Mitsubishi Lancer Evolution 5 User Manual

WORKSHOP MANUAL

EVOLUTION-IV
EVOLUTION-V

Pub. No. S9806CNCP9

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

00

EVOLUTION-IV
EVOLUTION-V

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.

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

Engine Lubrication . . . . . . . . . . . . .

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

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

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

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

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

11
12
13
14
15
16
17
21
22
26
27
32

TECHNICAL INFORMATION MANUAL

N9806CNCP9

All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.

July 1998

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Electrical Wiring . . . . . . . . . . . . . . . .

33
34
35
36
37
42
51
54

GENERAL

CONTENTS

MODELS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1

00-2

16 valves-intercooler

(4WD-5M/T)

controlled fuel

16

(4WD-5M/T)

MODELS

<LANCER EVOLUTION-IV>

GENERAL – Models

Model
code

E-CN9A SNDF ’97 RS 4G63 (2,000-DOHC –-W5M51

Class
code

SRGF ’97 GSR

Model
year

Grade Engine model Transmission

model

turbo)

<LANCER EVOLUTION-V>

Model
code

GF-CP9A SNDF ’98 EVOLUTION-V RS 4G63 (2,000-DOHC –

Class
code

SNGF ’98 EVOLUTION-V

Model
year

Grade Engine model Transmission

GSR

model
W5M51

valves-intercooler

turbo)

Applicable serial numbers

E-CN9A: CN9A – 0000001 Y
GF-CP9A: CP9A – 0000001 Y

Fuel supply
system

Electronically

­injection (MPI)

Fuel supply
system

MPI

f

ENGINE

CONTENTS

11-1

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .

SEALANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .

ENGINE ADJUSTMENTS 4. . . . . . . . . . . . . . . . .

1. Drive Belt Tension Check 4. . . . . . . . . . . . . . .

2. Auto Tensioner Check 5. . . . . . . . . . . . . . . . . . .

3. Lash Adjuster Check 5. . . . . . . . . . . . . . . . . . . .

4. Lash Adjuster Replacement 7. . . . . . . . . . . . . .

5. Ignition Timing Check 7. . . . . . . . . . . . . . . . . . .

6. Idle Speed Check and Idle Mixture Check 7

7. Compression Pressure Check 7. . . . . . . . . . . .

8. Manifold Vacuum Check 8. . . . . . . . . . . . . . . . .

CRANKSHAFT PULLEY 9. . . . . . . . . . . . . . . . . .

CAMSHAFT AND CAMSHAFT

OIL SEAL 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT OIL SEAL 15. . . . . . . . . . . . . .

CYLINDER HEAD GASKET 17. . . . . . . . . . . .

TIMING BELT . . . . . . . . . . . . . . 21. . . .

ENGINE ASSEMBLY 32. . . . . . . . . . . . . . . . . . .

11-2

ENGINE – Service Specifications / Sealants / Special Tools

SERVICE SPECIFICATIONS

Items Standard value Limit
Basic ignition timing 5_ BTDC ± 3_ –
Ignition timing (at idle) Approx. 5_ BTDC –
Idle speed rpm 850 ± 50 –
CO contents % 0.6 or less –
HC contents ppm 300 or less –
Compression pressure kg/cm2 – rpm 11.5 – 250 Min. 9.7 – 250
Compression pressure difference of all cylinders kg/cm
Intake manifold vacuum kPa {mmHg} – Min. 55 {410}
Cylinder head bolt shank length mm – 99.4

2

– Max. 1.0

SEALANTS

Items Specified sealants
Rocker cover Semi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g)
Oil pan Semi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)

NOTE:
Given in [ ] are MITSUBISHI GENUINE PART numbers.

SPECIAL TOOLS

Tool Number Name Use

MD998782 Valve lifter set Replacing the lash adjuster

MB990767 End yoke holder D Holding the crankshaft pulley

D Holding the camshaft sprocket

Tool UseNameNumber

ENGINE – Special Tools

11-3

MD998719 Crankshaft pulley

holder pin

MD998715 Pulley holder pin

MD998713 Camshaft oil seal

installer

MD998727 Oil pan remover Removing the oil pan

D Holding the crankshaft pulley
D Holding the camshaft sprocket

Pressfitting the camshaft oil seal

MD998781 Flywheel stopper Securing the flywheel or drive plate

MD998776 Crankshaft rear oil

seal installer

MB990938 Handle

MD998382 Crankshaft front oil

seal installer

Pressfitting the crankshaft rear oil seal

Installing the crankshaft front oil seal

MD998285 Crankshaft front oil

seal guide

11-4

Tool UseNameNumber

ENGINE – Special Tools / Engine Adjustments

MB991654 Cylinder head bolt

wrench

MD998767 Tensioner pulley

socket wrench

Recommended
tool MZ203826
by Anzen
Jidosha or
MZ203827 by
Banzai

MD991453 Engine hanger

Engine lifter Supporting the engine assembly during

assembly

Removing and reinstalling the cylinder head
bolt

Timing belt tension adjustment

removal and installation of the transmission

Auto tensioner

Indicator mark

B

A

ENGINE ADJUSTMENTS

1. DRIVE BELT TENSION CHECK

NOTE
Use of the auto tensioner eliminates the need for belt tension
adjustment. Check that the indicator mark on the auto
tensioner is in the range of A shown.
If it is outside the specified range (i.e., in range of B shown),
replace the drive belt.
(For the removal and installation of the drive belt, refer to
P.11-9.)

Good

Tool mounting hole

MAX

MIN

High-pressure
chamber

ENGINE – Engine Adjustments

2. AUTO TENSIONER CHECK

(1) Stop the engine from the idle speed and check that the

belt rests within the auto tensioner pulley width.

(2) Remove the drive belt.

(For the removal of the drive belt, refer to P.11-9.)

(3) Fit a spinner handle or similar tool into the tool mounting

hole of the auto tensioner and turn the tensioner clockwise
and counterclockwise to ensure that it does not bind.

(4) If step (1) or (3), or both, have been checked abnormally,

replace the auto tensioner.

(5) Reinstall the drive belt.

3. LASH ADJUSTER CHECK

NOTE
If an unusual knocking noise can be heard immediately after
the engine has started or while it is running and if that is
probably attributable to the lash adjuster, make the following
checks.

(1) Check the engine oil and add or change oil as necessary.

NOTE
(1) If the engine oil level is low, air is taken in through

the oil screen, entering the oil passage.

(2) If the oil level is too high, the cranks agitate oil causing

oil to trap a large amount of air.

(3) Air does not easily separate from a deteriorated oil

that can contain an increased amount of air.

When air trapped in oil for these reasons gets into the
high-pressure chamber of the lash adjuster, the air in
the high-pressure chamber is compressed to shrink the
lash adjuster excessively while the valve is opening,
resulting in an unusual noise occurring. This is the same
symptom developing when the valve clearance is adjusted
to an excessive value.
The problem in this case is gone when air is released
from the lash adjuster.

(2) Start the engine and carry out several cycles (10 or less)

of mild racing*.
If the noise is gone after racing, it indicates that air has
been released from the high-pressure chamber of the
lash adjuster, restoring the lash adjuster to normal
operating conditions.
*: Gradually (extending over a 30-sec. period) increase

the engine speed from idle speed to 3,000 r/min and
then reduce it down to the idle speed gradually
(extending over a 30-sec. period).

11-5

NOTE
(1) If the vehicle is parked on a slope for a long time,

the amount of oil in the lash adjuster will decrease,
causing air to get into the high-pressure chamber
when the engine is started.

(2) After the vehicle has been parked for a long time,

oil drains out of the oil passage and it takes a long
time for the oil to reach the lash adjuster. This can
cause air to get into the high-pressure chamber.

11-6

ENGINE – Engine Adjustments

Timing belt side

AA B B

ABAB

(3) If the noise is not eliminated by racing, follow these steps

to check the lash adjuster.
a. Stop the engine.
b. Bring no. 1 cylinder to TDC on the compression stroke.
c. Push the rocker arms indicated by arrow A on the

left to see if they go down.
d. Slowly turn the crankshaft clockwise 360_.
e. Perform the same step as step c for rocker arms

indicated by arrow B.

f. Push the part of the rocker arm which contacts the

top of the lash adjuster. If the rocker arm can be

easily moved down to the bottom, the lash adjuster

is defective, requiring replacement.

When the lash adjuster is replaced, be sure first to

bleed the lash adjuster of air before installation. Then,

perform steps a through e to ensure that no abnormal

symptoms are noted.

NOTE

(1) The leak-down test is an effective means to

accurately determine if the lash adjuster is
operational or not.

(2) For the leak-down test and bleeding procedures,

refer to ENGINE WORKSHOP MANUAL.
If the rocker arm is felt binding and cannot be
pushed downward as you push it, the lash adjuster
is operational. Check for other possible causes
for the noise.

MD998782

MD998782

(4) Lash adjuster replacement

Caution
From the cylinder from which the lash adjuster is
to be removed, turn the crankshaft to lower the piston,
as the valve contacts the piston when pushed down.
A rocker arm cannot be removed if it is lifted by the
cam. If this is the case, turn the crankshaft so that
the arm is not lifted.

a. Using the special tool, push the valve downward to

remove the roller rocker arm.
b. Remove the lash adjuster from the cylinder head.
c. Mount a brandnew lash adjuster which has been bled

of air in the cylinder head.
d. Using the special tool, lower the valve and install

the roller rocker arm.

NOTE

To mount the roller rocker arm, first place the pivot

side of the rocker arm on the lash adjuster, then push

down the valve; next, place the slipper side of the

rocker arm on the valve system side.

ENGINE – Engine Adjustments

4. LASH ADJUSTER REPLACEMENT

Refer to (4) of the preceding paragraph.

5. IGNITION TIMING CHECK

Check that ignition timing is at the standard value.

Standard value: approx. 5_BTDC

NOTE
Ignition timing is variable within about ±7_, even under normal
operating.

11-7

Crank angle
sensor connector

6. IDLE SPEED CHECK AND IDLE MIXTURE
CHECK

(1) Run the engine at 2,000 to 3,000 r/min for 2 minutes.
(2) Check the CO and HC contents at idle.

Standard value

CO contents: 0.6% or less
HC contents: 300 ppm or less

7. COMPRESSION PRESSURE CHECK

(1) Before inspection, check that the engine oil, starter and

battery are normal. In addition, set the vehicle to the
pre-inspection condition.

(2) Remove all of the spark plugs.
(3) Disconnect the crank angle sensor connector.

NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.

(4) Cover the spark plug hole with a shop towel etc., and

after the engine has been cranked, check that no foreign
material is adhering to the shop towel.

Caution
(1) Keep away from the spark plug hole when

cranking.

(2) If compression is measured with water, oil, fuel,

etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.

11-8

Compression gauge

ENGINE – Engine Adjustments

(5) Set compression gauge to one of the spark plug holes.
(6) Crank the engine with the throttle valve fully open and

measure the compression pressure.

Standard value

(at engine speed of 250 r/min): 11.5 kg/cm

Limit (at engine speed of 250 r/min): 9.7 kg/cm

2

2

(7) Measure the compression pressure for all the cylinders,

and check that the pressure differences of the cylinders
are below the limit.

Limit: Max. 1.0 kg/cm

2

(8) If there is a cylinder with compression or a compression

difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps (5) through (7).
a. If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.

b. If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.

(9) Connect the crank angle sensor connector.
(10)Install the spark plugs.
(11)Install the ignition coil and connect the ignition coil

connector.

(12)Erase the diagnosis codes by keeping the battery minus

(–) cable disconnected for more than 10 seconds.
NOTE

This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.

Fuel pressure
regulator valve

Vacuum gauge

8. MANIFOLD VACUUM CHECK

(1) Before inspection, set the vehicle to the pre-inspection

condition.

(2) Connect a tachometer connector.
(3) Attach a three-way union to the vacuum hose between

the fuel pressure regulator valve and the intake manifold,
and connect a vacuum gauge.

(4) Start the engine and check that idle speed is within

standard value.

Standard value: 850 ± 50 r/min

5. Check the manifold vacuum at idling.

Limit: Min. 55 kPa {410 mmHg}

ENGINE – Crankshaft Pulley

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

11-9

Pre-removal Operation

D Under Cover Removal

1

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11-4.)
D Under Cover Installation

25 {2.5}

2

Removal steps

AA" 1. Drive belt

2. Crankshaft pulley

Auto tensioner

Hole in arm

Hole in bracket

Unit: Nm {kgf@m}

REMOVAL SERVICE POINT

AA" DRIVE BELT REMOVAL

(1) Align the hole in the auto tensioner bracket with that

in the arm and insert a screwdriver into the holes.

(2) Remove the drive belt.

Phillips
screwdriver

11-10

ENGINE – Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Engine Coolant Draining and Refilling
(2) Air Hose C Removal and Installation

(Refer to GROUP 15 – Intercooler.)

(3) Spark Plug Cable and Ignition Coil Assembly Removal

and Installation

4

6

2

10 {1.0}

14

15

(4) Air Pipe Removal and Installation

(Refer to GROUP 15 – Air Control Valve.)

(5) Timing Belt Removal and Installation

(Refer to P.11-21.)

9 {0.9}

1

5

3

3.4 {0.35}

20 {2.0}

7

22 {2.2}

8

12 – 15 {1.2 – 1.5}

9

10

Removal steps

1. Breather hose connection

2. PCV hose connection

3. Crank angle sensor bracket con­nection

4. Control harness connection

5. Rocker cover

6. Radiator upper hose connection

7. Cover

"EA 8. Cam position sensing cylinder

17 16

13

12

88 {9.0}

11

Unit: Nm {kgf@m}

9. Cam position sensor support

10. Semi-circular packing

AA""DA 11. Camshaft sprocket

"CA 12. Camshaft oil seal
"BA 13. Front cam cap
"BA 14. Rear cam cap
"BA 15. Cam cap
"AA 16. Camshaft (exhaust side)
"AA 17. Camshaft (intake side)

ENGINE – Camshaft and Camshaft Oil Seal

Grease and adhesive application points

11-11

26

10 mm

φ 3 mm

Semi-drying sealant:

THREEBOND 1207F

10 mm

Semi-drying sealant: THREEBOND 1207D

Semi-drying sealant: THREEBOND 1207D

10 mm

Timing belt side

Timing belt side

Lip

Engine oil

MB990767

MD998719

Camshaft sprocket side

Camshaft (exhaust side)

Slit

REMOVAL SERVICE POINT

AA" CAMSHAFT SPROCKET REMOVAL

INSTALLATION SERVICE POINTS

"AA CAMSHAFT INSTALLATION

(1) Apply engine oil to the cams and journals of the camshaft.
(2) Mount the camshaft on the cylinder head.

Caution
Make sure that the camshaft has a unique orientation
for installation, the intake side and exhaust side. The
exhaust camshaft has a slit in the rear end face.

11-12

Approx. 12_

Dowel pin

ENGINE – Camshaft and Camshaft Oil Seal

"BA CAM CAP / REAR CAP / FRONT CAM CAP

INSTALLATION

(1) Locate the camshaft dowel pins as illustrated.

Intake side

Exhaust side

(2) Temporarily tighten cam cap in two to three steps, then

torque it to specification.

Tightening torque: 20 Nm {2.0 kgf@m}

"CA CAMSHAFT OIL SEAL INSTALLATION

(1) Apply engine oil to the entire periphery of the oil seal

lip.

(2) Pressfit the oil seal as shown.

ID paint

MD998713

90_

Dowel pin

"DA CAMSHAFT SPROCKET INSTALLATION

As you did during removal, secure the camshaft sprocket
with the special tool and tighten bolt to specification.

Tightening torque: 88 Nm {9.0 kgf@m}

"EA CAM POSITION SENSING CYLINDER

Install the cam position sensing cylinder so that the ID paint
on the cam position sensing cylinder is 90_ with respect to
the camshaft dowel pin as shown.

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Under Cover Removal and Installation
(2) Front Exhaust Pipe Removal and Installation

(Refer to GROUP 15.)

ENGINE – Oil Pan

(3) Oil Level Gauge Removal and Installation
(4) Engine Oil Draining and Supplying

Identification of bolt location

11-13

8

φ 4 mm

Groove

Semi-drying sealant: THREEBOND 1207D

Bolt
hole

9 {0.9}

3

A

B

A: 6 × 8 mm
B: 6 × 10 mm

B

8

B

B

B

2

1

30 {3.1}

5

8

7

4

39 – 44 {4.0 – 4.5}

"BA 3. Oil return pipe gasket

6

39 {4.0}

Removal steps

1. Starter

2. Oil return pipe

4. Engine oil cooler return pipe

7 {0.7}

26 {2.6}

5. Bell housing cover

6. Drain plug

"AA 7. Drain plug gasket

AA" 8. Oil pan

Washer
assembled bolt
9 {0.9}
Flange bolt
10 {1.0}

Unit: Nm {kgf@m}

11-14

ENGINE – Oil Pan

MD998727

Drain plug gasket

MD998727

Printed portion

Oil pan side

REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL

INSTALLATION SERVICE POINTS

"AA DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction so that it faces
as shown in the illustration.

