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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 Download Page 2

SERVICE MANUAL

Supplement

Summary of Contents for Lancer Evolution IX 2005

Page 1: ...LANCER Evolution IX Chassis Engine Wiring Diagrams ...

Page 2: ...SERVICE MANUAL Supplement ...

Page 3: ...ame 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 CONTENTS General Engine Fuel Engine Cooling Intake and Exhaust En...

Page 4: ...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 Indicates where the new model manual was published with the service manual in a single volume WARNING REGARDING THE SERVICING OF VEHICLES F...

Page 5: ...CAL CONTENTS Number plate lamp 1 bonnet 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: ...G GENERAL 54A 1 52B 1 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 SECTION 54A CHASSIS ELECTRICAL bonnet ...

Page 8: ... Notes ...

Page 9: ...ged in conjunction with the changes or additions listed below Other servicing guidelines remain unchanged Changes made to the shape and component of the front bumper Changes made to the shape and component of the rear bumper Changes made to the method for affixing the front 3 diamonds badge Changes made to the position for affixing the LANCER badge and the EVOLUTION badge ...

Page 10: ...valence 2 Centre valence 3 valence centre bracket 4 Front valence 5 Clip for attaching the splash shield Inter cooler water spray hose connection Ref Section 15 6 Front bumper ASSY 7 Front bumper stay Cross section through A A clip clip Cross section through B B Cross section through C C cap bumper ...

Page 11: ...umper lower plate 9 Front bumper upper plate 10 Front bumper upper support 11 Air intake cover 12 Front bumper net 13 Bumper side net LH 14 Oil cooler duct 15 Bumper side net RH Inter cooler water spray hose and nozzle Ref Section 15 16 Front bumper side plate 17 Front bumper upper reinforcement 18 Front bumper facing Note The main points for dismantling and assembly remain unchanged Cross section...

Page 12: ...r 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 Removal procedure 1 Screw for attaching the splash shield 2 Rear bumper bracket 3 Rear bumper ASSY 4 Rear number plate bracket Cross section through A A clip splash shield ...

Page 13: ...re 1 Number plate lamp bracket Number plate lamp ASSY 2 Rear bumper reinforcement 3 Rear bumper side plate 4 Rear bumper facing support side reinforcement 5 Rear bumper valence 6 Rear bumper facing Note The main points for dismantling and assembly remain unchanged A A A A ...

Page 14: ...ove the protective paper from the back of the badges and affix them in the designated places Caution 1 Perform this job in an ambient temperature of 20 38ºC and in a dust free location 2 If the job is being performed in an ambient temperature of less than 20ºC warm up the badges and the area of the body onto which they will be affixed to a temperature of 20 38ºC 3 Ensure that air bubbles are not t...

Page 15: ...g inner weather strip Window glass channel door opening weather strip GT GSR Removal and fitting front door rear door Note position of clips Cross section A A front door trim clip Removal of the front door opening inner lower weather strip 1 Front door opening inner lower weather strip Procedure for removing the front door opening inner weather strip Front scuff plate Cowl side trim Lower centre p...

Page 16: ... Notes ...

Page 17: ...or body B Arm set Dismantling and assembling the strut ASSY MB991680 A MB991681 B MB991682 Wrench set A Wrench B Socket Strut ASSY Dismantling guidelines A Removal of the self locking nut 1 Use the following special tools to compress the coil spring Spring compressor body MB991237 Arm set MB991238 Caution 1 In order to completely compress the coil spring ensure that the special tool is fixed when ...

Page 18: ...nut Caution Do not use an impact wrench because there is a danger that the special tool may be damaged 3 Align the holes in the lower spring plate and the upper spring plate of the strut ASSY Note This operation can be easily performed by using a pipe to align the holes 4 Line up the two ends of the coil spring with the slots in the spring plate and loosen the special tool 5 Use the following spec...

Page 19: ...es below Note When removing the repairing agent a container the empty bottle which contained the repairing agent and the insertion hose and the extraction hose from the emergency puncture repair kit are needed Caution 1 Carry out the operation in a well ventilated airy place 2 Take appropriate measures in order to prevent repairing agent getting onto the skin being inhaled coming into contact with...

Page 20: ...the tyre from the wheel Remove any repairing agent stuck onto the tyre and if the place from which air is escaping can be identified carry out a normal repair procedure If the place from which air is escaping cannot be identified replace the tyre Disposal of emergency puncture repairing agent Dispose of the repairing agent extracted from the tyre and any unused agent which has exceeded its use by ...

Page 21: ...l The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY has been changed Other servicing guidelines remain unchanged Differential carrier vehicles with an AYC system Removal and fitting Note 1 When the screw is dry 2 When the screw is lubricated NEW OLD fuel pressure unit hose ASSY differential carrier ASSY ...

Page 22: ... Notes ...

Page 23: ...The following alternator servicing guidelines have been prepared for vehicles which use the 4G63 MIVEC T C engine Other servicing guidelines remain unchanged Alternator Removal and fitting Jobs to be done before removal and after fitting Removal and refitting of the valence Checking the tension of the drive belt only after fitting Removal and refitting of the strut tower bar Removal and refitting ...

Page 24: ...tor 6 Fuel pressure solenoid valve connector 7 Fuel pressure solenoid valve ASSY 8 Knock sensor connector 9 Purge control solenoid valve connector 10 Purge control solenoid valve ASSY 11 Oil level gauge and guide ASSY 12 O ring 13 Drive belt 14 Alternator connector and terminal Engine mount 15 Alternator 16 Water pump pulley 17 O2 sensor connector 18 Alternator bracket engine oil A B C ...

Page 25: ...sert a 12 7sq spinner handle into the auto tensioner hole and turn the auto tensioner in an anti clockwise direction until it reaches the stopper 2 Align the A hole and the B hole hold them in place by inserting an L shaped hexagonal Allen Key and remove the drive belt Caution If planning to re use the drive belt ensure that it will be refitted the same way round by marking the back of the belt wi...

Page 26: ...value and the upper limit for plug caps has been changed in conjunction with the changes made to the spark plugs Other servicing guidelines remain unchanged Standard values and upper limits Cam position sensor Removal and fitting Removal procedure Exhaust side 1 Cam position sensor connector 2 Cam position sensor 3 O ring Removal procedure Inlet side 4 Cam position sensor connector 5 Cam position ...

Page 27: ...Other servicing guidelines remain unchanged Changes to the turbocharger supercharging pressure Changes to the inter cooler water spray hose Changes to the secondary air control valve Changes to the inlet manifold Changes to the exhaust manifold and the turbocharger Special tools On vehicle servicing Turbocharger supercharging pressure check The standard value for the turbocharger charging pressure...

Page 28: ...fitting the water spray hose ASSY 2 Water spray nozzle ASSY 3 Water spray hose ASSY 4 Clamp 5 Water spray nozzle top 6 Water spray nozzle bracket 7 Water spray nozzle bottom 8 Water spray hose 9 Three way joint 10 Washer valve Tape for attaching clip 11 Clip 12 Pad Procedure for removing the washer tank 1 Water spray hose connection 13 Water spray motor connector 14 Washer tank 15 Water spray hose...

Page 29: ...nd tape at the positions shown in the water spray hose diagram 2 Fit the water spray hose ASSY to the front bumper using the water spray hose ASSY clip 3 Affix tape as shown in the diagram so that the water spray hose ASSY does not slip View of the inside of the front bumper tape three way joint pads tape washer valve clip tape clip three way joint pad clip washer valve tape clip tape clip clip wa...

Page 30: ...d after fitting Removal and refitting of the air duct Removal and refitting of the strut tower bar Removal procedure 1 Control harness connection 2 Heat protector 3 Vacuum hose connection Air pipe C 4 Vacuum pipe 5 Harness bracket 6 Air hose 7 Air pipe ASSY 8 Gasket 9 Gasket 10 Secondary air control valve 11 Harness bracket air pipe C A ...

Page 31: ...Take measures to prevent fuel leaking only before removal Removal and refitting of the valence Ref Section 15 Front bumper Draining and refilling the coolant Removal and refitting of the air duct Removal and refitting of the strut tower bar Removal and refitting of the throttle body Removal and refitting of the secondary air control valve Ref P15 4 Removal and refitting of the cross member bar Rem...

Page 32: ...pressure sensor connector 9 Purge control solenoid valve connector 10 Knock sensor connector 11 Fuel pressure solenoid valve connector 12 Vacuum hose connection 13 Vacuum hose connection 14 Fuel return hose connection 15 Fuel high pressure hose connection 16 O ring 17 Delivery pipe injector and fuel pressure regulator ASSY 18 Insulator 19 Insulator 20 Oil level gauge guide ASSY 21 O ring 22 Brake ...

Page 33: ...SY Remove the deliver pipe with the injector and the fuel pressure regulator intact Caution When removing the delivery pipe be careful not to drop the injector Fitting guidelines A Connecting the O ring and the fuel high pressure hose 1 Apply a small quantity of fresh engine oil to the O ring and insert it into the delivery pipe without damaging the O ring 2 Check that the high pressure hose can b...

Page 34: ...e completed before removal and after fitting Removal and refitting of the valence Removal and refitting of the radiator Removal and refitting of the air intake hose and air hose A Removal and refitting of the cross member bar Removal and refitting of the front exhaust pipe Draining and refilling of the engine oil ...

Page 35: ...sket 23 Turbocharger water return pipe 24 Gasket 25 Exhaust manifold 26 Exhaust manifold gasket Removal guidelines A Removing the O2 sensor After removing the O2 sensor connector and the clamp use the special O2 sensor wrench MD998770 to remove the O2 sensor B Removing the oil feed pipe Caution After removing the oil feed pipe ensure that there is no foreign matter in the oil access hole on the tu...

Page 36: ...rn pipe gasket oil pan side Fit so that the printed side of the gasket is on the oil pan side D Fitting the oil return pipe gasket turbocharger side Fit so that the printed side of the gasket is on the turbocharger side turbocharger protruding part view A view A print print gasket gasket 3 Apply some fresh engine oil via the fitting hole for the oil feed pipe in the turbocharger ASSY ...

Page 37: ...CONTENTS General 1 Water pump 2 Water hose and pipe 3 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 Other servicing guidelines remain unchanged ...

Page 38: ...pump gasket 4 O ring Fitting guidelines A Fitting the O ring Fit the O ring into the O ring groove at the end of the water inlet pipe and insert it into the water pump after moistening with water the places where the O ring will make contact with the water pump Caution Ensure that absolutely no engine oil or other type of grease gets onto the O ring Positions for fitting different sized bolts Nomi...

Page 39: ... control valve Ref Section 15 Secondary air control system Removal procedure 1 Connection to the radiator upper hose 2 Connection to the radiator lower hose 3 Water temperature gauge unit connector 4 Water temperature sensor connector 5 Water hose 6 Bracket 7 Water outlet fitting and thermostat case ASSY 8 Thermostat case gasket 9 Connection to the knock sensor harness clamp 10 O ring 11 Water hos...

Page 40: ...ing with water the places where the O ring and the water inlet pipe will be in contact Caution Ensure that absolutely no engine oil or other type of grease gets onto the O ring B Connecting the radiator lower hose and the radiator upper hose 1 Insert the hose as far as the protrusion on the water inlet pipe and the water outlet fitting 2 Match up the indicator marks on the radiator hose and the ho...

Page 41: ...layout diagram 29 3 Checking the air temperature sensor 29 4 Checking the oil feeder control valve 30 GENERAL Servicing guidelines have been changed because of the changes listed below A variable valve timing control system V V T has been adopted Because of this an oil feeder control valve and an intake cam position sensor have been added A manifold absolute pressure MAP sensor has been added An a...

Page 42: ...rol valve Engine control relay Fuel pump relay 2 3 ON OFF Fuel pump relay HI LO switch A C relay Ignition coil Fan controller Condenser fan relay HI Condenser fan relay LO Engine warning light Diagnosis output terminal Alternator G terminal Inter cooler water spray relay Inter cooler water spray lamp O2 sensor heater È È I6 Purge control solenoid valve I7 Secondary air control solenoid valve Check...

Page 43: ...king the MPI system MB991955 A MB991824 B MB991827 C MB991910 D MB991911 E MB991825 F MB991826 MUT III sub ASSY A Vehicle Communication Interface V C I 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 Note If a MUT III main harness A is connected to a vehicle not fitted with CAN there is a chance...

Page 44: ...cope MB991658 Test harness Inspection using an oscilloscope MD998478 Test harness 3P triangular Troubleshooting voltage measurement Inspection using an oscilloscope MB991223 Inspection harness set connector Pin contact pressure inspection harness Commercial tester connection probe for ordinary connectors Terminal voltage measurement Red coloured harness for DLI White coloured harness for LC ...

Page 45: ...or Injector Ignition coil with built in power transistor Atmospheric pressure sensor O2 sensor O2 sensor heater Fuel system malfunction Knock sensor Intake cam position sensor system Oil feeder control valve system Item number Type of data Units condition 95 MAP sensor kPa Malfunctioning item Control measures taken when a malfunction occurs Air temperature sensor Regulation of the intake air tempe...

Page 46: ...em 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 2 Diagnosis code classification table ...

Page 47: ...0 Dealing with temporary malfunctions Measurements taken at the B 135 MAP sensor connector Undo the connector and take measurements using the harness 1 Voltage across earth at 3 ignition switch ON OK 4 9 5 1V 2 Resistance across earth at 2 OK 2Ω or less Temporary malfunction Ref Section 00 Dealing with temporary malfunctions Check connector B 135 NG 2 NG 1 NG OK NG OK OK Temporary malfunction Ref ...

Page 48: ...ition switch ON Voltage across earth at 92 OK altitude 0m 1 2 1 8V altitude 600m 1 1 1 7V altitude 1200m 1 0 1 6V altitude 1800m 0 9 1 5V MUT II III service data No 95 MAP sensor Ref P13A 24 Replace the engine ECU Check connector C 50 Check connector C 50 Inspect the harness between the MAP sensor and the engine ECU repair if necessary Check for damage to the power supply wire Check connector C 50...

Page 49: ... temporary malfunctions Measurements taken at the B 115 connector of the exhaust cam position sensor Undo the connector and take measurements using the harness 1 Voltage across earth at 3 ignition switch ON OK battery voltage 2 Voltage across earth at 2 ignition switch ON OK 4 9 5 1V 3 Resistance across earth at 1 OK Less than 2Ω NG Repair Repair OK NG OK OK NG OK NG NG OK NG NG NG OK Inspect the ...

Page 50: ...ent of the output wave at the exhaust cam position sensor connector B 115 using an oscilloscope Use test harness MB991709 connect it to the connector and take measurements at the pick up harness component Engine idling Voltage across earth at 2 OK An output wave as described on P 13A 25 Main points for oscilloscope testing is produced with the maximum value in excess of 4 8V and the minimum value ...

Page 51: ...etween the intake cam position sensor and the engine ECU repair if necessary Check if the output wire is cut Temporary malfunction Ref Section 00 Dealing with temporary malfunctions Temporary malfunction Ref Section 00 Dealing with temporary malfunctions Measurements taken at the B 33 connector of the intake cam position sensor Undo the connector and take measurements using the harness 1 Voltage a...

Page 52: ...ess between the intake cam position sensor and the engine control relay Check if the power wire is damaged Measurement of the output wave at the intake cam position sensor connector B 33 using an oscilloscope Use test harness MB991709 connect it to the connector and take measurements at the pick up harness component Engine idling Voltage across earth at 2 OK An output wave as described on P 13A 25...

Page 53: ...ions Replace the oil feeder control valve A 134 Measurement of the oil feeder control valve Measure using a harness connected to the connector Ignition switch ON Voltage across earth at 1 OK battery voltage C 49 Measurement of engine ECU Undo the connector and measure on the harness side Ignition switch ON Voltage across earth at 32 OK battery voltage Inspect the harness between the engine ECU and...

Page 54: ...or Undo the connector and measure on the harness side 1 Voltage across earth at 1 ignition switch ON OK 4 9 5 1V 2 Resistance across earth at 5 OK Less than 2Ω Measurement at C 50 engine ECU connector Measure the voltage at the engine ECU terminals Ignition switch ON Voltage across earth at 42 OK 4 9 5 1V Refer to the 03 1 Service Manual for the Lancer Evolution VIII No 1036K07 Code No P2226 Atmos...

Page 55: ...cessary Check if the output wire is cut or damaged Temporary malfunction Refer to Section 00 Dealing with temporary malfunctions Check connectors C 49 C 50 Inspect the harness between AFS and engine ECU Check if the output wire has short circuited or is damaged Inspect the harness between AFS and engine ECU repair if necessary Check if the power supply wire is damaged MUT II III Service data No 25...

Page 56: ...sensor Ref P13A 24 Reference Proceed to OK if all service data levels are normal Proceed via NG even if only one of the service data levels is abnormal Refer to the 03 1 Service Manual for the Lancer Evolution VIII No 1036K07 NO OK OK OK OK OK YES NG NG NG NG Inspection procedure Fault to be checked Reference page 11 Engine seems hesitant 13A 16 Acceleration malfunction Engine seems to stumble Eng...

Page 57: ...etween the engine ECU and the ignition coil Check for cut or short circuited wires or other damage MUT II III Actuator test No 12 Waste gate solenoid valve Ref P13A 87 2 Check the supercharge pressure of the turbo charger Ref Section 15 Intake Exhaust car servicing Check the supercharge pressure control system Ref Section 15 Intake Exhaust car servicing MUT II III Actuator test No 09 Fuel pressure...

Page 58: ...NG NG Repair Miss timed ignition Probable causes of the malfunction Probable causes of the malfunction are noted in the right hand column Malfunction of the crank angle sensor Malfunction of the exhaust cam position sensor Malfunction of the timing belt Malfunction of the engine ECU Inspection procedure 15 Refer to the diagnosis code classification table P13A 6 MUT II III Diagnosis code Is the dia...

Page 59: ... earth wire is cut or damaged Inspect the harness between the inter cooler water spray switch and the engine ECU repair if necessary Check if the signal wire is damaged Inspect the harness between the engine ECU and the inter cooler water spray switch Check if the signal wire is cut or has short circuited OK NG NG OK NG NG OK OK OK OK NG OK OK NG NG Repair Inspection procedure 35 Inter cooler wate...

Page 60: ...oler water spray relay and the ignition switch Check if the power supply wire is damaged Check connectors C 22 C 50 Inspect the harness between the inter cooler water spray relay and the engine ECU Check if the signal wire is damaged Check connector A 34 Replace the engine ECU Check the inter cooler water spray motor Ref Section 15 Intake Exhaust Check connectors C 209 C 210 C 201 and C 208 Inspec...

Page 61: ...gate solenoid valve and the engine control relay Check if the power supply wire is damaged Replace the engine ECU Inspect the harness between the No 2 waste gate solenoid valve and the engine control relay and repair if necessary Check if the power supply wire is cut or has short circuited Check connector C 50 Inspect the harness between the No 2 waste gate solenoid valve and the engine ECU Check ...

Page 62: ...t or damaged Check connector C 50 Inspect the harness between the air temperature sensor and the engine ECU and repair it if necessary Check if the output wire is cut Check connector C 51 Temporary malfunction Ref Section 00 Dealing with temporary malfunctions Check connector C 51 Check that the problem has been solved Replace the engine ECU Inspect the harness between the air temperature sensor a...

Page 63: ...nding temperature 0ºC 3 2 3 8V surrounding temperature 20ºC 2 3 2 9V surrounding temperature 40ºC 1 5 2 1V surrounding temperature 60ºC 0 8 1 4V surrounding temperature 80ºC 0 4 1 0V Check that the problem has been solved Replace the engine ECU Inspect the harness between the air temperature sensor and the engine ECU and repair it if necessary Check if the earth wire is damaged Check connector C 5...

Page 64: ...13A 24 MPI TROUBLESHOOTING 13A 23 6 Service data table 7 Engine ECU checks 7 1 Terminal voltage table ...

Page 65: ...hod 1 Disconnect the exhaust cam position sensor connector and connect the special test harness MB991709 in its place 2 Disconnect the crank angle sensor connector and connect the special test harness MB998478 in its place 3 Connect the No 2 terminal of the exhaust cam position sensor connector and the No 2 terminal the black coloured clip on the special tool of the crank angle sensor connector to...

Page 66: ...pression top dead centre for each cylinder and by simultaneous observation of these and other controlling signals it is possible to distinguish between the cylinders The crank angle sensor detects the crank angle for each cylinder There is an output of 4 evenly spaced crank angle sensor HIGH signals for every 2 revolutions of the engine Therefore by measuring the cycle time seconds engine revoluti...

Page 67: ...ect the special test harness MB991709 in its place All terminals should be connected 2 Connect the oscilloscope probe to the No 2 terminal of the intake cam position sensor connector Note When measuring at the engine ECU connector connect the No 53 terminal intake cam position sensor to the oscilloscope probe 3 When checking the output signal of the intake cam position sensor observe the output si...

Page 68: ...m from the intake cam position sensor is long the cam is at the reset angle when the time difference is short the cam is at the most advanced angle Note When the cam is at the most advanced angle the rise and fall of the output waveform from the intake cam position sensor should be at an advancing angle of about 60 Waveform observation points As engine revolutions approach 2500r min check that the...

Page 69: ...revolutions when idling 800 50 r min Name Code Name Code Intake cam position sensor C Oil feeder control valve A Air temperature sensor B Manifold absolute pressure sensor B Exhaust cam position sensor C 2 Layout diagram for MPI system components air temp sensor side connector air temp sensor 3 Inspection of the air temperature sensor 1 Disconnect the air temperature sensor connector 2 Measure the...

Page 70: ...f the valve 1 Disconnect the oil feeder control valve connector 2 Apply battery voltage across the terminals of the connector on the oil feeder control valve side and check that the sound of the oil feeder control valve operating can be heard Caution There is a chance that the coil may be damaged so apply the voltage in as short a time as possible Resistance across the terminals 1 Remove the oil f...

Page 71: ...ine 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 ...

Page 72: ...th 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...

Page 73: ...t 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 ...

Page 74: ... 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 a...

Page 75: ...ir Control System 5 Centre cover Ignition coil 6 O2 sensor 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 g...

Page 76: ...ust 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 beari...

Page 77: ...LVE 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 ...

Page 78: ...he application of lubricant and seals View from A Semi dry sealant Three bond 1207D around the lip Engine oil Semi dry sealant Three bond 1207F Semi dry sealant Three bond 1207F Viewed looking down onto the cylinder head Semi dry sealant Three bond 1207D ...

Page 79: ...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 gui...

Page 80: ...d 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 bearin...

Page 81: ...s 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 Fitt...

Page 82: ...g 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 torq...

Page 83: ... 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 sea...

Page 84: ... 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 replacin...

Page 85: ...ctor 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 Bra...

Page 86: ... 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 eng...

Page 87: ...on 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...

Page 88: ...n 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 maki...

Page 89: ...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 ...

Page 90: ...lence 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 p...

Page 91: ... 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 specia...

Page 92: ... 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 ...

Page 93: ...per 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 ...

Page 94: ...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 betwe...

Page 95: ... 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 A and 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 slowl...

Page 96: ...m of the screwdriver can be inserted Do not remove the screwdriver until the timing belt has been fitted 3 Install the timing belt in accordance with the following guidelines so that the side that is under tension does not get slack 1 Fit the timing belt around the crankshaft sprocket first then the oil pump sprocket and then fit it around the idler pulley 2 Fit the timing belt around the camshaft...

Page 97: ...arily tighten the mounting bolt for the tensioner pulley 5 Check that all the timing marks are aligned 6 Remove the screwdriver and replace the plug 7 Adjust the tension of the timing belt G Adjusting the tension of the timing belt 1 Remove the rubber plug from the rear cover of the timing belt and put the special adjusting bolt MD998738 in position Slowly twist the adjusting bolt a little at a ti...

Page 98: ...er rod is not projecting more than the amount specified Specified projection A 3 8 4 5 mm 10 If the wire or pin cannot be easily pulled out repeat steps 1 to 8 until the tension of the timing belt is just right 11 Recheck that the timing marks on all of the sprockets are in line Caution If the crankshaft bolt is turned in an anti clockwise direction the tightening torque of the crankshaft bolt mus...

Page 99: ...sor connector 8 Purge control solenoid valve connector 9 Throttle position connector 10 Injector connector 11 Exhaust cam position sensor connector 12 Inlet cam position sensor connector 13 Water temperature gauge unit connector 14 Joint control harness and transmission harness 15 Water temperature sensor connector 16 Alternator connector and terminal 17 Secondary air control solenoid valve connec...

Page 100: ...uum hose connection 22 Purge hose connection 23 Power steering oil pressure switch connector 24 Heat protector 25 Power steering oil pump 26 A C compressor connector For cars fitted with A C 27 A C compressor For cars fitted with A C 28 Heater hose connection 29 Fuel return hose connection 30 Fuel high pressure hose connection 31 O ring Transfer ASSY transmission ASSY 32 Engine mount bracket stopp...

Page 101: ...the back of the belt with chalk arrows indicating the direction of movement B Removing the power steering oil pump and the A C compressor 1 Remove the power steering oil pump and the A C compressor from the bracket with the hoses intact 2 Secure the removed power steering oil pump and the removed A C compressor with string and put them somewhere where they will not hinder the removal or fitting of...

Page 102: ...the engine is not taken by the engine mount bracket 5 Loosen the nuts and bolts and remove the engine mount bracket and stopper ASSY E Removing the engine ASSY After checking that all of the cables hoses and harness connectors etc have been disconnected slowly hoist the engine using a chain block and remove the engine from the engine compartment Fitting guidelines A Fitting the engine ASSY Install...

Page 103: ...cial mechanical engine hanger MZ203830 or MZ203831 Install the special mechanical engine hanger MZ203830 or MZ203831 2 When using the special engine hanger MB991928 Fit the following parts to the base hanger Slide bracket HI Foot standard MB991932 Joint 90 MB991930 Install the special engine hanger MB991928 C Fitting the transfer ASSY and the transmission ASSY 1 Fit the transfer ASSY and the trans...

Page 104: ...ing it from left to right Ensure that the hose is twisted smoothly 3 If the hose cannot be twisted smoothly there is a possibility that it may be biting into the O ring so remove the fuel high pressure hose and check for any damage to the O ring If the O ring is undamaged reinsert it into the delivery pipe and check once more whether the hose can be turned smoothly 4 Tighten the mounting bolts for...

Page 105: ...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 ...

Page 106: ... Notes ...

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