mitsubishi lancer evo9 2005 Service Manual

Workshop Manual - Supplement

LANCER

Evolution - IX

• Chassis

• Engine

• Wiring Diagrams

• Technical Information

SERVICE MANUAL

Supplement

LANCER

EVOLUTION IX

FOREWORD

This manual contains details of the main changes to the 2005 model Lancer Evolution IX. Only differences to the current Lancer Evolution VIII MR are included, so please use this manual in conjunction with the related manuals as listed on the following page. Please read this manual carefully so that servicing can be done correctly and quickly, and vehicle performance maintained. This manual is based on the current (March 2005) model. Please bear in mind that vehicle specifications may change and that future models may not be the same. Please note that all the units shown in this manual follow the internationally recognized SI unit system, and that the used previously are not shown alongside the SI units. (Nevertheless, please take care because units in reference documents may be shown in the units which were previously used).

March 2005

MITSUBISHI MOTOR CORPORATION

This manual is printed on recycled paper

Any opinions, requests or questions concerning this manual, should be written on the ‘Servicing Comments Form’ at the end of the manual, and sent to us by fax.

CONTENTS

General........................................................

Engine .........................................................

Fuel..............................................................

Engine Cooling...........................................

Intake and Exhaust ....................................

Engine Electrical ........................................

Rear axle .....................................................

Wheels and tyres........................................

Front suspension...............................................Body

13 14

15 16

27 31 33

Body.......................................................................

Exterior........................................................

Interior and SRS Airbag.............................N

Chassis Electrical.........................................

42 51 52 54

Related materials

*Indicates where the new model manual was published with the service manual in a single volume.

WARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRETENSIONERS Warning

1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fitted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitted seatbelt being activated unintentionally or accidentally.

2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensioner fitted seatbelts and the clock spring, should be removed if there is a chance of them being affected by heat during painting work.

• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring

should be removed.

• 90ºC and above: the pre-tensioner fitted seatbelts should be removed.

3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.

4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-SRS air bags) has been carefully studied.

Title No. Issue

date

New model manuals Body edition service manual

• Lancer Sedia 1036K30 2000/5 • Lancer Sedia 1036K50 2000/5

• Lancer Sedia 1036K31 2000/7 • Lancer Sedia (supplement) 1036K51 2000/7

• Lancer Evolution VII 1036K32 2001/1 • Lancer Evolution VII 1036K52 2001/5

• Lancer Sedia 1036K33 2001/5 (supplement)

• Lancer Sedia 1036K34 2001/5 • Lancer Sedia (supplement) 1036K53 2001/10

• Lancer Evolution VII 1036K35 2002/1 • Lancer Evolution VII_MR 1036K54 2004/2

• Lancer Sedia 1036K36 2002/5 (supplement)

• Lancer Evolution VII 1036K37 2003/1

• Lancer 1036K38 2003/2

• Lancer 1036K39 2003/12 Electrical wiring service manual

• Lancer Evolution VII_MR 1036K40 2004/2 • Lancer Evolution IX 1036K82 2005/3

• Lancer* 1036K41 2004/3

• Lancer 1036K42 2005/1

• Lancer Evolution IX 1036K43 2005/3 Service manuals Engine service manual

• Lancer Sedia 1036K00 2000/5 • 4G6 engine 1039G46 2001/1

• Lancer Sedia (supplement) 1036K01 2000/7 • 4G6 engine (supplement) 1039G63 2003/1

• Lancer Evolution VII 1036K02 2001/1 • 4G6 engine (supplement) 1039G71 2003/3 (supplement)

• Lancer Sedia (supplement) 1036K03 2001/5

• Lancer Sedia (supplement)

• Lancer Evolution VII 1036K05 2002/1 Transmission service manuals (supplement) • W5M51 manual transmission 1039M17 2001/1

• Lancer Sedia (supplement) 1036K06 2002/5 • W5M51 manual transmission 1039M22 2003/1

• Lancer Evolution VII 1036K07 2003/1 (supplement) (supplement) • WGMAA manual transmission 1039M23 2003/1

• Lancer Sedia (supplement) 1036K08 2003/2

• Lancer Sedia (supplement) 1036K09 2003/12

• Lancer Evolution VII MR 1036K10 2004/2

• Lancer* 1036K41 2004/3

• Lancer 1036K11 2005/1

1036K04 2001/10

Title No. Issue

date

GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP,

RELEVANT VEHICLE NUMBERS

00-1

SECTION 00

GENERAL

CONTENTS

Inspection guidelines and

troubleshooting..........................................1

Model line-up ..............................................1

Relevant vehicle numbers ........................1

Inspection guidelines and troubleshooting

With the introduction of new settings for the MB992006 (Extra Fine Probe) special tool, the guidelines for inspecting the connector have been changed. Other servicing guidelines remain unchanged.

Making an inspection with the connector attached (so the electrical circuit is complete) <non-waterproof connector>

The test bar should be inserted from the harness side. If the control unit or the connector is too small, and the test bar cannot be inserted, do not attempt to force it in. Instead, use the MB992006 (Extra Fine Probe) special tool.

