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Mitsubishi MOTORS Lancer Evolution IX 2005 Workshop Manual Supplement
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Mitsubishi MOTORS Lancer Evolution IX 2005 Workshop Manual Supplement

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Workshop Manual - Supplement
LANCER
Evolution - IX
• Chassis
• Engine
• Wiring Diagrams

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Summary of Contents for Mitsubishi MOTORS Lancer Evolution IX 2005

  • Page 1 Workshop Manual - Supplement LANCER Evolution - IX • Chassis • Engine • Wiring Diagrams...
  • Page 2 SERVICE MANUAL Supplement...
  • Page 3 LANCER CONTENTS EVOLUTION IX General ............Engine ............FOREWORD Fuel .............. This manual contains details of the main changes to the Engine Cooling ........... 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.
  • Page 4 Related materials Title Issue Title Issue date 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 •...
  • Page 5 SECTION 54A CHASSIS ELECTRICAL CONTENTS Number plate lamp ........1 Number plate lamp Due to changes made to the licence plate lamp, servicing guidelines have been changed to be the same as for the ’03 model Lancer. Other servicing guidelines remain unchanged.
  • Page 6 <Notes>...
  • Page 7 CHASSIS ELECTRICAL – LICENCE PLATE LAMP 54A-1 52B-1 SRS AIRBAG – GENERAL SECTION 52B SRS AIRBAG CONTENTS General............1 General A caution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged. Warning/caution label bonnet...
  • Page 8 <Notes>...
  • Page 9 EXTERIOR – GENERAL 51-1 SECTION 51 EXTERIOR CONTENTS General............1 Rear bumper..........4 Front bumper..........2 Rear bumper ............4 Markings .............6 Front bumper............2 General Servicing guidelines have been changed in conjunction with the changes or additions listed below. Other servicing guidelines remain unchanged. •...
  • Page 10 51-2 EXTERIOR – FRONT BUMPER Front bumper Front bumper Removal and fitting Cross section through A-A clip Cross section through B-B clip Cross section through C-C bumper Removal procedure 1. Side valence • Inter-cooler water spray hose connection 2. Centre valence (Ref Section 15) 3.
  • Page 11 EXTERIOR – FRONT BUMPER 51-3 Dismantling and assembly Cross section through A-A hook Cross section through B-B clip Dismantling procedure 1. Front 3-diamonds badge 11. Air intake cover 2. Front bumper nut 12. Front bumper net 3. Front number plate garnish 13.
  • Page 12 51-4 EXTERIOR – FRONT BUMPER, REAR BUMPER Rear bumper Jobs to be completed before removal and after fitting • Removal and refitting of the rear combination lamp • Removal and refitting of the rear end trim • Removal and refitting of the boot area side trim lid Rear bumper Removal and fitting Cross section...
  • Page 13 EXTERIOR – REAR BUMPER 51-5 Dismantling and assembly Dismantling procedure 1. Number plate lamp bracket 4. Rear bumper facing support, side • Number plate lamp ASSY reinforcement 2. Rear bumper reinforcement 5. Rear bumper valence 3. Rear bumper side plate 6.
  • Page 14 51-6 EXTERIOR – MARKINGS Markings Removal and affixing 1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge 3. EVOLUTION badge Guidelines for affixing markings Affixing markings 1. Positioning 2. LANCER badge 3. EVOLUTION badge edge of boot lid 2. Guidelines for affixing (1) Using white spirit, remove any grease from the place where the badges will be affixed.
  • Page 15 BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP 42-1 SECTION 42 BODY CONTENTS General............1 Window glass channel, door-opening weather strip <GT, GSR>......1 General Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain unchanged.
  • Page 16 <Notes>...
  • Page 17 FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY 33-1 SECTION 33 FRONT SUSPENSION CONTENTS General............1 Strut ASSY ..........1 Special tools..........1 General The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the shape of the Bilstein shock absorbers.
