Workshop Manual - Supplement LANCER Evolution - IX • Chassis • Engine • Wiring Diagrams • Technical Information
SERVICE MANUAL Supplement
LANCER EVOLUTION IX FOREWORD This manual contains details of the main changes to the 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. Please read this manual carefully so that servicing can be done correctly and quickly, and vehicle performance maintained. This manual is based on the current (March 2005) model.
Related materials Title No. Issue date New model manuals Title No.
GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP, RELEVANT VEHICLE NUMBERS 00-1 SECTION 00 GENERAL CONTENTS Inspection guidelines and troubleshooting..........................................1 Relevant vehicle numbers ........................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.
ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS 11-1 SECTION 11 ENGINE CONTENTS General .......................................................1 Servicing standards .................................1 Sealants .....................................................1 Special tools ..............................................2 Engine tuning .............................................4 Camshaft, valve stem seals .....................4 Cylinder head gaskets.............................
11-2 ENGINE – SPECIAL TOOLS Special tools Tool Number Name Function MB991502 MUT-II Sub ASSY Checking and adjusting the tension in timing belt B MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826 DO NOT USE 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 MUT-III Sub ASSY activated.
ENGINE – SPECIAL TOOLS Tool 11-3 Number Name Function MD998737 Valve stem seal installer Valve stem seal installation MD998713 Camshaft oil seal installer Camshaft oil seal installation MB991654 Cylinder head bolt 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
11-4 ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL Tool Slide bracket (HI) Number Name Function MB991454 Engine hanger balancer Holding the engine assembly while the transmission assembly is removed/installed Recommended tools MZ203830 panzai or MZ203831 safe vehicle handling Mechanical engine hanger MB991928 A: MB991929 B: MB991930 C: MB991931 D: MB991932 E: MB991933 F: MB991934 Engine hanger A: joint (50) x2 B: joint (90) x2 C: joint (140) x2 D: Foot (standard) x4 E: Foot (
ENGINE – CAMSHAFT, VALVE STEM SEAL Removal procedure 1. Oil feeder control valve connector O 2. Oil feeder control valve O 3. O-ring 4. Breather hose • Secondary air control valve (refer to Section 15-2: Secondary Air Control System) 5. Centre cover • Ignition coil 6. O2 sensor connector 7. Crank angle sensor connector 11-5 8. Connection of the control harness 9. Vacuum hose 10. PCV hose A N 11. Connection of the radiator upper hose 12.
-6 ENGINE – CAMSHAFT, VALVE STEM SEAL During assembly, apply engine oil to all sliding parts. L J K J B I G F F 18. Camshaft position sensor support cover 19. Camshaft position sensor support cover gasket 20. Camshaft position sensing cylinder (exhaust side) 21. Camshaft position sensor support 22. Camshaft position sensor support cover 23. Camshaft position sensor support cover gasket 24. Camshaft position sensing cylinder (inlet side) 25.
ENGINE – CAMSHAFT, VALVE STEM SEAL 46. Rocker arm D 47. Rush adjuster 48. Oil delivery body 49. Spark plug C C 50. Valve spring retainer lock 51. Valve spring retainer B 52. Valve spring A 53. Inlet valve stem seal A 54.
11A-8 ENGINE – CAMSHAFT, VALVE STEM SEAL Locations for the application of lubricant and seals Semi-dry sealant: Three bond 1207F Semi-dry sealant: Three bond 1207D (around the lip): Engine oil Semi-dry sealant: Three bond 1207F Semi-dry sealant: Three bond 1207D
ENGINE – CAMSHAFT, VALVE STEM SEAL 11-9 Removal guidelines A 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 B Removing the camshaft sprockets Grip the hexagonal part of the camshaft with a wrench, loosen the mounting bolt, and remove the camshaft sprocket.
11-10 ENGINE – CAMSHAFT, VALVE STEM SEAL B Fitting the valve spring Fit the valve spring so that the end of the valve spring which has the smaller radius is on the rocker arm side. Rocker arm side C 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 retainer lock.
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. bearing cap No. Front of engine mark indicating inlet side or exhaust side Identification marks (stamped on the front bearing cap, and on bearing cap Nos. 2~5). I: inlet side E: exhaust side 3.
11-12 ENGINE – CAMSHAFT, VALVE STEM SEAL Front of engine (engine oil) camshaft sprocket Front of engine (engine oil) H 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 camshaft. 2. Match up the camshaft dowel pins with the dowel pin holes in the camshaft sprocket, and fit the camshaft into the camshaft sprocket. 3.
ENGINE – CAMSHAFT, VALVE STEM SEAL dowel pin 11-13 K Fitting the camshaft position sensing cylinder (inlet side) 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. Tightening torque: 22 ± 4 N•m pane approx. 45º dowel pin pane (small) pane (large) L Fitting the camshaft position sensing cylinder (exhaust side) 1.