Model line-up

Note

● Indicates a new model,  indicates a special model, X indicates a discontinued model.

Relevant vehicle numbers

GH-CT9A: CT9A-0400001 ~

ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS

11-1

SECTION 11

ENGINE

CONTENTS

General

The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.

Servicing standards

General .......................................................1

Servicing standards .................................1

Sealants .....................................................1

Special tools ..............................................2

Engine tuning.............................................4

1. Checking of revolutions when idling ................4

2. Checking compression pressure.......................4

Camshaft, valve stem seals .....................4

Cylinder head gaskets.............................14

Timing belt, timing belt B........................20

Engine ASSY ............................................28

Sealants

Note The code inside the brackets ( ) is the actual product number.

ENGINE – SPECIAL TOOLS

11-2 Special tools

Tool Number Name Function

MB991502 MUT-II Sub

ASSY

Checking and adjusting the tension in timing belt B

Note If a MUT-III main harness A is connected to a vehicle not fitted with CAN, there is a chance that a pulse signal will be entered in the simulated vehicle speed line, when the MUT-III is activated. Therefore, use a MUT-III main harness B with vehicles not fitted with CAN.

MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826

MUT-III Sub ASSY A: Vehicle

Communication

Interface (VCI) B: USB cable C: MUT-III Main

harness A

(For vehicles

fitted with CAN) D: MUT-III Main

harness B

(For vehicles

not fitted with

CAN) E: Adaptor F: Trigger harness

MB991668 A: MB991969 B: MB991670

Belt tension meter set A: Tension meter

cartridge B: Mic ASSY

• Checking the tension in the drive belt. (Use in conjunction with VCI)

• Checking the tension in the balancer timing belt. Adjusting (Use in conjunction with VCI)

MD998772 Valve spring

compressor

Compression of the valve spring.

DO NOT USE

ENGINE – SPECIAL TOOLS

11-3

Tool Number Name Function

MD998737 Valve stem seal

installer

Valve stem seal installation

MD998713 Camshaft oil seal

installer

Camshaft oil seal installation

MB991654 Cylinder head bolt

wrench

Cylinder head bolt removal, installation

MB991367 Special spanner Holding the crankshaft sprocket

MB991385 Pins

MB991704 Battery harness Checking and adjustment of the tension in the

balancer timing belt (Use in conjunction with VCI or MUT-II)

MD998738 Adjusting bolt Holding the tensioner arm or the auto-tensioner

adjuster

MD998767 Tensioner pulley

socket wrench

Adjusting the tension of the timing belt

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL

11-4

Engine tuning

1. Checking revolutions when the engine is idling

The standard revolutions for when the engine is idling have been changed. Other servicing guidelines remain unchanged.

Standard revolutions: 800 ± 50 r/min

2. Checking compression pressure

The standard for compression pressure and the limit for compression pressure have been changed. Other servicing

guidelines remain unchanged.

Standard compression pressure: 1000 kPa – 250 r/min Compression pressure limit: 650 kPa – 250r/min

Camshaft, valve stem seal

Removal and fitting Caution

1. 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.

2. Parts marked with * should be removed and then fitted for each cylinder in turn.

Jobs to be completed before removal and after fitting

• Removal and refitting of the undercover (Ref Section 51: Front bumper)

• Checking the tension of the drive belt (only after fitting)

• Draining and refilling of the coolant

• Removal and refitting of the air duct

• Removal and refitting of air pipe C

• Removal and refitting of the timing belt (refer to P11-20)

Tool Number Name Function

MB991454 Engine hanger

balancer

Holding the engine assembly while the transmission assembly is removed/installed

Recommended tools MZ203830 panzai or MZ203831 safe vehicle handling

Mechanical engine hanger

MB991928 A: MB991929 B: MB991930 C: MB991931 D: MB991932 E: MB991933 F: MB991934

Engine hanger A: joint (50) x2 B: joint (90) x2 C: joint (140) x2 D: Foot (standard) x4 E: Foot (short) x4 F: Chain and hook

ASSY

Slide bracket (HI)

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-5

O O

Removal procedure

1. Oil feeder control valve connector

2. Oil feeder control valve

3. O-ring

4. Breather hose

• Secondary air control valve (refer to Section 15-2: Secondary Air Control System)

5. Centre cover

• Ignition coil

6. O2sensor connector

7. Crank angle sensor connector

8. Connection of the control harness

9. Vacuum hose

10.PCV hose

11. Connection of the radiator upper hose

12.Camshaft position sensor connector (exhaust side)

13.Camshaft position sensor connector (inlet side)

14.Connection of the earth cable

15.Rocker cover ASSY

16.Spark plug hole gasket

17.Rocker cover gasket

A N

M

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-6

18.Camshaft position sensor support cover

19.Camshaft position sensor support cover gasket

20.Camshaft position sensing cylinder (exhaust side)

21.Camshaft position sensor support

22.Camshaft position sensor support cover

23.Camshaft position sensor support cover gasket

24.Camshaft position sensing cylinder (inlet side)

25.Camshaft position sensor support

26.Camshaft sprocket (exhaust side)

27.Camshaft oil seal

28.Camshaft bearing cap front

29.Camshaft bearing cap rear left

30.Camshaft bearing cap No. 2

31.Camshaft bearing cap No. 5

32.Camshaft bearing cap No. 3

33.Camshaft bearing cap No. 4

34.Exhaust camshaft

35.Camshaft sprocket cap

36.Washer

37.Camshaft sprocket (inlet side)

38.Camshaft oil seal

39.Camshaft bearing cap front

40.Camshaft bearing cap rear right

41.Camshaft bearing cap No. 2

42.Camshaft bearing cap No. 5

43.Camshaft bearing cap No. 3

44.Camshaft bearing cap No. 4

45.Inlet camshaft

During assembly, apply engine oil to all sliding parts.

F F F F E

B H

G

F F F F F F E

L

J

K

J

B I

G

F F

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-7

46.Rocker arm

47.Rush adjuster

48.Oil delivery body

49.Spark plug

50.Valve spring retainer lock

51.Valve spring retainer

52.Valve spring

53.Inlet valve stem seal

54.Exhaust valve stem seal

D

C C

B A A

ENGINE – CAMSHAFT, VALVE STEM SEAL

11A-8 Locations for the application of lubricant and seals

Semi-dry sealant: Three bond 1207D

(around the lip): Engine oil

Semi-dry sealant: Three bond 1207F

Semi-dry sealant: Three bond 1207D

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-9

Removal guidelines

A

Detaching the radiator upper hose

Align the indicator marks on the radiator upper hose and the hose clamp, and then detach the radiator upper hose.

B

Removing the camshaft sprockets

Grip the hexagonal part of the camshaft with a wrench, loosen the mounting bolt, and remove the camshaft sprocket.

C

Removing the valve spring retainer lock

Compress the valve spring using the special tool for compressing valve springs (MD998772), and remove the valve spring retainer lock.

Caution When removing the valve spring retainer lock, each cylinder piston should be in the top dead centre position. If pistons are not in the top dead centre position, valves could fall into the cylinders.

Fitting guidelines

A

Fitting the exhaust valve stem seals and the inlet valve

stem seals

1. Inlet valve stem seals and exhaust valve stem seals can be distinguished by checking the colour of the rubber parts.

2. Apply a small quantity of engine oil to the valve stem seals.

3. Place the valve stem component into the guides, and then insert a new valve stem seal into the valve stem guide by using the special tool for installing valve stem seals.

Caution (1) Valve stem seals cannot be re-used. (2) Please use the special tool for installing valve stem seals

(MD998737) because oil could leak if the valve stem seals are not fitted correctly.

Indicator marks

Colour of main

body: grey

Colour of main

body: grey/green

Inlet side Exhaust side

Valve

Valve guide

Valve stem seal

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-10

B

Fitting the valve spring

Fit the valve spring so that the end of the valve spring which has the smaller radius is on the rocker arm side.

C

Fitting the valve spring retainer lock

In the same way as when the valve spring retainer lock was removed, compress the valve spring using the special tool for compressing valve springs (MD998772), and fit the valve spring retainer lock.

D

Fitting the rush adjuster Caution If a rush adjuster is being reused, it must be washed and inspected before fitting. (Ref: Engine Service Manual)

E

Fitting the camshaft

1. Remove any sealant from the cylinder head.

2. Apply engine oil to the camshaft cams and journals.

3. Fit the camshaft to the cylinder head.

Caution Ensure that the inlet and exhaust sides are not the wrong way round.

F

Fitting the camshaft bearing cap No.4, the camshaft bearing cap No.3, the camshaft bearing cap No.5, the camshaft bearing cap No.2, the rear camshaft bearing cap, and the front camshaft bearing cap

1. Set the camshaft dowel pins in the position shown in the

diagram.

Rocker arm side

Front of engine

slit

Approx. 4°

dowel pins

inlet side

exhaust side

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

engine

Front

engine

front mark

front mark

camshaft oil seal

(engine oil)

ENGINE – CAMSHAFT, VALVE STEM SEAL

11-12

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)

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 fitting

indicator marks

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET

11-14

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. <Only before removal>

• Check for fuel dripping. <Only after fitting>

• 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. <Only after fitting>

• Adjustment of the axle letter cable. <Only after fitting>

• 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. O2sensor 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 connector

12.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 GASKET

11-16

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 gasket

35. 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)

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 GASKET

11-18

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 mark

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 B

11-20 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. <Only after fitting>

• 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 <Only after fitting>

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 sensor

16. Crankshaft sprocket

17. Crankshaft sensing blade

• Adjust the tension of the timing belt B <Only after fitting>

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 B

11-22

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 B

11-24

2. <Measuring the amount of give>

(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:

<when adjusted> 5~7mm <when replaced> 5~7mm

(2) If the specified values are not met, readjust the tension of the

belt.

3. <When using MUT-II/III>

(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 Aand 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 bolt

crankshaft sensing blade

remove grease

wire or pin

tensioner pulley holes

+ 99 hidden pages

mitsubishi lancer evo9 2005 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual