Mitsubishi Car 1999-05

Engine 2

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Removal & Installation



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this product.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined herein.
 

  1. Relieve fuel system pressure.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover if equipped.
  4.  
  5. Matchmark the hood and hinges and remove the hood assembly.
  6.  
  7. Remove the air cleaner assembly and all adjoining air intake duct work.
  8.  
  9. Drain the engine coolant, remove the radiator hoses, and remove the radiator assembly, coolant reservoir, and intercooler, as equipped.
  10.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the transaxle and transfer case as equipped.
  2.  
  3. Tag and detach the following electrical connections:
  4.  


    Accelerator cable
     
    Heater hoses
     
    Brake booster vacuum hose
     
    Vacuum hoses
     
    Fuel lines
     
    Engine ground cables
     
    Any applicable sensors
     
    Coolant temperature and oil pressure sending units
     
    Exhaust Gas Recirculation (EGR) temperature sensor
     
    Connection for the idle speed control motor
     
    Fuel injectors
     
    Power transistor
     
    Ignition coil and any applicable distributor connections
     
    The connections for the alternator
     
    Power steering pressure switch
     
    A/C compressor
     
    Refrigerant temperature switch
     
    Condenser
     

  5. Remove the air conditioner drive belt and the air conditioning compressor. Leave the hoses attached. Do not discharge the system. Place the compressor aside and secure it using a suitable device.
  6.  
  7. Remove the power steering pump and place the pump aside and secure it using a suitable device.
  8.  
  9. Remove the exhaust manifold-to-exhaust pipe nuts. Discard the gasket.
  10.  
  11. Install the engine hoist equipment and make certain the attaching points on the engine are secure.
  12.  
  13. Raise the hoist enough to support the engine.
  14.  
  15. Remove the front and rear engine roll stoppers.
  16.  
  17. Remove the left engine mount and support bracket.
  18.  


WARNING
Double check that all cables, hoses, harness connectors, etc., are disconnected from the engine.

  1. Slowly lift the engine and remove it from the vehicle.
  2.  

To install:

  1. Install the engine and secure all control brackets and mounts.
  2.  
  3. Install the transaxle, and transfer case if equipped.
  4.  
  5. The balance of the installation is the reverse of removal with the addition of the following notes:
  6.  

  1. Use new clamps or O-rings to connect the high pressure fuel line and the fuel return line.
  2.  
  3. Use new gaskets to connect the exhaust system to the engine.
  4.  
  5. Fill the engine with the proper amount of engine oil and coolant.
  6.  
  7. Start the engine, allow it to reach normal operating temperature.
  8.  
  9. Check for leaks.
  10.  
  11. Check the ignition timing and adjust if necessary.
  12.  
  13. Road test the vehicle and check all fluid levels and functions for proper operation.
  14.  



Click image to see an enlarged view

Fig. Alignment of the engine mount stopper bracket-Diamante shown

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the hood assembly.
  8.  
  9. Remove the air cleaner assembly and all adjoining air intake duct work.
  10.  
  11. Disconnect and remove the cruise control linkage and actuator assemblies.
  12.  
  13. Drain the engine coolant.
  14.  
  15. Remove the radiator assembly, coolant reservoir and intercooler.
  16.  
  17. Disconnect the Heated Oxygen (HO 2 S) sensor connection at the front exhaust pipe.
  18.  
  19. Unbolt and remove the front exhaust pipe assembly.
  20.  
  21. Remove the transaxle assembly.
  22.  
  23. Disconnect the accelerator cable, breather hose and heater hose connections from the engine.
  24.  
  25. Note locations and remove the vacuum hoses from the engine.
  26.  
  27. Disconnect the fuel feed and return hoses.
  28.  
  29. Remove the solenoid valve assembly and disconnect the ground cable.
  30.  
  31. Disconnect the purge hose and Exhaust Gas Recirculation (EGR) temperature sensor, if equipped.
  32.  
  33. Remove the A/C and power steering drive belts.
  34.  
  35. Unbolt and remove the A/C compressor and the power steering pump assemblies.
  36.  
  37. Disconnect the harness connections for the Idle Speed Control (ISC) motor position sensor and Throttle Position (TP) sensor.
  38.  
  39. Disconnect the EGR temperature sensor (California).
  40.  
  41. For the turbocharger, disconnect the following:

    Booster vacuum hose
     
    Oil cooler lines
     

  42.  
  43. Disconnect the wiring at the oil pressure switch and oil pressure gauge unit.
  44.  
  45. Disconnect the fuel injection wiring harness plug.
  46.  
  47. Disconnect the wiring from the knock sensor and the Crankshaft Position (CKP) sensor.
  48.  
  49. Disconnect the Engine Coolant Temperature (ECT) switch, sensor and gauge unit connections.
  50.  
  51. Disconnect the wiring to the ignition coil, condenser and the power transistor.
  52.  
  53. Disconnect the variable induction motor connection.
  54.  
  55. Open the cover of the relay box and disconnect the alternator wiring.
  56.  
  57. Attach a hoist to the engine and support the engine weight. Remove the engine mount bracket.
  58.  
  59. Remove the front and rear roll stopper bracket mounting bolts.
  60.  
  61. Remove the engine assembly from the vehicle.
  62.  

To install:

  1. Install the engine and secure into position. Secure the engine mount bracket to block and tighten bolts to 72-87 ft. lbs. (100-120 Nm). Install through-bolt and tighten bolt to 51 ft. lbs. (70 Nm).
  2.  
  3. Install the front and rear roll stopper through-bolt and tighten to 36-43 ft. lbs. (50-60 Nm).
  4.  
  5. Open the cover of the relay box and connect alternator wiring.
  6.  
  7. Connect the variable induction motor connection.
  8.  
  9. Connect the fuel feed and return hoses. Using a new sealing ring, tighten pressure hose connection to 4 ft. lbs. (5 Nm).
  10.  
  11. Connect the wiring to the ignition coil, condenser and power transistor.
  12.  
  13. Connect the ECT switch, sensor and gauge unit connections.
  14.  
  15. Connect the wiring from the knock sensor and the CKP sensor.
  16.  
  17. Connect the fuel injection wiring harness plug.
  18.  
  19. Connect the wiring at the oil pressure switch and oil pressure gauge unit.
  20.  
  21. Connect the following for the turbocharger:

    Booster vacuum hose
     
    Oil cooler lines
     

  22.  
  23. Connect EGR temperature sensor (California).
  24.  
  25. Connect harness connections for the ISC motor position sensor and TP sensor.
  26.  
  27. Install the A/C compressor and the power steering pump assemblies.
  28.  
  29. Install the engine drive belts.
  30.  
  31. Connect the purge hose and the EGR temperature sensor, if equipped.
  32.  
  33. Install the solenoid valve assembly and connect ground cable to engine block.
  34.  
  35. Reconnect the vacuum hoses to the engine.
  36.  
  37. Connect the accelerator cable, breather hose and heater hose connections to the engine.
  38.  
  39. Install the transaxle assembly.
  40.  
  41. Install the front exhaust pipe assembly, using new gaskets. Tighten manifold mounting bolts to 36 ft. lbs. (50 Nm).
  42.  
  43. Connect the HO 2 S sensor connection at the front exhaust pipe.
  44.  
  45. Replace the radiator assembly, coolant reservoir and intercooler. Refill the cooling system.
  46.  
  47. Install and connect the cruise control linkage and the actuator assemblies.
  48.  
  49. Install the hood assembly, air cleaner assembly and all adjoining air intake duct work.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Start the engine and check for leaks.
  54.  

  1. Remove the hood assembly.
  2.  
  3. Drain the engine oil.
  4.  
  5. Relieve fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative, then the positive battery cable
     
    Battery
     
    Air cleaner assembly and all adjoining air intake duct work
     

  8.  
  9. Drain the engine coolant and remove the radiator assembly and coolant reservoir (and bracket).
  10.  
  11. Remove or disconnect the following:

    Engine undercover, if equipped
     
    Front exhaust pipe
     
    Transaxle assembly
     
    Accelerator cable from the throttle body
     
    Vacuum hoses from the intake manifold, label for installation
     
    High pressure fuel line and the fuel return line
     
    Vacuum hoses from the solenoid valves
     
    Vacuum hoses from the purge canister
     
    Heater hose connections from the engine
     
    Harness for the Exhaust Gas Recirculation (EGR) temperature sensor connection, if equipped
     
    Engine drive belts
     
    Power steering pump oil pressure switch connection from the pump
     
    Power steering pump and secure away from the work area
     
    Air conditioning compressor. Wire the compressor aside. Do not discharge or disconnect the air conditioning lines.
     