11-14 ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET Tape O 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 (seal tape etc) around the oil channel of the oil feeder control valve, in order to prevent damage to the O-ring. If the O-ring touches the oil it could start an oil leak. 1. Apply engine oil to the O-ring on the oil feeder control valve. 2. Fit the oil feeder control valve to the cylinder head.
ENGINE – CYLINDER HEAD GASKET 11-15 (engine oil) Removal procedure 1. Ignition coil connector 2. O2 sensor connector 3. Oil feeder control valve connector 4. Crank angle sensor connector 5. Manifold absolute pressure sensor connector 6. Fuel pressure solenoid valve connector 7. Knock sensor connector 8. Purge control solenoid valve connector 9. Throttle position sensor connector 10. Injector connector 11. Exhaust camshaft position sensor connector 12. Inlet camshaft position sensor connector 13.
11-16 ENGINE – CYLINDER HEAD GASKET (engine oil) (when cool) (engine oil) 22. 23. E 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Alternator bracket connection Inlet manifold stay Eye bolt Gasket Eye bolt Gasket Oil feeder control valve pipe Filter Oil pipe joint Gasket Oil return pipe gasket Oil return pipe Oil return pipe gasket D 35. Oil return pipe gasket C C A B A 36.
ENGINE – CYLINDER HEAD GASKET 11-17 Removal guidelines A 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 A Fitting the cylinder head gasket 1. Remove the gaskets which have been stuck onto the surface of the gasket.
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. (3) In the order shown in the diagram, tighten the bolts to 20 ± 2 N•m.
ENGINE – CYLINDER HEAD GASKET 11-19 D 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. Protrusion 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.
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. Jobs to be completed before removal and after fitting • Removal and refitting of the valence.
ENGINE – TIMING BELT, TIMING BELT B 11-21 (engine oil) B 10. 11. 12. 13. 14. 15. Power steering oil pressure switch connector Heat protector Power steering oil pump ASSY Power steering oil pump bracket Idler pulley Crank angle sensor C C 16. Crankshaft sprocket C 17. Crankshaft sensing blade B • Adjust the tension of the timing belt B A 18. Timing belt B tensioner D A 19. Timing belt B Removal guidelines A Removing the timing belt 1.
11-22 ENGINE – TIMING BELT, TIMING BELT B timing belt tensioner arm 3. Twist the special tool for adjusting bolts (MD998738) by hand 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 (MD998738) may become bent. 4.
ENGINE – TIMING BELT, TIMING BELT B 11-23 D 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 side of belt under tension timing marks balancer shaft sprocket A Fitting timing belt B and the timing belt B tensioner 1.
11-24 ENGINE – TIMING BELT, TIMING BELT B approx. 100 N amount of give 2. (1) As shown in the diagram, apply a force of about 100N to the middle of the belt between the sprockets (indicated by the arrow), and check that the amount of give is as specified. Specified values: 5~7mm 5~7mm (2) If the specified values are not met, readjust the tension of the belt. 3.
ENGINE – TIMING BELT, TIMING BELT B Front of engine crankshaft crankshaft sprocket clean here washer 11-25 C Fitting the crankshaft sensing blade and the crankshaft sprocket 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. 2. Fit the crankshaft sensing blade and the crankshaft sprocket in the direction shown in the diagram. 3. Clean the screw hole in the crankshaft. 4.
11-26 ENGINE – TIMING BELT, TIMING BELT B F Fitting the timing belt 1. Check that all the timing marks for the camshaft sprocket, the crankshaft sprocket and the oil pump sprocket are aligned. timing marks camshaft sprocket (exhaust side) camshaft sprocket (inlet side) timing marks timing marks oil pump sprocket crankshaft sprocket more than 60 mm plug screwdriver 2.
ENGINE – TIMING BELT, TIMING BELT B paper clips 11-27 (3) Use a wrench to align the timing marks on the rocker cover and 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. (4) Fit the timing belt around the tensioner pulley. (5) Remove the two paper clips.
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. Tightening torque: 48 ± 5 N·m Caution When tightening the installed bolt, take care that the tensioner pulley does not turn around with it.
ENGINE – ENGINE ASSY Removal procedure 1. Ignition coil connector 2. O2 sensor connector 3. Oil feeder control valve connector 4. Crank angle sensor connector 5. Manifold absolute pressure sensor connector 6. Fuel pressure solenoid valve connector 7. Knock sensor connector 8. Purge control solenoid valve connector 9. Throttle position connector 10. Injector connector A 11-29 11. Exhaust cam position sensor connector 12. Inlet cam position sensor connector 13.
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) B B 20. Vacuum tank, solenoid valve, vacuum pipe and hose ASSY 21. Brake booster vacuum 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 27.
ENGINE – ENGINE ASSY 11-31 Removal guidelines A 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. 2. Align hole A and hole B, insert an L-shaped hexagonal Allen Key, to hold the position, and remove the drive belt.
11-32 ENGINE – ENGINE ASSY MZ203830 or MZ203831 D Removing the engine mount bracket & stopper ASSY 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. Support the engine oil pan component with the garage jack through the engine block, so that the weight of the engine is not taken by the engine mount bracket. 5.
ENGINE – ENGINE ASSY engine side engine side engine mount stopper MZ203830 or MZ203831 slide bracket (HI) front of chassis 11-33 B Fitting the engine mount bracket & stopper ASSY 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.
11-34 ENGINE – ENGINE ASSY D 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. Ensure that the hose is twisted smoothly. 3.
MPI – GENERAL 13A-1 SECTION 13A MPI (Multi-point Fuel Injection) CONTENTS General..................................................................... 2 Servicing standards .................................................3 Special tools ............................................................3 Troubleshooting ......................................................5 Servicing the vehicle ............................................29 1. Adjusting specified revolutions when idling.....29 2.
13A-2 MPI – GENERAL MPI system diagram H 1. O2 sensor H 2. Air flow sensor H 3. Intake air temp. sensor H 4. Throttle position sensor H 5. Intake Cam position sensor H 6. Exhaust Cam position sensor H 7. Crank angle sensor H 8. Atmospheric pressure sensor H 9. Water temp. sensor H 10. Knock sensor H 11. Manifold absolute pressure (MAP) sensor H 12. Air temp.
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 0.23~0.42 Oil feeder control valve resistance (at 20 ºC) Ω 6.9~7.
13A-4 MPI- SPECIAL TOOLS Tool Red coloured harness (for DLI) White coloured harness (for LC) 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 (3P, triangular) • Troubleshooting voltage measurement • Inspection using an oscilloscope MB991223 Inspection harness set connector • Pin contact pres
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.
13A-6 MPI- TROUBLESHOOTING 2. Diagnosis code classification table Code No.
13A-7 MPI – TROUBLESHOOTING 3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE Code No. P0105 MAP sensor system Conditions for the inspection • Ignition switch: ON • Wait for 2 seconds after the ignition switch has been turned on or the engine has started. Evaluation conditions • Sensor output voltage is 4.6V or more for 4 seconds (when atmospheric pressure is more than 313 kPa) • Sensor output voltage is 0.
MPI – TROUBLESHOOTING 13A-8 Continued from the previous page OK NG NG Check connector C-50 Measurements taken at the B-135 MAP sensor connector • Connect the test harness (MB991348) to the connector and measure at the pick-up harness component. • Ignition switch: ON • Voltage across earth at 2 OK: 4.9~5.1V Repair OK Inspect the harness between the MAP sensor and the engine ECU, repair if necessary. • Check for damage to the power supply wire.
13A-9 MPI – TROUBLESHOOTING Code No.
MPI – TROUBLESHOOTING 13A-10 Continued from the previous page OK NG NG Measurement 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 pickup 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 less than 0.
13A-11 MPI – TROUBLESHOOTING Code No.
MPI – TROUBLESHOOTING 13A-12 Continued from the previous page OK NG 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 pickup 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 less than 0.6V.
13A-13 MPI – TROUBLESHOOTING Code No.
MPI – TROUBLESHOOTING 13A-14 Code No.P2226 Atmospheric pressure sensor system Probable cause of the malfunction Conditions for inspection • Ignition switch: ON • Wait for 2 seconds after the ignition switch has been turned on or the engine has started. Evaluation conditions • Output voltage from the sensor is more than 4.5V (when atmospheric pressure is in excess of 114kPa) for 4 seconds. Or, • Output voltage from the sensor is more than 0.2V (when atmospheric pressure is less than 5kPa) for 4 seconds.
13A-15 MPI – TROUBLESHOOTING Continued from previous page OK (1) NG Measurements taken at B-08 AFS connector • Only connect the test harness (MB991709) to terminals No.1, No.2 and No.5 of the connector and measure at the pick up harness component. • Ignition switch: ON (1) Voltage across earth at 1 (2) NG OK: 4.9~5.1V (2) Voltage across earth at 2 OK: altitude 0m 3.8~4.2V altitude 600m 3.5~3.9V altitude 1200m 3.3~3.7V altitude 1800m 3.0~3.
MPI – TROUBLESHOOTING 13A-16 4. Checklist of faults Inspection procedure Fault to be checked Engine seems hesitant Acceleration malfunction 11 Engine seems to stumble Engine has a power surge 15 Mis-timed ignition 35 Inter-cooler water spray circuit system 37 No.2 waste gate solenoid valve system 38 Air temperature sensor system Reference page 13A-16 13A-18 13A-19 13A-21 13A-22 5.
MPI – TROUBLESHOOTING 13A-17 Continued from previous page OK Check the spark plug wire (Ref: Section 16: Ignition apparatus) Replace the spark plug wire OK Check the spark plug (Ref: Section 16: Ignition apparatus) NG Replace the spark plug OK NG Check connectors B-123 & B-119 Repair OK NG Check the ignition coil (Ref: Section 16: Ignition Apparatus) Replace the ignition coil OK NG Inspect the harness and the connectors between each cylinder’s ignition coil and the body earth, and between the eng
MPI – TROUBLESHOOTING 13A-18 Inspection procedure 15 Miss-timed ignition Probable causes of the malfunction Probable causes of the malfunction are noted in the right hand column.
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 water spray manual ‘ON’ signal will be input in the engine ECU. When this signal is received, the engine ECU will turn the inter-cooler water spray relay ON, and will start the inter-cooler water spray motor.
MPI – TROUBLESHOOTING 13A-20 Continued from the previous page OK NG Measure at the inter-cooler water spray relay connector C-220 • Undo the connector, and measure on the harness side • Voltage across earth 3 and 1 (ignition switch: ON) OK: battery voltage OK OK NG NG Check connectors C-22 and C-208 OK Inspect the harness between the inter-cooler water spray relay and the engine ECU • Check if the signal wire is cut or has short circuited NG Repair NG Repair NG Repair Inspect the harness between t
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 introduced to the waste gate actuator in the turbocharger. • • • Malfunction of the No.2 waste gate solenoid valve. Circuit break, short circuit or a faulty connection in the No.2 waste gate solenoid valve circuit. Malfunction of the engine ECU. OK Repair Check connector: B-32 NG NG Replace the No 2.
MPI – TROUBLESHOOTING 13A-22 Inspection procedure 38 Air temperature sensor system Probable causes of the malfunction The air temperature sensor controls the temperature inside the inlet manifold, and compensates for any burning of fuel. • • • Malfunction of the air temperature sensor. Circuit break, short circuit or a faulty connection in the air temperature sensor circuit. Malfunction of the engine ECU.
13A-23 MPI – TROUBLESHOOTING Continued from the previous page OK NG NG Check connector: C-51 Measure at the air temperature sensor connector B-34 • Connect the test harness (MB991658), to the connector and measure at the pick-up harness component. • Ignition switch: ON • Voltage across earth at 1 OK: surrounding temperature -20ºC 3.8~4.4V surrounding 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.
13A-24 6. Service data table 7.
13A-24 MPI – TROUBLESHOOTING 13A-25 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. exhaust cam position sensor connector crank angle sensor connector oscilloscope 8.
MPI – TROUBLESHOOTING 13A-26 Observation conditions Exhaust cam position sensor Crank angle sensor Probe switch X1 x1 AC-GND-DC DC DC TIME/DIV. 10ms 10 ms VOLTS/DIV.
MPI – TROUBLESHOOTING 13A-27 • 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. There is an abnormality in the sensor disc.
13A-28 MPI – TROUBLESHOOTING Standard waveform 2 engine revolutions (1 camshaft revolution) (cam reset angle) (cam most advanced angle) crank angle sensor output waveform (phaseangle) exhaust cam position sensor output waveform • 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.
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. Adjusting standard engine revolutions when idling The standard engine revolutions when idling have been changed. All other servicing requirements are the same as before. Standard engine revolutions when idling: 800 ± 50 r/min 2.
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. (6) Tighten the air temperature sensor to the specified torque. Tightening torque: 14 ± N·m air temp. sensor 4.
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. Other servicing guidelines remain unchanged.
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. Alternator bracket 2. Water pump 3. Water pump gasket A 4.
ENGINE COOLING – WATER HOSE AND PIPE 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 • Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C • Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system) Removal procedure A B
14-4 ENGINE COOLING – WATER HOSE AND PIPE Removal guidelines A 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.
INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS, ON-VEHICLE SERVICING 15-1 SECTION 15 INTAKE & EXHAUST CONTENTS General................................................................................1 Servicing standards ..........................................................1 Special tools.......................................................................1 On-vehicle servicing..........................................................1 Turbocharger super charging pressure check ....
15-2 INTAKE & EXHAUST INTER-COOLER WATER SPRAY Inter-cooler water spray Removal and fitting Procedure for removing the water spray nozzle and the hose 1. Water spray hose connection • Front bumper ASSY (Ref: Section 51) A • Tape (for fitting the water spray hose ASSY) 2. Water spray nozzle ASSY A 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.
INTAKE & EXHAUST INTER-COOLER WATER SPRAY 15-3 Fitting guidelines A 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. tape washer valve clip three-way joint pads three-way joint washer valve tape clip clip tape 2.
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 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 A 9. Gasket 10. Secondary air control valve 11.
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD 15-5 Fitting guidelines A Fitting the gasket Fit the gasket so that the protruding part points in the direction shown in the diagram.
15-6 INTAKE & EXHAUST – INLET MANIFOLD Removal procedure 1. Centre cover 2. Ignition coil connector 3. O2 sensor connector 4. 5. 6. 7. 8. Oil feeder control valve connector Crank angle sensor connector Injector connector Air temperature sensor connector Manifold absolute pressure sensor connector 9. Purge control solenoid valve connector 10. Knock sensor connector 11. Fuel pressure solenoid valve connector A 12. Vacuum hose connection 13. Vacuum hose connection 14.
INTAKE & EXHAUST – INLET MANIFOLD Removal procedure 24. Knock sensor connector 25. Purge control solenoid valve ASSY 26. Vacuum hose 27. Fuel pressure solenoid valve ASSY 28. PCV hose • Alternator (Ref Section 16: Alternator) 29. Secondary air control solenoid valve connector 30. Vacuum tank, ACV solenoid valve, vacuum hose & pipe ASSY 15-7 31. Inlet manifold stay 32. Cover 33. Gasket 34. Harness connection 35. Crank angle sensor connector 36. Alternator bracket 37. Inlet manifold 38.
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 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
INTAKE & EXHAUST – EXHAUST MANIFOLD A Removal procedure 1. Exhaust manifold heat protector 2. Air pipe ASSY connection 3. O2 sensor 4. Turbocharger heat protector 5. Turbocharger water feed pipe connection 6. Gasket 7. Water hose connection B 8. Oil feed pipe 9. Gasket 10. Starter 11. Oil return pipe D 12. Oil return pipe gasket (turbocharger side) C 13. Oil return pipe gasket (oil pan side) 15-9 14. Vacuum hose connection 15. Air outlet fitting B 16.
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. turbocharger protruding part B Fitting the air outlet fitting gasket Fit the gasket so that the protruding part is in the position located in the diagram. view “A” view “A” print C Fitting the oil return pipe gasket (oil pan side) Fit so that the printed side of the gasket is on the oil pan side.
ENGINE ELECTRICAL – CHARGING SYSTEM 16-1 SECTION 16 ENGINE ELECTRICAL CONTENTS Charging system........................................1 General .................................................................1 Alternator...............................................................1 Ignition system...........................................4 Servicing standards...................................4 On-vehicle servicing..................................4 Checking, cleaning and replacing spark plugs ....
16-2 ENGINE ELECTRICAL – CHARGING SYSTEM (engine oil) A Removal procedure 1. Injector connector 2. Accelerator cable connection 3. Delivery pipe, injector, and fuel pressure regulator ASSY 4. Insulator 5. Insulator 6. Fuel pressure solenoid valve connector 7. Fuel pressure solenoid valve ASSY 8. Knock sensor connector 9. Purge control solenoid valve connector B C 10. Purge control solenoid valve ASSY 11. Oil level gauge and guide ASSY 12. O-ring 13. Drive belt 14.
ENGINE ELECTRICAL – CHARGING SYSTEM 16-3 Removal guidelines A 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. B Removing the drive belt The following procedures are necessary because a serpentine drive system with auto-tensioner has been installed. 1. Insert a 12.
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 Spark plug cap mm Standard Value 0.5~0.6 Upper Limit 0.
REAR AXLE – GENERAL, DIFFERENTIAL CARRIER 27B-1 SECTION 27B REAR AXLE CONTENTS General........................................................1 Differential carrier ..............................................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. Other servicing guidelines remain unchanged.
TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING 31-1 SECTION 31 WHEELS AND TYRES CONTENTS General........................................................1 Removal of emergency puncture repairing agent....1 On-vehicle servicing..................................1 Disposal of emergency puncture repairing agent ....2 General The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.
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 through the hole made by removing the valve, so that the tip of the hose is submerged in the repairing agent. extraction hose repairing agent raised surface extraction hose injection hose bottle 5. Hold the bottle so that it is, as far as possible, below the tyre, and suck the repairing agent out of the tyre by squeezing the bottle by hand.
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.
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 selflocking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose. Assembly guidelines A Fitting the self-locking nut 1. Check that the bearing has completely slotted in. 2.
BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP 42-1 SECTION 42 BODY CONTENTS General........................................................1 Window glass channel, door-opening weather strip ...........................1 General Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain unchanged.
EXTERIOR – GENERAL 51-1 SECTION 51 EXTERIOR CONTENTS General........................................................1 Front bumper..............................................2 Rear bumper...............................................4 Front bumper.......................................................2 Markings .....................................................6 Rear bumper ........................................................
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 cap Removal procedure 1. Side 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.
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 2. Front bumper nut 3. Front number plate garnish 4. Front bumper cover A 5. Front bumper cover B 6. Air dam skirt panel 7. Front bumper centre net 8. Front bumper 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.
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 through A-A clip splash shield Removal procedure 1. Screw for attaching the splash shield 2. Rear bumper bracket 3. Rear bumper ASSY 4.
EXTERIOR – REAR BUMPER Dismantling and assembly Dismantling procedure 1. Number plate lamp bracket • Number plate lamp ASSY 2. Rear bumper reinforcement A A 3. Rear bumper side plate A A 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.
51-6 EXTERIOR – MARKINGS Markings Removal and affixing A 2. LANCER badge A 3. EVOLUTION badge 1. Front 3-diamonds badge (Ref P.51- 3) Guidelines for affixing markings A 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. (2) Remove the protective paper from the back of the badges, and affix them in the designated places.
CHASSIS ELECTRICAL – LICENCE PLATE LAMP 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 SECTION 54A CHASSIS ELECTRICAL CONTENTS Number plate lamp ....................................
CHASSIS ELECTRICAL – LICENCE PLATE LAMP 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 SECTION 54A CHASSIS ELECTRICAL CONTENTS Number plate lamp ....................................
Service Manual Supplement Lancer Evolution IX
Service Manual CONTENTS General Information . . . . . . . . . . . . . . . 4 Servicing Specification Values . . . . . . 4 4G6 DOHC ENGINE Tightening torques . . . . . . . . . . . . . . . . 5 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator / Ignition system. . . . . . . . . 8 FOREWORD This manual contains information about the 4G6 DOHC engine. It only covers those points that are different from the service manuals listed below.
2 HOW TO USE THIS MANUAL How to Use this Manual Range of description This manual explains the service procedure for the engine after it has been removed from the vehicle. For information on removing the engine from the vehicle, or "on-vehicle" servicing of the engine, please refer to the separate service manual for the relevant vehicle model.
HOW TO USE THIS MANUAL Page number Engine type Title 3
4 4G6 – GENERAL INFORMATION/ SERVICING SPECIFICATIONS General Information The 4G63 MIVEC T/C engine fitted in the Lancer Evolution IX incorporates the following changes with respect to the previous 4G63 T/C engine. • Adoption of variable valve timing control system • Modification to clearance gap in piston No.
4G6 – TIGHTENING TORQUES Tightening Torques Part Alternator, ignition system Oil level gauge guide bolt Water pump pulley bolt Auto tension bolt (washer) Auto tension bolt (flange) Alternator bracket bolt (flange) Alternator bracket bolt (washer M8 x 22) Alternator bracket bolt (washer M8 x 32) Alternator nut Crankshaft pulley bolt Centre cover holt Ignition coil bolt Spark plug Timing belt Timing belt cover bolt (flange) Timing belt cover bolt (washer) Power steering pump bracket bolt Connector bracket bol
6 4G6 – TIGHTENING TORQUE Part Air pipe assembly bolt (eye bolt) Air pipe assembly bolt (M6 flange) Air pipe assembly bolt (M8 flange) Air pipe assembly bolt (M8 washer) Air control valve assembly bolt Engine hanger bolt Intake air temperature sensor Boost sensor bolt Intake manifold stay bolt Intake manifold bolt (M8) Intake manifold bolt nut (M10) Exhaust manifold Engine hanger bolt Turbocharger heat protector bolt Oxygen sensor Exhaust fitting bracket bolt Exhaust filling bolt nut Air outlet fitting bol
7 4G6 - TIGHTENING TORQUES Part Oil control pump Check valve Eye bolt Oil pipe Oil pipe joint Oil pump / Sump Drain plug Sump bolt Oil screen bolt Baffle plate bolt Oil pressure switch Oil cooler bypass valve Relief plug Oil filter bracket bolt Plug cap Flange bolt Front case bolt Oil pump cover bolt Oil pump cover screw Piston / Connecting rod Connecting rod cap nut Crankshaft / Cylinder block Flywheel bolt Rear plate bolt Bell housing cover bolt (flange) Bell housing cover bolt (washer) Rear oil seal cas
8 4G6 – ALTERNATOR / IGNITION SYSTEM Alternator / Ignition System Removal and Installation Note : The ignition coil boot must only be removed from the ignition coil when it is to be replaced. If removed, always replace with a new part. Removal sequence 1. 2. 3. 4. 5. 6. 7. Oil level gauge O-ring Oil level gauge guide O-ring Water pump pulley Auto tensioner assembly Alternator bracket 8. Alternator 9. Crankshaft pulley 10. Centre cover 11. Spark plug cable 12. Ignition coil A * 13.
4G6 – ALTERNATOR, IGNITION SYSTEM 9 Removal Service Point Air blow hole Removal of ignition coil boot A * Coupling section Note : Air blow hole Upper face White powder coating on interior part. Do not touch • If the ignition coil boot is not installed according to the specifications, then this can lead to various problems, such as malfunction of the ignition coil, damage to the ignition coil, leaking of high voltage to external parts, infiltration of water into the hole, etc.
10 4G6 – TIMING BELT Timing Belt Removal and Installation Note : NEVER disassemble the V.V.T. sprocket. Removal Sequence 1. Timing belt front upper cover 2. Timing belt front lower cover 3. Power steering pump bracket 4. 5. 6. 7. 8.
11 4G6 – TIMING BELT 9. Connector bracket * *1 10. Rocker cover *1 * 11. Rocker cover gasket A 12. Rocker cover gasket B *1 * 13. Semi-circular packing B * 14. Plug cap * A *1 * 15. Timing belt * *1 *1 * 16. Tensioner pulley 17. Tensioner arm *1 * 18. Auto tensioner * *1 *1 * 26. Timing belt B * *1 *1 * 27. Counterbalance shaft sprocket *1 * 28. Spacer * *1 *1 * 29. Crankshaft sprocket B 30. Crankshaft key *1 * 31. Engine support bracket A * 32. V.V.T.
12 4G6 – TIMING BELT 3. Push the V.V.T. sprocket firmly to the end and, holding the hexagonal part of the camshaft with a wrench, check that the V.V.T. sprocket does not rotate. 4. Hold the hexagonal section of the camshaft with a wrench and tighten the V.V.T. sprocket bolt to the specified torque of 65 ±5 N-m. 5. Hold the hexagonal section of the camshaft with a wrench and check that the V.V.T. sprocket does not rotate. Note : This check shows that the V.V.T.
4G6 – FUEL SYSTEM Fuel System Removal and Installation Removal Sequence 1. Throttle body assembly Throttle body gasket Cover 4. Gasket 5. Fuel hose *1 * 6. Fuel pressure regulator 7. O ring 8. Delivery pipe and injector 9. Insulator 10. Fuel return pipe 11. Insulator *1 * 12. Injector 13. O ring *1 * 2. A * 3. 14. Grommet 15. Delivery pipe 16. Vacuum hose 17. Vacuum hose 18. Vacuum hose 19. Solenoid valve assembly 20. Solenoid valve assembly 21. Vacuum hose and pipe 22.
14 4G6 – FUEL SYSTEM Gasket side Installation Service Point Cover Gasket Inlet manifold A Installation of cover The side of the cover marked “gasket side” should be assembled facing the inlet manifold.
4G6 – SECONDARY AIR SYSTEM / INLET MANIFOLD Secondary Air System / Inlet Manifold Removal and Installation Removal Sequence 1. Exhaust manifold heat protector Air pipe assembly 3. Air control valve gasket 4. Air control valve assembly 5. Engine hanger *1 * 2. 6. Intake air temperature sensor Boost sensor Inlet manifold stay 9. Inlet manifold 10. Inlet manifold gasket *1 * 7. *1 * 8.
16 4G6 – EXHAUST MANIFOLD Exhaust Manifold Removal and Installation Removal Sequence 1. 2. 3. 4. 5. 6. 7. *1 * 8. 9. Engine hanger Turbocharger heat protector Oxygen sensor Exhaust fitting bracket Exhaust fitting Exhaust fitting gasket Air outlet fitting Air outlet fitting gasket Oil return pipe 10. Oil return pipe gasket *1 * 11. Oil return pipe gasket 12. Turbocharger assembly & pipe assembly *1 * 13. Turbocharger gasket 14. Oil pump 15. Water pipe B 16. Water pipe A 17.
4G6 – WATER PUMP / WATER HOSE Water Pump / Water Hose Removal and Installation Removal Sequence 1. 2. 3. 4. *1 * 5. *1 * 6. 7. 8. Water hose Water hose Water hose Water hose Coolant temperature sensor Coolant temperature gauge unit Water outlet fitting Thermostat 9. Thermostat housing 10. Gasket *1 * 11. Water inlet pipe *1 * 12. O-ring 13. O-ring 14. Water pump 15. Water pump gasket 16.
18 4G6 – ROCKER ARM / CAMSHAFT Rocker Arm / Camshaft Removal and Installation Apply engine oil to all sliding parts before installing. Removal Sequence 1. Cam position sensor O ring Cover Gasket Cam position sensing cylinder 6. Cam position sensor support 7. Cam position sensor 8. O ring E * 9. Cover E * 10. Gasket D * 11. Cam position sensing cylinder C * 12. Cam position sensor support *1 * 13. Camshaft oil seal *1 * 14. Bearing cap : rear right *1 * 15.
4G6 – ROCKER ARM / CAMSHAFT 19 Installation Service Point A * Installation of OCV filter Note : Before fitting the filter, check that it is clean and is not damaged or deformed in any way. B * Installation of eye bolt Note : The oil pump may be damaged if the oil pipe joint turns with the eye bolt when it is fitted. Hold the oil pipe joint in place with a spanner, etc., and then tighten the eye bolt to the specified torque 42 ±2 N-m. Eye bolt Oil pipe joint Hold with spanner, etc.
20 4G6 – ROCKER ARM / CAMSHAFT Exhaust side No cutaway Intake side No installation direction Comment : The cover and gasket do not have distinct front and rear sides. Tab Tab Cutaway Cutaway * A * * * * * * * * * 2. Ensure that the cutaways in the intake side cover and the tabs on the gasket are aligned with the positions shown in the diagram, and tighten at the specified torque of 14 ±1 N-m. The exhaust side cover and gasket do not have a specified installation direction.
21 4G6 – OIL PUMP / SUMP Oil Pump / Oil Pan Removal and Installation Apply engine oil to all sliding parts before installing. Removal Sequence 1. Drain plug Drain plug gasket Oil filter Oil pan 5. Oil screen 6. Oil screen gasket 7. Baffle plate *1 * 8. Oil pressure switch 9. Oil cooler bypass valve 10. Relief plug 11. Gasket 12. Relief spring 13. Relief plunger 14. Oil filter bracket 15. Oil filter bracket gasket * *1 *1 * 16. Plug cap 17. O ring *1 * 2. *1 * 3. * *1 *1 * 4. *1 * 18.
22 4G6 – PISTONS / CONNECTING RODS Piston / Connecting Rod Removal and Installation Apply engine oil to all sliding parts before installing. Removal Sequence *1 * 1. *1 * 2. * *1 * 3. A *1 * 4. A * 5. *1 * 6. Connecting rod cap nut Connecting rod cap Connecting rod bearing Piston connecting rod Connecting rod bearing Piston ring No. 1 *1 * 7. Piston ring No. 2 *2 * 8. Oil ring * *1 *1 * 9. Piston pin 10. Piston 11. Connecting rod 12.
23 4G6 - PISTONS / CONNECTING RODS Position of crankshaft pin diameter identification marks Installation Service Point A * Installation of bearings on connecting rod 1. When replacing a bearing, connecting rod or crankshaft, choose a bearing of the correct size which corresponds to the external diameter of the crankshaft pin, in accordance with the identification marks on the crankshaft pin and the connecting rod bearing given in the table below. 2.
24 4G6 – PISTONS CONNECTING RODS Inspection Piston rings 1. Check the clearance between the piston rings and the piston grooves. If it exceeds the clearance limit value, replace the piston ring, or both the piston ring and the piston. Standard values : No. 1 0.03 – 0.07 mm No. 2 0.02 – 0.06 mm Limit value : 0.1 mm Press with piston 2. Insert the piston ring and the side rail of the oil ring into the cylinder bore, and press in using the top surface of the piston.
4G6 – CRANKSHAFT / CYLINDER BLOCK 25 Crankshaft / Cylinder Block Removal and Installation Bolt with washer : 9.0 ± 1.0 N-m Flange bolt : 10 ± 2 N-m (supplementary part) Apply engine oil to all sliding parts before installing. Removal Procedure 1. 2. 3. 4. *1 * 5. *1 * 6. *1 * 7. *1 * 8. Flywheel bolt Flywheel Rear plate Bell housing cover Rear oil seal case Rear oil seal Bearing cap bolt Beam being cap A * 9. Crankshaft bearing lower 10. Crankshaft A * 11.
26 4G6 – CRANKSHAFT / CYLINDER BLOCK Position of crankshaft journal diameter identification marks Installation Service Point A * Installation of crankshaft bearings 1. Using the table below, select a bearing of the correct size corresponding to the diameter of the crankshaft journal. (Selecting a bearing : Example) If the identifier on the crankshaft journal is 0, and the identifier on the cylinder block bearing is 1, then a bearing with identification mark 1 should be chosen.
4G6 – TURBOCHARGER Turbocharger Disassembly and Reassembly Disassembly Procedure 1. 2. *1 * 3. *1 * 4. *1 * 5. * *1 * *1 *1 * 6. 7. *1 * 8.