  • Page 18 33-2 FRONT SUSPENSION – STRUT ASSY 2. Use the following tools to loosen the self-locking nut. • Wrench (MB991681) • Socket (MB991682) Caution Do not use an impact wrench when loosening the self- locking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose.
  • Page 19 TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING 31-1 SECTION 31 WHEELS AND TYRES CONTENTS General............1 Removal of emergency puncture repairing agent..1 Disposal of emergency puncture repairing agent ..2 On-vehicle servicing........1 General The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit. On-vehicle servicing Removal of emergency puncture repairing agent...
  • Page 20 31-2 TYRES AND WHEELS – ON-VEHICLE SERVICING 4. Put the tyre on a raised surface and tilt it to an angle. Insert the extraction hose extraction hose through the hole made by removing the valve, so that the tip of the hose is submerged in the repairing agent. repairing agent raised surface...
  • Page 21 REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM> 27B-1 SECTION 27B REAR AXLE CONTENTS General............1 Differential carrier <vehicles with an AYC system> ..........1 General The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been changed.
  • Page 22 <Notes>...
  • Page 23 ENGINE ELECTRICAL – CHARGING SYSTEM 16-1 SECTION 16 ENGINE ELECTRICAL CONTENTS Charging system........1 Servicing standards........4 General ..............1 On-vehicle servicing........4 Alternator...............1 Checking, cleaning and replacing spark plugs ..4 Ignition system...........4 Cam position sensor .........4 General ..............4 Charging system General The following alternator servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
  • Page 24 16-2 ENGINE ELECTRICAL – CHARGING SYSTEM (engine oil) Removal procedure 10. Purge control solenoid valve ASSY 1. Injector connector 11. Oil level gauge and guide ASSY 2. Accelerator cable connection 12. O-ring 3. Delivery pipe, injector, and fuel pressure 13. Drive belt regulator ASSY 14.
  • Page 25 ENGINE ELECTRICAL – CHARGING SYSTEM 16-3 Removal guidelines 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. Removing the drive belt The following procedures are necessary because a serpentine drive system with auto-tensioner has been installed.
  • Page 26 16-4 ENGINE ELECTRICAL – IGNITION SYSTEM Ignition system General The following servicing guidelines for spark plugs and the cam position sensor have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged. Servicing standards Item Standard Value Upper Limit Spark plug cap mm 0.5~0.6...
  • Page 27 INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS, 15-1 ON-VEHICLE SERVICING SECTION 15 INTAKE & EXHAUST CONTENTS General................1 Inter-cooler water spray ............2 Servicing standards ............1 Secondary air control system ..........4 Special tools...............1 Inlet manifold ..............5 Exhaust manifold and turbocharger........8 On-vehicle servicing............1 Turbocharger super charging pressure check ....1 General...
  • Page 28 15-2 INTAKE & EXHAUST INTER-COOLER WATER SPRAY Inter-cooler water spray Removal and fitting <Water spray nozzle, hose and washer tank> Procedure for removing the water spray nozzle 10. Washer valve and the hose • Tape (for attaching clip) 1. Water spray hose connection 11.
  • Page 29 INTAKE & EXHAUST INTER-COOLER WATER SPRAY 15-3 Fitting guidelines Fitting the water spray hose ASSY and fixing tape (for securing the water spray hose ASSY) 1. After fitting the water spray hose, the three-way joint and the washer valve, affix pads, clips and tape at the positions shown in the water spray hose diagram.
  • Page 30 15-4 INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM Secondary air control system Removal and fitting Jobs to be completed before removal and after fitting • Removal and refitting of the air duct • Removal and refitting of the strut tower bar air pipe C Removal procedure 6.
  • Page 31 INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD 15-5 Fitting guidelines Fitting the gasket Fit the gasket so that the protruding part points in the direction shown in the diagram. protruding part Inlet manifold Removal and fitting Jobs to be completed before removal and •...
  • Page 32 15-6 INTAKE & EXHAUST – INLET MANIFOLD Removal procedure 12. Vacuum hose connection 1. Centre cover 13. Vacuum hose connection 2. Ignition coil connector 14. Fuel return hose connection 3. O 2 sensor connector 15. Fuel high pressure hose connection 16.
  • Page 33 INTAKE & EXHAUST – INLET MANIFOLD 15-7 Removal procedure 24. Knock sensor connector 31. Inlet manifold stay 25. Purge control solenoid valve ASSY 32. Cover 26. Vacuum hose 33. Gasket 27. Fuel pressure solenoid valve ASSY 34. Harness connection 28. PCV hose 35.
  • Page 34 15-8 INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER Exhaust manifold and turbocharger Removal and fitting Jobs to be completed before removal and after fitting • Removal and refitting of the valence • Removal and refitting of the cross member bar •...
  • Page 35 INTAKE & EXHAUST – 15-9 EXHAUST MANIFOLD Removal procedure 1. Exhaust manifold heat protector 14. Vacuum hose connection 2. Air pipe ASSY connection 15. Air outlet fitting 3. O 2 sensor 16. Air outlet fitting gasket 17. Exhaust fitting bracket 4.
  • Page 36 15-10 INTAKE & EXHAUST – EXHAUST MANIFOLD 3. Apply some fresh engine oil via the fitting hole for the oil feed pipe in the turbocharger ASSY. Fitting the air outlet fitting gasket turbocharger protruding part Fit the gasket so that the protruding part is in the position located in the diagram.
  • Page 37 ENGINE COOLING – GENERAL 14-1 SECTION 14 ENGINE COOLING CONTENTS General............1 Water hose and pipe........3 Water pump ..........2 General The following servicing guidelines for the water pump and the water hose and pipe have been prepared for vehicles which use the 4G63-MIVEC-T/C engine.
  • Page 38 14-2 ENGINE COOLING – WATER PUMP Water pump Removal and fitting Jobs to be completed before removal and after fitting • Draining and refilling of the coolant • Removal and refitting of the timing belt (Ref Section 11) Positions for fitting different sized bolts Nominal diameter and nominal length (mm) Removal procedure 1.
  • Page 39 ENGINE COOLING – WATER HOSE AND PIPE 14-3 Water hose and pipe Removal and fitting Jobs to be completed before removal and after fitting • Removal and refitting of the valence • Draining and refilling of the water coolant • Removal and refitting of the air cleaner ASSY •...
  • Page 40 14-4 ENGINE COOLING – WATER HOSE AND PIPE Removal guidelines Removing the radiator upper hose and the radiator lower hose Mark the radiator hose and the hose clamp with indicator marks and then remove the radiator hose. indicator marks Fitting guidelines water pump and thermostat case Fitting the O-ring and the water inlet pipe...
  • Page 41 MPI – GENERAL 13A-1 SECTION 13A MPI (Multi-point Fuel Injection) CONTENTS General..............2 Servicing the vehicle ..........29 Servicing standards ..........3 1. Adjusting specified revolutions when idling..29 Special tools ............3 2. MPI system components layout diagram..29 Troubleshooting ............5 3. Checking the air temperature sensor....29 4.
  • Page 42 13A-2 MPI – GENERAL MPI system diagram H 1. O 2 sensor • Power supply • Engine control relay I1. Injector • Ignition switch IG • Fuel pump relay 2,3 I2. ISC servo (Stepper H 2. Air flow sensor • Ignition switch ST (ON/OFF) motor) H 3.
  • Page 43 MPI – SERVICING STANDARDS, SPECIAL TOOLS 13A-3 Servicing standards Item Standard level Revolutions when idling r/min 800 ± 50 Air temperature sensor resistance kΩ at -20 ºC 13~18 at 0 ºC 5.1~6.9 at 20 ºC 2.0~3.0 at 40 ºC 0.9~1.5 at 60 ºC 0.40~0.78 at 80 ºC...
  • Page 44 13A-4 MPI- SPECIAL TOOLS Tool Number Name Function MB991348 Test harness Inspection using an oscilloscope MB991709 Test harness • Troubleshooting voltage measurement • Inspection using an oscilloscope MB991658 Test harness Inspection using an oscilloscope MD998478 Test harness • Troubleshooting voltage measurement (3P, triangular) •...
  • Page 45 MPI – TROUBLESHOOTING 13A-5 TROUBLESHOOTING 1. Diagnosis Functions 1-1 Engine warning light (Check engine lamp) Changes have been made to engine warning lights. Checklist for engine warning lights. Engine ECU Air flow sensor (AFS) Manifold absolute pressure (MAP) sensor system Intake air temperature sensor Throttle position sensor (TPS) Water temperature sensor...
  • Page 46 13A-6 MPI- TROUBLESHOOTING 2. Diagnosis code classification table Code No. Diagnosis item Page P0105 MAP sensor 13A-7 P0340 Exhaust cam position sensor system 13A-9 P1012 Intake cam position sensor system 13A-11 P1021 Oil feeder control valve system 13A-13 P2226 Atmospheric pressure system 13A-14...
  • Page 47 13A-7 MPI – TROUBLESHOOTING 3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE Code No. P0105 MAP sensor system Probable cause of the malfunction Conditions for the inspection • MAP sensor malfunction • Ignition switch: ON • Broken circuit or short circuit in the MAP •...
  • Page 48 13A-8 MPI – TROUBLESHOOTING Continued from the previous page Check connector C-50 Repair Measurements taken at the B-135 MAP sensor connector • Connect the test harness (MB991348) to the connector Inspect the harness between the and measure at the pick-up MAP sensor and the engine ECU, harness component.
  • Page 49 13A-9 MPI – TROUBLESHOOTING Code No.P0340 Exhaust cam position sensor system Probable cause of the malfunction Conditions for inspection • Malfunction of the exhaust cam position • Ignition switch: ON sensor • With engine cranking or running • Broken circuit or short circuit in the exhaust Evaluation conditions cam position sensor circuit, or poor connector •...
  • Page 50 13A-10 MPI – TROUBLESHOOTING Continued from the previous page Measurement of the output wave Repair Check connector B-19X at the exhaust cam position sensor connector B-115 (using an oscilloscope) Inspect the harness between the Repair • Use test harness (MB991709), exhaust cam position sensor and connect it to the connector, and the engine control relay...
  • Page 51 13A-11 MPI – TROUBLESHOOTING Code No.P1012 Intake cam position sensor system Probable cause of the malfunction Conditions for inspection • Malfunction of the intake cam position sensor • With engine cranking or running • Broken circuit or short circuit in the intake Evaluation conditions cam position sensor circuit, or poor •...
  • Page 52 13A-12 MPI – TROUBLESHOOTING Continued from the previous page Measurement of the output wave Check connectors B-19X & C-23 Repair at the intake cam position sensor connector B-33 (using an oscilloscope) Inspect the harness between the Repair • Use test harness (MB991709), intake cam position sensor and connect it to the connector, and the engine control relay...
  • Page 53 13A-13 MPI – TROUBLESHOOTING Code No.P1021 Oil feeder control valve system Probable cause of the malfunction Conditions for inspection • Malfunction of the oil feeder control • Oil feeder control valve: OFF valve Evaluation conditions • Broken circuit or short circuit in the oil •...
  • Page 54 13A-14 MPI – TROUBLESHOOTING Code No.P2226 Atmospheric pressure sensor system Probable cause of the malfunction Conditions for inspection • Malfunction of the atmospheric pressure • Ignition switch: ON sensor • Wait for 2 seconds after the ignition switch has been turned on or the •...
  • Page 55 13A-15 MPI – TROUBLESHOOTING Continued from previous page (1) NG Measurements taken at B-08 AFS Check connectors C-49 & C-50 Repair connector • Only connect the test harness Inspect the harness between AFS (MB991709) to terminals and engine ECU, repair if No.1, No.2 and No.5 of the necessary connector and measure at the...
  • Page 56 13A-16 MPI – TROUBLESHOOTING 4. Checklist of faults Inspection procedure Fault to be checked Reference page Engine seems hesitant Acceleration malfunction 13A-16 Engine seems to stumble Engine has a power surge Mis-timed ignition 13A-18 Inter-cooler water spray circuit system 13A-19 No.2 waste gate solenoid valve system 13A-21 Air temperature sensor system...
  • Page 57 13A-17 MPI – TROUBLESHOOTING Continued from previous page Check the spark plug wire (Ref: Section 16: Ignition Replace the spark plug wire apparatus) Replace the spark plug Check the spark plug (Ref: Section 16: Ignition apparatus) Check connectors B-123 & B-119 Repair Check the ignition coil (Ref: Section 16: Ignition Replace the ignition coil...
  • Page 58 13A-18 MPI – TROUBLESHOOTING Inspection procedure 15 Miss-timed ignition Probable causes of the malfunction Probable causes of the malfunction are noted in the right • Malfunction of the crank angle sensor hand column. • Malfunction of the exhaust cam position sensor •...
  • Page 59 13A-19 MPI – TROUBLESHOOTING Inspection procedure 35 Inter-cooler water spray circuit system Probable causes of the malfunction • If the inter-cooler water spray switch (manual) is turned ON, the inter-cooler • Malfunction of the inter-cooler water water spray manual ‘ON’ signal will be input in the engine ECU. When this spray switch.
  • Page 60 13A-20 MPI – TROUBLESHOOTING Continued from the previous page Measure at the inter-cooler water Check connectors C-209, C-210, C-201 and C-208 Repair spray relay connector C-220 • Undo the connector, and Inspect the harness between the inter-cooler water spray measure on the harness side Repair relay and the ignition switch •...
  • Page 61 13A-21 MPI – TROUBLESHOOTING Inspection procedure 37 No.2 waste gate solenoid valve system Probable causes of the malfunction The No.2 waste gate solenoid valve controls the supercharge pressure • Malfunction of the No.2 waste gate introduced to the waste gate actuator in the turbocharger. solenoid valve.
  • Page 62 13A-22 MPI – TROUBLESHOOTING Inspection procedure 38 Air temperature sensor system Probable causes of the malfunction The air temperature sensor controls the temperature inside the inlet • Malfunction of the air temperature sensor. manifold, and compensates for any burning of fuel. •...
  • Page 63 13A-23 MPI – TROUBLESHOOTING Continued from the previous page Check connector: C-51 Repair Measure at the air temperature sensor connector B-34 • Connect the test harness (MB991658), to the connector Inspect the harness between the and measure at the pick-up air temperature sensor and the harness component.
  • Page 64 13A-24 MPI – TROUBLESHOOTING 13A-23 6. Service data table 7. Engine ECU checks 7-1 Terminal voltage table...
  • Page 65 13A-24 13A-25 MPI – TROUBLESHOOTING 7-2 Table showing resistance and continuity across the terminals of harness side connectors 8. Checks using an oscilloscope Sensor output signals and actuator drive signals can be checked visually by taking waveform measurements using an oscilloscope.
  • Page 66 13A-26 MPI – TROUBLESHOOTING <Standard waveforms> Observation conditions Exhaust cam position sensor Crank angle sensor Probe switch AC-GND-DC TIME/DIV. 10ms 10 ms VOLTS/DIV. Other Engine Idling Standard waveform 2 engine revolutions (1 camshaft revolution) crank angle sensor output waveform exhaust cam position sensor output waveform...
  • Page 67 13A-27 MPI – TROUBLESHOOTING <Examples of abnormal waveforms> • Example 1 Waveform characteristics A rectangular waveform is produced even though the engine has not been started. Cause of the problem Sensor interface fault • Example 2 Waveform characteristics The waveform is displaced to the left or the right. Cause of the problem The timing belt is loose.
  • Page 68 13A-28 MPI – TROUBLESHOOTING Standard waveform 2 engine revolutions (1 camshaft revolution) (cam reset angle) (cam most advanced angle) crank angle sensor output waveform (phase- angle) exhaust cam position sensor output waveform <Explanation of waveforms> • The intake cam position sensor detects the position of the inlet camshaft. The notch located on the intake side of the camshaft creates 4 output pulses for each revolution of the camshaft.
  • Page 69 MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING 13A-29 • Example 2 Waveform characteristics The waveform is displaced to the left or the right. Cause of the problem The timing belt is loose There is an abnormality in the fuel pump camshaft On-vehicle servicing 1.
  • Page 70 13A-30 MPI – ON-VEHICLE SERVICING (3) Remove the air temperature sensor (4) Use a hair dryer to increase the temperature and measure the resistance. Normal conditions: Temperature (ºC) Resistance (kΩ ) Temperature increases Resistance decreases (5) If the resistance deviates from the standard values, or if it does not change, replace the air temperature sensor.

  • Page 71: Table Of Contents

    ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS 11-1 SECTION 11 ENGINE CONTENTS General ............1 Camshaft, valve stem seals .....4 Servicing standards .........1 Cylinder head gaskets......14 Sealants .............1 Timing belt, timing belt B......20 Special tools ..........2 Engine ASSY ..........28 Engine tuning ..........4 1.

  • Page 72: Special Tools

    11-2 ENGINE – SPECIAL TOOLS Special tools Tool Number Name Function MB991502 MUT-II Sub Checking and adjusting the tension in ASSY 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 MB991955...
  • Page 73 ENGINE – SPECIAL TOOLS 11-3 Tool Number Name Function MD998737 Valve stem seal Valve stem seal installation installer MD998713 Camshaft oil seal Camshaft oil seal installation installer MB991654 Cylinder head bolt Cylinder head bolt removal, installation wrench MB991367 Special spanner Holding the crankshaft sprocket MB991385 Pins...

  • Page 74: Engine Tuning

    11-4 ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL Tool Number Name Function MB991454 Engine hanger Holding the engine assembly while the balancer transmission assembly is removed/installed Recommended Mechanical engine tools MZ203830 hanger panzai or MZ203831 safe vehicle handling MB991928 Engine hanger Slide bracket (HI)
  • Page 75 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-5 Removal procedure 1. Oil feeder control valve connector 8. Connection of the control harness 2. Oil feeder control valve 9. Vacuum hose 3. O-ring 10. PCV hose 4. Breather hose 11. Connection of the radiator upper hose •...
  • Page 76 11-6 ENGINE – CAMSHAFT, VALVE STEM SEAL During assembly, apply engine oil to all sliding parts. 18. Camshaft position sensor support cover 30. Camshaft bearing cap No. 2 19. Camshaft position sensor support cover 31. Camshaft bearing cap No. 5 gasket 32.
  • Page 77 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-7 46. Rocker arm 51. Valve spring retainer 47. Rush adjuster 52. Valve spring 48. Oil delivery body 53. Inlet valve stem seal 49. Spark plug 54. Exhaust valve stem seal 50. Valve spring retainer lock...
  • Page 78 11A-8 ENGINE – CAMSHAFT, VALVE STEM SEAL Locations for the application of lubricant and seals <View from A> Semi-dry sealant: Three bond 1207F Semi-dry sealant: Three bond 1207D (around the lip): Engine oil Semi-dry sealant: Three bond 1207F <Viewed looking down onto the cylinder head> Semi-dry sealant: Three bond 1207D...
  • Page 79 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-9 Removal guidelines 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. Indicator marks Removing the camshaft sprockets Grip the hexagonal part of the camshaft with a wrench, loosen the mounting bolt, and remove the camshaft sprocket.
  • Page 80 11-10 ENGINE – CAMSHAFT, VALVE STEM SEAL Fitting the valve spring Rocker arm side Fit the valve spring so that the end of the valve spring which has the smaller radius is on the rocker arm side. 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...
  • Page 81 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.
  • Page 82 11-12 ENGINE – CAMSHAFT, VALVE STEM SEAL 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 Front of (engine oil) camshaft.
  • Page 83 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-13 Fitting the camshaft position sensing cylinder (inlet <Intake side> side) dowel pin 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.

