Mitsubishi Lancer Evolution IX. Manual — part 83

TIMING BELT

ENGINE OVERHAUL

11B-23

1. Clean and then degrease the crankshaft sprocket,

sprocket fitting surface of the crankshaft, and
crankshaft sensing blade. Install the crankshaft
sprocket and crankshaft sensing blade on the
crankshaft.

2. Clean the bolt hole in the crankshaft, and then

washer.

3. Apply a necessary minimum amount of oil to the

threads and seating surface of the crankshaft bolt.

4. Hold the drive plate using the special tool

Flywheel stopper (MD998781).

5. Tighten the crankshaft bolt to a torque of 167 N

⋅m.

>>I<< OIL PUMP SPROCKET
INSTALLATION

1. Prevent the counterbalancer shaft from rotating in

the same method as in the removal procedure.

2. Install the oil pump sprocket.
3. Apply a thin coat of engine oil to the seating

surface of the nut.

4. Tighten the flange nut to 54

± 5 N⋅m.

>>J<< AUTO-TENSIONER INSTALLATION

1. If the auto-tensioner rod remains in its fully

extended position, reset it to the retracted position
as follows:
(1) Clamp the auto-tensioner in a vise at right

angles to the jaws.

(2) Push in the rod little by little with the vise until

the set hole A in the rod is aligned with the set
hole "B" in the cylinder.

(3) Insert a piece of wire (1.4 mm diameter) into

the set holes.

(4) Remove the auto-tensioner from the vise.

2. Install the auto-tensioner in position. Leave the

wire installed until the auto-tensioner is
completely installed.

>>K<< TENSIONER PULLEY
INSTALLATION

Install the tensioner pulley with its holes aligned as
shown in the drawing.

AK202738

MD998781

AC

AK300172

AK301074

A

B

AD

AK300154

AK300147

Tensioner
pulley hole

AE

TIMING BELT

ENGINE OVERHAUL

11B-24

>>L<< TIMING BELT INSTALLATION

1. Bring the timing mark on the exhaust camshaft

sprocket to a point one sprocket tooth away from
the timing mark on the rocker cover in the
anti-clockwise direction.
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned anti-clockwise
by one sprocket tooth and stay there by the force
of the valve springs.

2. Align the timing mark on the intake camshaft

sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.

3. Bring the timing mark on the crankshaft sprocket

to a point one sprocket tooth away from the
mating timing mark in the anti-clockwise direction
like in the operation with the exhaust camshaft
sprocket.

4. Align the timing mark on the oil pump sprocket

with that on the cylinder block.
(1) Remove the plug from the cylinder block.
(2) Insert a crosspoint screwdriver with a shank

diameter of 8 mm through the plug hole. If it
can be inserted 60 mm or more, the sprocket
is in the correct phase. If the insertion depth is
up to 20

− 25 mm, the screwdriver is blocked

by the counterbalancer shaft. Then turn the oil
pump sprocket one turn and realign the timing
marks. Then check that the screwdriver can
be inserted 60 mm or more. Keep the
screwdriver inserted until installation of timing
belt is finished.

(3) Turn the oil pump sprocket anti-clockwise by

one sprocket tooth.

5. Install the timing belt on the exhaust camshaft

sprocket, and hold it in place with a paper clip at
the point indicated in the drawing.

AK304440AB

Timing marks

AK501745

Timing marks

AB

AK304563AB

Timing marks

AK202752

Crosspoint
screwdriver

AD

Plug

AK202761

Timing marks

AD

AK202771

TIMING BELT

ENGINE OVERHAUL

11B-25

6. Turn the intake camshaft sprocket anti-clockwise

to bring the timing mark on it one sprocket tooth
away from the mating timing mark in the
anti-clockwise direction. Then install the timing
belt on the sprocket and hold it in place with a
paper clip.
NOTE: The timing marks will be aligned when the
belt is installed since the intake camshaft is turned
slightly clockwise by the force of the valve
springs.

7. Turn the exhaust camshaft sprocket clockwise to

align the timing marks, and make sure that the
intake camshaft sprocket timing marks are also
aligned.

8. Install the timing belt on the idler pulley, oil pump

sprocket, and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed
portion of the belt.

9. Install the timing belt on the tensioner pulley.

NOTE: Turning slightly the intake camshaft
sprocket anti-clockwise will facilitate installation of
the belt on the tensioner pulley.

10.Turn slightly the crankshaft sprocket clockwise to

take up the slack in the idler pulley portion of the
timing belt.

11.Check that each of the timing marks on the

crankshaft, oil pump, and exhaust camshaft
sprockets is one sprocket tooth away from its
mating timing mark in the anti-clockwise direction.

12.Turn the tensioner pulley anti-clockwise using the

special tool Tension pulley socket wrench
(MD998767) to give tension to the belt and hold
the tensioner in position by temporarily tightening
the tensioner lock bolt.
NOTE: Take up the slack in the belt portion
between the intake and exhaust camshaft sprock-
ets.

AK501746

AK501747

Timing marks

AB

AK202762AE

Crankshaft
sprocket

Oil pump
sprocket

AK501748AB

V.V.T.
sprocket

Tensioner
pulley

AK202763AB

Crankshaft
sprocket

AK202764

MD998767

AD

TIMING BELT

ENGINE OVERHAUL

11B-26

13.Turn the crankshaft clockwise to make the timing

mark align with the No.1 cylinder top dead centre
mark.

14.Install the special tool Set screw (MD998738) and

turn down the tool until the wire (inserted in the
auto-tensioner when it was installed) can be
moved freely.

15.Loosen the tensioner pulley lock bolt.

CAUTION

Prevent the timing belt from slipping as it
becomes loose following rotation of the intake
and exhaust camshafts.
16.Turn the torque wrench attached to the special

tool Tension pulley socket wrench (MD998767)
anti-clockwise until the slack in the timing belt is
taken up.

17.Turn the torque wrench clockwise from the

position of step 16 until the torque wrench reading
becomes 3.5 N

⋅m, then tighten the tensioner

pulley lock bolt.

18.Remove the special tool Set screw (MD998738)

that was installed in step 14.

19.Turn the crankshaft clockwise two turns, then let it

alone for approx. 15 minutes.

20.Check that the wire (inserted in the auto-tensioner

when it was installed) can be moved freely. If the
wire can be pulled freely, the belt tensioner is
adjusted properly. Remove the wire. At that time,
check that the auto-tensioner rod extends by the
specified amount.

Standard value: 3.8

− 4.5 mm

CAUTION

Be sure to check the tightening torque of the
crankshaft bolt anytime the crankshaft has been
turned anti-clockwise. If the torque lower than
specification, tighten the bolt to the specified
torque.
21.If the wire cannot be pulled out freely, perform the

steps 14 through 18 again to make the belt
tension proper.

>>M<< PLUG CAP INSTALLATION

CAUTION

Do not reuse the washer.
1. Install the washer to the plug cap.
2. Holding the hexagonal portion of the camshaft

with a wrench, tighten the plug cap to the
specified torque of 32

± 2 N⋅m.

AK202774

MD998738

AD

AK202775

MD998767

AD

AK202829

Extension
amount

AB

AK403836