WORKSHOP MANUAL

EVOLUTION-IV EVOLUTION-V

Pub. No. S9806CNCP9

General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . .

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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. TECHNICAL INFORMATION MANUAL N9806CNCP9

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............

Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . Service Brakes . . . . . . . . . . . . . . . . .

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

Parking Brakes . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . . Electrical Wiring . . . . . . . . . . . . . . . .

00-1

GENERAL
CONTENTS
MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

00-2 MODELS
<LANCER EVOLUTION-IV>
Model code E-CN9A Class code SNDF SRGF Model year 97 97 Grade RS GSR

GENERAL Models

Engine model 4G63 (2,000-DOHC 16 valves-intercooler turbo)

Transmission model W5M51 (4WD-5M/T)

Fuel supply system Electronically controlled fuel injection (MPI)

<LANCER EVOLUTION-V>
Model code GF-CP9A Class code SNDF SNGF Model year 98 98 Grade EVOLUTION-V RS EVOLUTION-V GSR Engine model 4G63 (2,000-DOHC valves intercooler 16 valves-intercooler turbo) Transmission model W5M51 (4WD 5M/T) (4WD-5M/T) Fuel supply system MPI

Applicable serial numbers E-CN9A: CN9A 0000001 Y GF-CP9A: CP9A 0000001 Y

11-1

ENGINE
CONTENTS
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 2 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 2 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 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

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 Basic ignition timing Ignition timing (at idle) Idle speed rpm CO contents % HC contents ppm Compression pressure kg/cm2 rpm Compression pressure difference of all cylinders kg/cm2 Intake manifold vacuum kPa {mmHg} Cylinder head bolt shank length mm Standard value 5_ BTDC 3_ Approx. 5_ BTDC 850 50 0.6 or less 300 or less 11.5 250 Limit Min. 9.7 250 Max. 1.0 Min. 55 {410} 99.4

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

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

SPECIAL TOOLS
Tool Number MD998782 Name Valve lifter set Use Replacing the lash adjuster

MB990767

End yoke holder

D D

Holding the crankshaft pulley Holding the camshaft sprocket

ENGINE Special Tools

Tool Number MD998719 Name Crankshaft pulley holder pin Use D D Holding the crankshaft pulley Holding the camshaft sprocket

11-3

MD998715

Pulley holder pin

MD998713

Camshaft oil seal installer

Pressfitting the camshaft oil seal

MD998727

Oil pan remover

Removing the oil pan

MD998781

Flywheel stopper

Securing the flywheel or drive plate

MD998776

Crankshaft rear oil seal installer

Pressfitting the crankshaft rear oil seal

MB990938

Handle

MD998382

Crankshaft front oil seal installer

Installing the crankshaft front oil seal

MD998285

Crankshaft front oil seal guide

11-4
Tool

ENGINE Special Tools / Engine Adjustments

Number MB991654 Name Cylinder head bolt wrench Use Removing and reinstalling the cylinder head bolt

MD998767

Tensioner pulley socket wrench

Timing belt tension adjustment

Recommended tool MZ203826 by Anzen Jidosha or MZ203827 by Banzai MD991453

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

Engine assembly

hanger

ENGINE ADJUSTMENTS
Auto tensioner

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.)

Indicator mark

ENGINE Engine Adjustments 2. AUTO TENSIONER CHECK

11-5

Tool mounting hole

(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

Good

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.
MAX MIN

(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). 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.

High-pressure chamber

11-6
Timing belt side A A B B

ENGINE Engine Adjustments

(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.

(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.
MD998782

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.

MD998782

ENGINE Engine Adjustments 4. LASH ADJUSTER REPLACEMENT

Refer to (4) of the preceding paragraph.

11-7

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.

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.
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/cm2 Limit (at engine speed of 250 r/min): 9.7 kg/cm2 (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/cm2 (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.

8. MANIFOLD VACUUM CHECK

Vacuum gauge

Fuel pressure regulator valve

(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

11-9

CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation D Under Cover Removal Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11-4.) D Under Cover Installation

25 {2.5}

1 2
Unit: Nm {kgf@m} AA" Removal steps 1. Drive belt 2. Crankshaft pulley

REMOVAL SERVICE POINT

Auto tensioner

Hole in arm

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.

Hole in bracket

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) 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 4 5 3
3.4 {0.35}

6 2
10 {1.0}

14 15
20 {2.0}

7
22 {2.2}

17 16 13 12 8

12 15 {1.2 1.5}

9 10
88 {9.0}

11
Unit: Nm {kgf@m} 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

AA" "DA "CA "BA "BA "BA "AA "AA

9. 10. 11. 12. 13. 14. 15. 16. 17.

Cam position sensor support Semi-circular packing Camshaft sprocket Camshaft oil seal Front cam cap Rear cam cap Cam cap Camshaft (exhaust side) Camshaft (intake side)

ENGINE Camshaft and Camshaft Oil Seal

Grease and adhesive application points

11-11

26
10 mm 10 mm 10 mm Timing belt side

Semi-drying sealant: THREEBOND 1207D

Lip

Engine oil

3 mm

Semi-drying sealant: THREEBOND 1207F

Timing belt side

Semi-drying sealant: THREEBOND 1207D

REMOVAL SERVICE POINT

MB990767

AA" CAMSHAFT SPROCKET REMOVAL

MD998719

INSTALLATION SERVICE POINTS

Camshaft sprocket side Slit

"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.

Camshaft (exhaust side)

11-12

ENGINE Camshaft and Camshaft Oil Seal

"BA CAM CAP / REAR CAP / FRONT CAM CAP INSTALLATION (1) Locate the camshaft dowel pins as illustrated.

Approx. 12_

Dowel pin

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.

MD998713

"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}

Dowel pin 90_

"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.

ID paint

ENGINE Oil Pan

11-13

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

Identification of bolt location

8 A

4 mm
Groove

Bolt hole

B
A: 6 8 mm B: 6 10 mm

B B

Semi-drying sealant: THREEBOND 1207D

9 {0.9}

2 1
30 {3.1}

3 5

8 4 7 6
39 {4.0} 7 {0.7} 26 {2.6} Washer assembled bolt 9 {0.9} Flange bolt 10 {1.0}

39 44 {4.0 4.5}

Unit: Nm {kgf@m}

Removal steps 1. Starter 2. Oil return pipe "BA 3. Oil return pipe gasket 4. Engine oil cooler return pipe

5. 6. "AA 7. AA" 8.

Bell housing cover Drain plug Drain plug gasket Oil pan

11-14
MD998727 MD998727

ENGINE Oil Pan REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL

INSTALLATION SERVICE POINTS

Drain plug gasket Oil pan side

"AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration.

Printed portion

"BA OIL RETURN PIPE GASKET INSTALLATION Install the gasket with the printed portion toward the oil pan.

Gasket

ENGINE Crankshaft Oil Seal

11-15

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION
4
127 137 {13.0 14.0}

3 2 1

Engine oil Unit: Nm {kgf@m} 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 Crankshaft rear oil seal removal steps D Transmission assembly D Clutch cover and disc AA" "BA 4. Flywheel "AA 5. Crankshaft rear oil seal

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 Crankshaft MB990938

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.

MB998776

"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}

Crankshaft

Oil seal

"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

11-17

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION
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.) 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} Delivery pipe

3 {0.3}

4 19 18
O-ring

15 3 16

14

Engine oil

5 {0.5}

18 10 17 6 8 5 9 8 11 8 7 12 13 3

9 {0.9}

12 15 {1.2 1.5}

20

Unit: Nm {kgf@m} 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

11. 12. 13. 14. 15. 16. 17. "DA 18. 19. 20.

Water hose connection Oxygen sensor connector Injector connector Cam position sensor connector Coolant temperature sensor connector Water temperature gauge unit connector Control harness Fuel pipe pressure hose connection Fuel return hose connection Oil level gauge guide assembly