  • Page 84: Cylinder Head Gaskets

    11-14 ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET 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 Tape (seal tape etc) around the oil channel of the oil feeder control valve, in order to prevent damage to the O-ring.
  • Page 85 ENGINE – CYLINDER HEAD GASKET 11-15 (engine oil) Removal procedure 12. Inlet camshaft position sensor 1. Ignition coil connector connector 2. O 2 sensor connector 13. Water temperature gauge unit connector 3. Oil feeder control valve connector 14. Joint control harness and transmission 4.
  • Page 86 11-16 ENGINE – CYLINDER HEAD GASKET (engine oil) (when cool) (engine oil) 22. Alternator bracket connection 35. Oil return pipe gasket 23. Inlet manifold stay 36. Exhaust fitting bracket 24. Eye bolt • Water outlet fitting and thermostat case 25. Gasket assembly (Refer to Section 14: Water hose 26.
  • Page 87 ENGINE – CYLINDER HEAD GASKET 11-17 Removal guidelines 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. Front of engine Fitting guidelines Fitting the cylinder head gasket...
  • Page 88 11-18 ENGINE – CYLINDER HEAD GASKET 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.
  • Page 89 ENGINE – CYLINDER HEAD GASKET 11-19 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.

  • Page 90: Timing Belt, Timing Belt B

    11-20 ENGINE – TIMING BELT, TIMING BELT B 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.
  • Page 91 ENGINE – TIMING BELT, TIMING BELT B 11-21 (engine oil) 10. Power steering oil pressure switch connector 16. Crankshaft sprocket 11. Heat protector 17. Crankshaft sensing blade 12. Power steering oil pump ASSY • Adjust the tension of the timing belt B 13.
  • Page 92 11-22 ENGINE – TIMING BELT, TIMING BELT B 3. Twist the special tool for adjusting bolts (MD998738) by hand timing belt tensioner 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...
  • Page 93 ENGINE – TIMING BELT, TIMING BELT B 11-23 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 timing marks Fitting timing belt B and the timing belt B tensioner...
  • Page 94 11-24 ENGINE – TIMING BELT, TIMING BELT B 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 approx. 100 N arrow), and check that the amount of give is as specified.
  • Page 95 ENGINE – TIMING BELT, TIMING BELT B 11-25 Fitting the crankshaft sensing blade and the crankshaft sprocket Front of engine 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.
  • Page 96 11-26 ENGINE – TIMING BELT, TIMING BELT B Fitting the timing belt 1. Check that all the timing marks for the camshaft sprocket, the timing marks crankshaft sprocket and the oil pump sprocket are aligned. camshaft sprocket camshaft (exhaust sprocket (inlet side) side) timing...
  • Page 97 ENGINE – TIMING BELT, TIMING BELT B 11-27 (3) Use a wrench to align the timing marks on the rocker cover and paper clips 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.

  • Page 98: Engine Assy

    11-28 ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY 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.
  • Page 99 ENGINE – ENGINE ASSY 11-29 Removal procedure 1. Ignition coil connector 11. Exhaust cam position sensor connector 2. O 2 sensor connector 12. Inlet cam position sensor connector 13. Water temperature gauge unit connector 3. Oil feeder control valve connector 14.
  • Page 100 11-30 ENGINE – ENGINE ASSY Caution Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is being supported by the chassis. (engine oil) 20. Vacuum tank, solenoid valve, vacuum 28. Heater hose connection pipe and hose ASSY 29.
  • Page 101 ENGINE – ENGINE ASSY 11-31 Removal guidelines 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.
  • Page 102 11-32 ENGINE – ENGINE ASSY Removing the engine mount bracket & stopper ASSY MZ203830 or MZ203831 1. Support the engine using a garage jack. 2. Remove the special mechanical engine hanger (MZ203830, MZ203831 or MB991928). slide bracket (HI) 3. Hold the engine ASSY using a chain block. 4.
  • Page 103 ENGINE – ENGINE ASSY 11-33 Fitting the engine mount bracket & stopper ASSY engine side engine side 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.
  • Page 104 11-34 ENGINE – ENGINE ASSY 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.
  • Page 105 GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP, 00-1 RELEVANT VEHICLE NUMBERS SECTION 00 GENERAL CONTENTS Inspection guidelines and Relevant vehicle numbers ......1 troubleshooting..........1 Model line-up..........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.
  • Page 106 <Notes>...