"BA OIL RETURN PIPE GASKET INSTALLATION

Install the gasket with the printed portion toward the oil pan.

Gasket

ENGINE – Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

11-15

4

127 – 137
{13.0 – 14.0}

5

3

2

1

Crankshaft front oil seal removal
steps

D Timing belt and timing belt B

(Refer to P.11-21.)

D Crank angle sensor

(Refer to GROUP 16.)

1. Crankshaft sprocket B

2. Key

"CA 3. Crankshaft front oil seal

3

Engine oil

Crankshaft rear oil seal removal
steps

D Transmission assembly
D Clutch cover and disc

AA""BA 4. Flywheel

"AA 5. Crankshaft rear oil seal

5

Unit: Nm {kgf@m}

11-16

ENGINE – Crankshaft Oil Seal

REMOVAL SERVICE POINT

AA" FLYWHEEL ASSEMBLY REMOVAL

Use the special tool to secure the flywheel assembly and
remove the bolts.

MD998781

Crankshaft
rear oil seal

MB990938

MB998776

Crankshaft

Oil seal

Crankshaft

INSTALLATION SERVICE POINTS

"AA CRANKSHAFT REAR OIL SEAL INSTALLATION

(1) Apply a small mount of engine oil to the entire

circumference of the oil seal lip.

(2) Install the oil seal with the special tool as far as the

chamfered position of the oil seal case as shown in the
illustration.

"BA FLYWHEEL ASSEMBLY INSTALLATION

Use the special tool to hold the flywheel in the same manner
as removal, and install the bolt. Tighten the bolts to the
specification.

Tightening torque: 127 – 137 Nm {13.0 – 14.0 kgf@m}

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

Apply a small amount of engine oil to the entire circumference
of the oil seal lip.
Pressfit the oil seal until it is flush with the chamfered end
of the oil pump case.

MD998382

MD998285
(Lubricate outer
circumference with oil)

ENGINE – Cylinder Head Gasket

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

11-17

Pre-removal Operation

(1) Fuel Discharge Prevention
(2) Engine Oil Removal
(3) Strut Tower Bar Removal
(4) Timing Belt Removal (Refer to P.11-21.)
(5) Thermostat Case Assembly Removal

(Refer to GROUP 14 – Water Hose Pipe.)

(6) Front Exhaust Pipe Removal (Refer to GROUP 15.)

Delivery pipe

19

15

18

O-ring

Engine oil

16

18

10

17

8

9

Post-installation Operation

(1) Front Exhaust Pipe Installation

(Refer to GROUP 15.)

(2) Thermostat Case Assembly Installation

(Refer to GROUP 14 – Water Hose Pipe.)
(3) Engine Oil Filling
(4) Timing Belt Installation (Refer to P.11-21.)
(5) Strut Tower Bar Installation
(6) Accelerator Cable Adjustment

10 {1.0}

3 {0.3}

4

1

14

3

2

5 {0.5}

9 {0.9}

6

5

3

8

11

8

7

Removal steps

1. Center cover

2. Accelerator cable connection

3. Ignition coil connector

4. Ignition coil

5. Crank angle sensor connector

6. Crank angle sensor bracket con­nection

7. Brake booster vacuum hose con­nection

8. Vacuum hose connection

9. TPS connector

10. ISC motor connector

13

12

12 – 15 {1.2 – 1.5}

20

Unit: Nm {kgf@m}

11. Water hose connection

12. Oxygen sensor connector

13. Injector connector

14. Cam position sensor connector

15. Coolant temperature sensor con­nector

16. Water temperature gauge unit con­nector

17. Control harness

"DA 18. Fuel pipe pressure hose connection

19. Fuel return hose connection

20. Oil level gauge guide assembly

11-18

ENGINE – Cylinder Head Gasket

78 → 0 → 20 → +90_ → +90_
{8.0 → 0 → 2.0 → +90_ → +90_}

31

29

23

22

3.4 {0.35}

27

32

33

28

25

24

30

22 {2.2}

21

26

9 {0.9}

10 mm

30 {3.1}

22

10 mm

10 mm

9 {0.9}

Removal steps

21. PCV hose connection

22. Rocker cover

23. Semi-circular packing

24. Starter

25. Oil return pipe

"CA 26. Oil return pipe gasket

27. Vacuum tank/solenoid valve/vacuum
hose assembly

30 {3.1}

10 mm10 mm

23

Semi-drying sealant:

THREEBOND 1207D

28. Intake manifold stay

29. Heater hose connection

30. Alternator brace stay mounting bolt

AA""BA 31. Cylinder head bolt

32. Cylinder head assembly

"AA 33. Cylinder head gasket

22

Unit: Nm {kgf@m}

MB991654

ENGINE – Cylinder Head Gasket

REMOVAL SERVICE POINT

AA" CYLINDER HEAD BOLT REMOVAL

Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.