    Wiring to the alternator
     
    Harness plugs for the Barometer (BARO) sensor, Idle Speed Control (ISC) motor, Throttle Position (TP) sensor, fuel injectors and Knock (KS) sensor
     
    Harness plugs for the Engine Coolant Temperature (ECT) switch, sensor and gauge
     
    Harness plugs for the ignition coil, condenser and ignition power transistor
     
    Harness plugs for the variable induction control motor and the Manifold Absolute Pressure (MAP) sensor
     
    Harness plugs for the Crankshaft Position (CKP) and Camshaft Position (CMP) sensors
     
    Radiator overflow tank and remove the mounting bracket
     
    Ground cable connections
     

  12.  
  13. Attach a hoist to the engine and take up the engine weight. Remove the engine mount bracket. Remove any torque control brackets (roll stoppers).
  14.  
  15. Lift the engine slowly and remove from the engine compartment.
  16.  

To install:

Click image to see an enlarged view

Fig. Alignment of the engine mount stopper bracket-3.5L engine

  1. Install or connect the following:

    Engine and secure all control brackets
     
    Transaxle assembly
     
    Engine ground cable connections
     
    Harness plugs for the CKP and CMP sensors
     
    Harness plugs for the variable induction control motor and the MAP sensor
     
    Harness plugs for the ignition coil, condenser and ignition power transistor
     
    Harness plugs for the ECT switch, sensor and gauge
     
    Harness plugs for the BARO sensor, ISC motor, TP sensor, fuel injectors and KS sensor
     
    Wiring to the alternator
     
    Air conditioning compressor assembly
     
    Power steering pump assembly
     
    Power steering pump oil pressure switch harness plug to the pump
     
    Engine drive belts, adjust
     
    Harness for the EGR temperature sensor
     
    Heater hose connections to the engine, using new hose clamps
     
    Vacuum hoses to the purge canister
     
    Vacuum hoses to the solenoid valves
     
    High pressure fuel line and the fuel return line, using new clamps or O-rings
     
    Vacuum hoses
     
    Accelerator cable to the throttle body
     
    Air cleaner assembly and all adjoining air intake duct work
     
    Radiator and coolant reservoir assembly
     
    Transaxle assembly
     
    Exhaust system to the engine, using new gaskets
     
    Battery to the vehicle
     
    Positive, then the negative battery cables
     
    Engine undercover, if equipped
     

  2.  
  3. Refill the cooling system to the correct level.
  4.  
  5. Refill the engine oil to the correct level.
  6.  
  7. Install the hood.
  8.  
  9. Start the engine and check for leaks.
  10.  

  1. Relieve fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover, if equipped
     
    Hood assembly
     
    Air cleaner assembly and all adjoining air intake duct work
     

  4.  
  5. Drain the engine coolant and engine oil.
  6.  
  7. Remove or disconnect the following:

    Radiator
     
    Front exhaust pipe
     
    Battery and battery tray
     
    Accelerator cable
     

  8.  
  9. Detach the electrical connectors from the following components:

    Air Conditioning (A/C) compressor
     
    Power steering oil pressure switch
     
    Crank angle sensor
     
    Manifold differential pressure sensor
     
    Evaporative emission (EVAP) purge solenoid
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     
    Ignition coil
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Engine Coolant Temperature (ECT) sensor
     
    Camshaft Position (CMP) sensor
     
    Knock Sensor (KS)
     
    ECT gauge unit
     
    Heated Oxygen (HO 2 S) sensor
     
    Starter and alternator
     
    Oil pressure switch
     

  10.  
  11. Remove or disconnect the following:
    NOTE
    Matchmark the installed position of the radiator hoses before disconnecting them.



    Brake booster vacuum hose
     
    Power steering pump and A/C compressor drive belt
     
    Power steering pump and brace. Position the assembly aside, but do NOT disconnect the fluid line.
     
    A/C compressor, but do NOT disconnect the lines
     



    Upper and lower radiator hoses
     
    Heater and purge hoses
     
    Fuel lines. Discard the O-rings
     
    Transaxle assembly. Do NOT remove the flywheel bolt indicated by the arrow in the accompanying illustration. Removal of this bolt will cause the flywheel to be out of balance.

    Click image to see an enlarged view

    Fig. These special tools are needed to support the engine while the transaxle is removed-Lancer 2.0L engine

     

  12.  
  13. Remove the engine mount insulator and bracket as follows:
    1. Support the engine with a suitable floor jack.
    2.  
    3. Remove the special tools that were installed for transaxle removal.
    4.  
    5. Support the engine with special tool MB991453 attached to a chain block or engine hoist.

      Click image to see an enlarged view

      Fig. View of the special tool needed to support the engine during mount removal-Lancer 2.0L engine

    6.  
    7. Place a jack under the oil pan with a block of wood in between to protect the pan. Jack up the engine to take the weight off the engine mount insulator and bracket, then remove the insulator and bracket.
    8.  

  14.  
  15. Make sure that all cables, hoses and harnesses are disconnected from the engine, then use the engine hose to slowly lift the engine up and out of the engine compartment
  16.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Fill the coolant system and engine crankcase.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  8.  
  9. Turn the ignition switch to the ON position.
  10.  
  11. Select -check mode- from the menu screen.
  12.  
  13. Select -erase memory- from the menu screen.
  14.  
  15. Initialize the learning value.
  16.  
  17. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  18.  
  19. Stop the engine and place the ignition switch in the LOCK position.
  20.  
  21. After ten seconds, restart the engine.
  22.  
  23. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  24.  

  1. Relieve fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover, if equipped
     
    Hood assembly
     
    Air cleaner assembly and all adjoining air intake duct work
     

  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Radiator assembly and coolant reservoir
     
    Transaxle assembly
     
    Ground cable, accelerator cable, breather hose and heater hose connections from the engine
     

  8.  
  9. Note locations and remove vacuum hoses from engine.
  10.  
  11. Remove or disconnect the following:

    Fuel feed and return hoses
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor wiring
     
    Heated Oxygen (HO 2 S sensor), Engine Coolant (ECT) gauge and ECT sensor connections
     
    Oil pressure switch
     
    Thermo switch, with automatic transmissions
     
    Harness connections for the Idle Speed Control (ISC) motor and Throttle Position (TP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    Exhaust Gas Recirculation (EGR) temperature sensor (California)
     
    Injector harness plugs
     
    Power transistor and the ignition coil connections
     
    Alternator and power steering switch wiring
     
    Air conditioning compressor and hang it out of the way. Do NOT allow the compressor to hang by the hoses.
     
    Power steering pump and hang it out of the way-Do not allow the pump to hang by the hoses.
     
    Starter and alternator harness clamp, for 1.8L engines
     
    Exhaust manifold to head pipe nuts
     

  12.  
  13. Attach a hoist to the engine and support the engine weight. Remove the engine mount bracket. Remove any torque control brackets (roll stoppers).
  14.  
  15. Remove the engine assembly from the vehicle.
  16.  

To install:

  1. Install the engine and secure in position. The front lower mount through-bolt nut should not be tightened until the full weight of the engine is on the mount. Tighten through-bolt to 72 ft. lbs. (100 Nm) and bracket mounting bolts to 42 ft. lbs. (58 Nm). Tighten bracket mounting nut to 38 ft. lbs. (53 Nm).
  2.  
  3. Using a new gasket, position exhaust pipe onto the manifold and tighten the flange nuts to 36 ft. lbs. (50 Nm).
  4.  
  5. Install or connect the following:

    Power steering pump, alternator and air conditioning compressor
     
    Accessory drive belts
     
    Alternator and power steering wiring
     
    Alternator and starter harness clamp for 1.8L engines
     
    Ignition coil and power transistor connections
     
    Fuel injector harness connections
     
    EGR temperature sensor plug-California models
     
    IAT sensor
     
    IAC and TPS connectors
     
    Thermo switch, automatic transmission
     
    Oil pressure switch wiring
     
    HO 2 S sensor, ECT gauge and ECT sensor
     
    CKP and CMP sensors
     
    Fuel feed hose and tighten bolts to 44 inch lbs. (5 Nm), using new O-rings
     
    Fuel return hose, using a new hose clamp
     
    Vacuum hoses and the brake booster vacuum supply
     
    Breather hose, heater hoses, accelerator cable and ground cables. Inspect accelerator cable for proper adjustment.
     
    Transaxle assembly
     
    Radiator assembly and refill the cooling system
     
    Air cleaner and hood assembly
     
    Negative battery cable
     

  6.  

2.0L (4g63) Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Intake air duct
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Radiator
     
    Engine undercover
     

  10.  
  11. Attach an engine lifting fixture to the engine and remove the transaxle assembly.

    Click image to see an enlarged view

    Fig. Common method of supporting the engine using a fixture specifically designed for that purpose



    Power steering pressure switch, oil pressure switch, oil pressure gauge sender and the alternator wiring connectors
     
    Alternator
     
    Power steering pump from the bracket and position the pump out of the way
     
    Air conditioning compressor from the bracket and position it out of the way. Do not disconnect the hoses.
     
    Accelerator cable from the throttle body and mounting bracket
     

  12.  
  13. Disconnect the following connectors:

    IAC motor
     
    Knock sensor
     
    HO 2 S sensor
     
    ECT gauge sender
     
    ECT sensor
     
    Ignition module (power transistor)
     
    TP sensor
     
    Condenser
     
    MAP sensor
     
    Injectors
     
    Ignition coil
     
    CMP sensor
     
    CKP sensor
     
    air conditioning compressor connector
     
    Engine control wiring harness
     

  14.  
  15. Remove or disconnect the following:

    Brake booster vacuum hose
     
    Fuel lines from the fuel supply rail
     
    The A and B water hose connections
     
    Vacuum hoses, label
     
    Front exhaust pipe from the turbocharger
     

  16.  
  17. Support the engine under the oil pan with a floor jack and a piece of wood.
  18.  
  19. Remove the engine support fixture and replace it with a hoist. Lift up the engine to take the weight off of the engine mount bracket.
  20.  
  21. Remove the engine mount bracket.
  22.  
  23. Lift the engine up slowly out of the engine compartment.
  24.  

To install:

  1. Slowly lower the engine assembly into the vehicle.
  2.  
  3. Position the floor jack under the oil pan with a piece of wood in between. Use the floor jack to adjust the height of the engine while installing the engine mount bracket.
  4.  
  5. Remove the chain hoist and install the engine support fixture.
  6.  
  7. Install or connect the following:

    Front exhaust pipe to the turbocharger
     
    Vacuum hoses
     
    The A and B water hoses
     
    New O-ring on the high pressure fuel line. Apply a small amount of clean engine oil to the O-ring and connect the fuel lines to the fuel supply rail.
     
    Brake booster vacuum hose
     

  8.  
  9. Connect the following connectors:

    IAC motor
     
    Knock sensor
     
    HO 2 S sensor
     
    ECT gauge sender
     
    ECT sensor
     
    Ignition module (power transistor)
     
    TP sensor
     
    Condenser
     
    MAP sensor
     
    Injectors
     
    Ignition coil
     
    CMP sensor
     
    CKP sensor
     
    air conditioning compressor connector
     
    Engine control wiring harness
     

  10.  
  11. Install or connect the following:

    Air conditioning compressor and the power steering pump in their brackets
     
    Alternator
     
    Oil pressure gauge sender, oil pressure switch and the power steering pressure switch connectors
     
    Transaxle assembly and remove the engine support fixture
     
    Engine undercover
     
    Radiator and connect the hoses
     
    Intake air duct
     

  12.  
  13. Refill the engine with coolant to the correct level.
  14.  
  15. Refill the engine oil to the correct level.
  16.  
  17. Install the hood.
  18.  
  19. Connect the negative battery cable.
  20.  

2.4L (4g69) Engine
  1. Disconnect the negative battery cable. Relieve the fuel system pressure.
  2.  
  3. Remove the engine under cover. Drain the engine oil. Drain the engine coolant. Drain the transaxle fluid.
  4.  
  5. Remove the hood. Remove the battery and battery tray.
  6.  
  7. Remove the engine air cleaner. Remove the ECM/PCM.
  8.  
  9. Remove the upper and lower radiator hoses. Remove the radiator. Remove the number one and two exhaust pipes.
  10.  
  11. Disconnect the engine electrical wiring harness. Disconnect the EVAP hose connection.
  12.  
  13. Disconnect the brake booster vacuum hose connection. Remove the drive belt.
  14.  
  15. Remove the power steering pump and bracket assembly. Lay the power steering pump to the side. Do not disconnect the fluid lines from the pump.
  16.  
  17. Remove the air conditioning compressor. Lay the air conditioning compressor to the side. Do not disconnect the fluid lines from the pump.
  18.  
  19. With the hose installed, remove the automatic transaxle fluid cooler and bracket assembly from the transaxle case front stopper bracket.
  20.  
  21. Remove the heater hoses. Remove the fuel high pressure hose connection.
  22.  
  23. Secure the engine front end structure bar tool in a location that will not interfere with the engine removal.

    Click image to see an enlarged view

    Fig. Front end structure bar-2004-2005 Galant 2.4L engine

  24.  
  25. Remove the transaxle assembly from the vehicle.
  26.  
  27. Remove the grounding cable connection and power steering fluid reservoir.
  28.  
  29. Support the engine with a garage jack. Remove tool MB991895, MB991454 and MB991527.
    NOTE
    These special tools were needed and installed to remove the transaxle from the vehicle.



    Click image to see an enlarged view

    Fig. These special tools are needed to support the engine while the transaxle is removed-2004-2005 Galant 2.4L engine

  30.  
  31. Hold the engine assembly in place with the engine lifting device. Properly position a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the front mounting bracket.
  32.  
  33. Loosen the engine front mounting bracket mounting nuts and blots. Remove the front engine mounting bracket.
  34.  
  35. After checking that all cables, hoses and wiring are disconnected from the engine, lift the engine hoist slowly and remove the engine from the vehicle.
  36.  

To install:

  1. Slowly lower the engine assembly into the vehicle.
  2.  
  3. The installation is the reverse of the removal procedure.
  4.  
  5. Be sure to fill the engine with the proper grade and type fluids.
  6.  
  7. Be sure to fill the transaxle with the proper grade and type fluid.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  
  11. Complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  12.  
  13. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  14.  
  15. Turn the ignition switch to the ON position.
  16.  
  17. Select -check mode- from the menu screen.
  18.  
  19. Select -erase memory- from the menu screen.
  20.  
  21. Initialize the learning value.
  22.  
  23. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  24.  
  25. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  26.  
  27. Stop the engine and place the ignition switch in the LOCK position.
  28.  
  29. After ten seconds, restart the engine.
  30.  
  31. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  32.  
  33. Roadtest the vehicle.
  34.  
  35. Check the front end alignment and correct as required.
  36.  
  37. Reprogram the radio stations and security codes, as necessary.
  38.  

2.4L And 2.0L (420a) Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Intake air duct
     

  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Hoses and remove the radiator
     
    Engine undercover
     

  10.  
  11. Attach an engine lifting fixture to the engine and remove the transaxle assembly.
  12.  
  13. Disconnect the following connectors:

    Air conditioning compressor
     
    Power steering pressure switch
     
    Heated Oxygen (HO 2 S) sensor
     
    Engine Coolant Temperature (ECT) gauge sender
     
    ECT sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     

  14.  
  15. Remove or disconnect the following:

    Power steering pump from the bracket and position the pump out of the way
     
    Air conditioning compressor from the bracket and position it out of the way. Do not disconnect the hoses.
     
    Accelerator cable from the throttle body and mounting bracket
     

  16.  
  17. Disconnect the following connectors:

    Idle Air Control (IAC) motor
     
    Knock (KS) sensor
     
    Ignition module (power transistor)
     
    Exhaust Gas Recirculation (EGR) solenoid
     
    Oil pressure switch
     
    Throttle Position (TP) sensor
     
    Condenser
     
    Injectors
     
    Ignition coil
     
    Camshaft Position (CMP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Engine control wiring harness
     

  18.  
  19. Remove or disconnect the following:

    Heater hoses from the engine
     
    Fuel lines from the fuel supply rail
     
    Purge air hose and the brake booster vacuum hose
     
    Front exhaust pipe from the manifold
     

  20.  
  21. Place a floor jack against the oil pan with a piece of wood in between to protect the oil pan.
  22.  
  23. Raise the engine with the jack and remove the engine support fixture.
  24.  
  25. Install a chain hoist to the top of the engine.
  26.  
  27. Remove the engine mount bracket.
  28.  
  29. Lift the engine up slowly out of the engine compartment.
  30.  

To install:

  1. Slowly lower the engine assembly into the vehicle.
  2.  
  3. Position the floor jack under the oil pan with a piece of wood in between. Use the floor jack to adjust the height of the engine while installing the engine mount bracket.
  4.  
  5. Remove the chain hoist and install the engine support fixture.
  6.  
  7. Install or connect the following:

    Front exhaust pipe to the manifold
     
    Brake booster vacuum hose
     
    New O-ring on the high pressure fuel line. Apply a small amount of clean engine oil to the O-ring and connect the fuel lines to the fuel supply rail.
     

  8.  
  9. Connect the following connectors:

    IAC motor
     
    KS sensor
     
    Ignition module (power transistor)
     
    EGR solenoid
     
    Oil pressure switch
     
    TP sensor
     
    Condenser
     
    Injectors
     
    Ignition coil
     
    CMP sensor
     
    CKP sensor
     
    Engine control wiring harness
     

  10.  
  11. Install or connect the following:

    Accelerator cable, adjust
     
    Air conditioning compressor and the power steering pump in their brackets
     
    IAT sensor, MAP sensor, ECT sensor and gauge sender, HO 2 S sensor, power steering pressure switch and the air conditioning compressor harness connectors
     
    Radiator and hoses
     
    Transaxle and remove the engine support fixture
     
    Engine undercovers
     
    Intake air duct
     
    Negative battery cable
     
    Hood
     

  12.  
  13. Refill the engine oil to the correct level.
  14.  
  15. Refill the cooling system to the correct level.
  16.  
  17. Start the engine and check for leaks.
  18.  

2.4L And 3.0L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil and the transmission oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Transaxle assembly
     
    Radiator hoses and remove the radiator
     
    Accelerator cable and remove the bracket
     
    Air intake and breather hoses
     
    Heater hoses
     
    Brake booster vacuum hose at the engine
     
    Vacuum hoses at the throttle body, label
     
    Fuel feed and return hoses
     

  10.  
  11. Disconnect the following:

    Power steering pressure switch
     
    Alternator
     
    Oil pressure switch
     
    Air conditioning compressor
     
    Each injector
     
    Power transistor
     
    Ignition coil
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Engine Coolant Temperature (ECT) switch
     
    ECT sensor
     
    Exhaust Gas Recirculation (EGR) temperature sensor
     
    Engine control wiring harness
     
    Heated Oxygen (HO 2 S) sensor
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor
     
    Refrigerant temperature switch
     
    Condenser connection
     

  12.  
  13. Remove or disconnect the following:

    Power steering pump and position it aside
     
    Air conditioning compressor drive belt
     
    Compressor from its mount and hang it out of the way. Do not disconnect the hoses and do not allow the compressor to hang by the hoses.
     
    Front exhaust pipe
     

  14.  
  15. Install engine hoist equipment and make certain the attaching points on the engine are secure.
  16.  
  17. Raise the hoist enough to support the engine.
  18.  
  19. Remove or disconnect the following:

    Front and rear engine roll stoppers
     
    Left engine mount and support bracket
     

  20.  
  21. Slowly lift the engine and remove it from the vehicle.
  22.  

To install:

  1. Lower the engine into the vehicle.
  2.  
  3. Install the front and rear roll stoppers and the left engine mount. Do not torque the through-bolts at this time.
  4.  
  5. Remove the lifting apparatus from the engine.
  6.  
  7. Connect the exhaust system to the manifold, using a new gasket and new locking nuts. Tighten the nuts and the small bolt to 33 ft. lbs. (44 Nm)
  8.  
  9. Tighten the engine mount nuts and bolts. Correct torque values are:
    1. Upper mount to engine nuts: 42 ft. lbs. (57 Nm).
    2.  
    3. Upper mount to engine bolt: 108 inch lbs. (12 Nm).
    4.  
    5. Upper mount through-bolt: 72-87 ft. lbs. (98-118 Nm).
    6.  
    7. Rear roll stopper through-bolt: 32 ft. lbs. (44 Nm).
    8.  
    9. Front roll stopper through-bolt: 41 ft. lbs. (57 Nm).
    10.  

  10.  
  11. Install or connect the following:

    Air conditioning compressor, tightening the mounting bolts to 18 ft. lbs. (25 Nm)
     
    Power steering pump, tightening the front bolts to 21 ft. lbs. (28 Nm) and the rear bolt to 16 ft. lbs. (22 Nm)
     
    Accessory drive belts
     

  12.  
  13. Connect the following:

    Power steering pressure switch
     
    Alternator
     
    Oil pressure switch
     
    Air conditioning compressor
     
    Each injector
     
    Power transistor
     
    Ignition coil
     
    TP sensor
     
    IAC motor
     
    ECT switch
     
    ECT sensor
     
    EGR temperature sensor
     
    Engine control wiring harness
     
    HO 2 S sensor
     
    CKP sensor
     
    CMP sensor
     
    Refrigerant temperature switch
     
    Condenser connection
     

  14.  
  15. Install or connect the following:

    Fuel return hose and secure with the retaining clamp
     
    New O-ring, connect the high pressure fuel line and tighten the bolts to 48 inch lbs. (6 Nm)
     
    Vacuum lines running to the throttle body
     
    Heater hoses
     
    Accelerator cable bracket, tightening the bolts to 48 inch lbs. (6 Nm), and connect the accelerator cable
     
    Radiator and connect the hoses
     
    Transaxle
     

  16.  
  17. Fill the coolant system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the engine and check for leaks.
  22.  
  23. Install the hood.
  24.  

3.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil and the transmission oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    All wires, cables and hoses connected to the engine
     
    Hood
     
    Air intake and breather hoses
     
    Radiator hoses and remove the radiator
     
    Front exhaust pipe
     
    Power steering pump and position it aside
     
    Air conditioning compressor drive belt
     
    Compressor from its mount and hang it out of the way. Do not disconnect the hoses and do not allow the compressor to hang by the hoses.
     

  10.  
  11. Install engine hoist equipment and make certain the attaching points on the engine are secure.
  12.  
  13. Raise the hoist enough to support the engine.
  14.  
  15. Remove or disconnect the following:

    Front and rear engine roll stoppers
     
    Left engine mount and support bracket
     

  16.  
  17. Slowly lift the engine and remove it from the vehicle.
  18.  

3.8L Engine
  1. Disconnect the negative battery cable. Relieve the fuel system pressure.
  2.  
  3. Remove the engine under cover. Drain the engine oil. Drain the engine coolant. Drain the transaxle fluid.
  4.  
  5. Remove the hood. Remove the battery and battery tray.
  6.  
  7. Remove the engine air cleaner. Remove the ECM/PCM.
  8.  
  9. Remove the front exhaust pipe. Remove the strut tower bar. Remove the radiator grille.
  10.  
  11. Remove the top engine cover. Disconnect the control wiring harness connection. Disconnect the EVAP hose connection.
  12.  
  13. Disconnect the high pressure fuel hose connection. Disconnect and remove the top and bottom radiator hoses. Remove the radiator.
  14.  
  15. Remove the driveshaft.
  16.  
  17. Remove the exhaust manifold right bank. Remove the intake manifold plenum.
  18.  
  19. Remove the drive belt. Remove the power steering pump belt. Disconnect the power steering pressure switch connector.
  20.  
  21. Remove the power steering pump from its mounting. Position it to the side where it will not interfere with the engine removal.
  22.  
  23. Remove the starter. Remove the intake manifold plenum stay, throttle body stay, engine oil dipstick assembly and engine hanger, and install special tools MB992012 and MB992013 to the engine.
  24.  
  25. Remove the transaxle from the vehicle.
  26.  
  27. Remove the air conditioning compressor and bracket. