASSY
20. Exhaust fitting gasket
21. Exhaust fitting
22. Turbocharger gasket
23. Turbocharger water return pipe
24. Gasket
25. Exhaust manifold
26. Exhaust manifold gasket
Removal guidelines
 
A


Removing the O
2sensor
After removing the O
2sensor connector and the clamp, use the
special O
2 sensor wrench (MD998770) to remove the O
2sensor.
 
B


Removing the oil feed pipe
Caution
After removing the oil feed pipe, ensure that there is no foreign
matter in the oil access hole on the turbocharger.
Fitting guidelines



A 
Fitting the turbocharger ASSY
1. Clean away any grease clogging the connection between the oil
pipe and the water pipe, and any grease clogging the eyebolts
and the inside of the pipes.
2. If there is any carbon in the oil access on the turbocharger
ASSY, clean it or blow it away.
Caution
Ensure that no foreign matter gets inside the turbocharger
ASSY.
 
A


 
B






D 



C 




B 



A 
O
2sensor

INTAKE & EXHAUST – EXHAUST MANIFOLD15-10



B 
Fitting the air outlet fitting gasket
Fit the gasket so that the protruding part is in the position located in
the diagram.



C 
Fitting the oil return pipe gasket (oil pan side)
Fit so that the printed side of the gasket is on the oil pan side.



D 

Fitting the oil return pipe gasket (turbocharger side)
Fit so that the printed side of the gasket is on the turbocharger side.turbocharger
protruding part
view “A”
view “A”
print
print
gasket
gasket
3. Apply some fresh engine oil via the fitting hole for the oil feed
pipe in the turbocharger ASSY.

EXTERIOR – FRONT BUMPER
51-3
Dismantling and assembly
Dismantling procedure
1. Front 3-diamonds badge
2. Front bumper nut
3. Front number plate garnish
4. Front bumper cover A
5. Front bumper cover B
6. Air dam skirt panel
7. Front bumper centre net
8. Front bumper lower plate
9. Front bumper upper plate
10. Front bumper upper support11.Air intake cover
12. Front bumper net
13. Bumper side net (LH)
14. Oil cooler duct
15. Bumper side net (RH)
•Inter-cooler water spray hose and nozzle
(Ref Section 15)
16. Front bumper side plate
17. Front bumper upper reinforcement
18. Front bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
Cross section through A-A
hook
Cross section through B-B
clip
 
A






A