11-19

Intake side

Exhaust side

Washer

A

Cylinder
head

Front of engine

Cylinder head bolt

(Engine
oil)

INSTALLATION SERVICE POINTS

"AA CYLINDER HEAD GASKET INSTALLATION

(1) Wipe off all oil and grease from the gasket mounting

surface.

(2) Install so that the shapes of the cylinder head holes match

the shapes of the respective cylinder head gasket holes.

"BA CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, the length below

the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.

Limit (A): 99.4 mm

(2) Apply a small amount of engine oil to the thread section

and the washer of the cylinder head bolt.

11-20

MB991654

Intake side

Exhaust side

Front of engine

ENGINE – Cylinder Head Gasket

(3) Tighten the bolts by the following procedure.

Step Operation

1 Tighten to 78 Nm {8.0 kgf@m} in the order shown in the

illustration.

2 Fully loosen in the reverse order of that shown in the

illustration.

3 Tighten to 20 Nm {2.0 kgf@m} in the order shown in the

illustration.

4 Mark the head of the cylinder head bolt and cylinder head

by paint, then tighten 90_ of a turn in the order shown in
the illustration.

5 Tighten 90_ of a turn in the order shown in the illustration.

Check that the painted mark of the head bolt is lined up
with that of the cylinder head.

Caution
(1) Always make a tightening angle just 90_. If it is less

than 90_, the head bolt will be loosened.

(2) If it is more than 90_, remove the head bolt and repeat

the procedure from step 1.

Step 4

90_

Painted mark

Gasket

Step 5

Painted mark

Printed portion

90_

"CA OIL RETURN PIPE GASKET INSTALLATION

Install the gasket with the printed portion toward the oil pan.

"DA HIGH-PRESSURE FUEL HOSE INSTALLATION

(1) Apply a small amount of new engine oil to the O-ring,

then fit the O-ring in the delivery pipe.

Caution
Do not let any engine oil get into the delivery pipe.

(2) Check that the high pressure hose turns smoothly.

If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-install
the hose to the delivery pipe and check that the hose
turns smoothly.

(3) Tighten the mounting bolts to the specification.

TIMING BELT

REMOVAL AND INSTALLATION

ENGINE – Timing Belt

11-21

11 {1.1}

2

9 {0.9}

25

5

1

49 {5.0}

12

118 {12.0}

3

19 {1.9}

6

24 {2.4}

13

45 {4.6}

24 {2.4}

8

11 {1.1}

23

49 {5.0}

18

17

3.5 {0.35}

21

7

22

26

11 {1.1}

27

30 {3.1}

4

15

24

88 {9.0}

48 {4.9}

AA""LA 5. Timing belt

"KA 6. Tensioner pulley
"JA 8. Auto tensioner

AB""IA 11. Oil pump sprocket
AC""HA 12. Crankshaft bolt
AD" 13. Crankshaft sprocket

9

Removal steps

1. Front upper cover

2. Front center cover

3. Front lower cover

4. Bracket

7. Tensioner arm

9. Idle pulley

10. Crankshaft position sensor

14. Sensing blade

54 {5.5}

11

14

16

28

20

19

9 {0.9}

AE""GA 16. Timing belt B
AF""FA 17. Counterbalance shaft sprocket

AG" 19. Crankshaft sprocket B

AH""AA 24. Camshaft sprocket bolt

10

49 {5.0}

15. Tensioner B

"EA 18. Spacer

20. Crankshaft key

"DA 21. Rocker cover
"CA 22. Semi-circular packing
"BA 23. Engine support bracket

25. Camshaft sprocket

26. Timing belt rear right cover

27. Timing belt rear left upper cover

28. Timing belt rear left lower cover

Unit: Nm {kgf@m}

11-22

Timing mark

ENGINE – Timing Belt

REMOVAL SERVICE POINTS

AA" TIMING BELT REMOVAL

(1) If the timing belt is to be reused, chalk an arrow mark

on the back surface of the belt so that the belt can be
reinstalled in the same direction.

(2) Place the exhaust camshaft sprocket in a position where

the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.

Caution
The camshaft sprocket on the exhaust side can turn
very easily because of the valve spring tension. Use
care not to allow your fingers to get caught by the
sprocket.

(3) Loosen the lock nut of the tensioner pulley, then remove

the timing belt.

AB" OIL PUMP SPROCKET REMOVAL

(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the

counterbalance shaft.
(3) Loosen the flange bolt.
(4) Remove the oil pump sprocket.

AC" CRANKSHAFT BOLT LOOSENING

AD" CRANKSHAFT SPROCKET REMOVAL

If it is difficult to remove the sprocket, use the special tool.

ENGINE – Timing Belt

AE" TIMING BELT “B” REMOVAL

Make an arrow mark on the back of the timing belt indicating
the direction of rotation so it may be reassembled in the
same direction if it is to be reused.

6EN1322

AF" COUNTERBALANCE SHAFT SPROCKET

REMOVAL

11-23

AG" CRANKSHAFT SPROCKET “B” REMOVAL

If it is difficult to remove the sprocket, use the special tool.

AH" CAMSHAFT SPROCKET BOLT LOOSENING

Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.

INSPECTION

TIMING BELT

Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.

Back side is glossy without resilience and leaves no indent

when pressed with fingernail.

11-24

ENGINE – Timing Belt

Peeling of
canvas

Cracks on rib root

Cracks

Tooth missing

Cracks

Cracks
on sides

(2) Cracks on rubber back.
(3) Cracks of canvas.
(4) Cracks on rib root.
(5) Cracks on belt sides.

(6) Abnormal wear of belt sides.

NOTE

The sides are normal if they are sharp as if cut by a

knife.

(7) Abnormal wear on teeth.

Initial stage:

Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white, and
unclear canvas texture)

Final stage:

Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)

(8) Missing tooth.

12 mm

98 to 196 N {10 to 20 kgf}

Movement

6EN1033

AUTO TENSIONER

(1) Check the auto tensioner for possible leaks and replace

as necessary.
(2) Check the rod end for wear or damage and replace as

necessary.
(3) Measure the rod protrusion. If it is out of specification,

replace the auto tensioner.

Standard value: 12 mm

(4) Press the rod with a force of 98 – 196 N {10 – 20 kgf}

and measure its protrusion. If it is out of specification,

replace the auto tensioner.

Standard value: 1 mm or less

ENGINE – Timing Belt

INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT TIGHTENING

Using a wrench, hold the camshaft at its hexagon and tighten
the bolt to the specification.

Caution
Locking the camshaft sprocket with a tool damages the
sprocket.

11-25

Apply sealant

"BA ENGINE SUPPORT BRACKET LEFT

INSTALLATION

Coat the bolts illustrated with sealant before tightening.

Specified sealant: THREEBOND 1207F or equivalent

"CA SEALANT APPLICATION ON SEMI-CIRCULAR

PACKING

Apply sealant to the areas indicated in the illustration.

Specified sealant: THREEBOND 1212D or equivalent

10 mm

Semi-circular
packing

Cylinder head

Apply
sealant

10 mm

11-26

10 mm

ENGINE – Timing Belt

"DA SEALANT APPLICATION ON ROCKER COVER

Apply sealant to the areas indicated in the illustration.

Specified sealant: THREEBOND 1212D or equivalent

10 mm

Apply sealant

10 mm

Apply sealant

Spacer

Chamfer

10 mm

Oil seal

Apply sealant

"EA SPACER INSTALLATION

(1) Apply very thin coat of oil to the outer periphery of the

spacer (oil seal contacting surface).
(2) Install the spacer with the chamfered end toward the

oil seal. Mounting in the reverse direction can damage

the oil seal lip.

"FA COUNTERBALANCE SHAFT SPROCKET

INSTALLATION

Timing
marks

Timing
marks

"GA TIMING BELT “B” INSTALLATION

(1) Align timing marks on the crankshaft sprocket “B” and

counterbalance shaft sprocket with the marks on the front

case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”

and counterbalance shaft sprocket. There should be no

slack on the tension side.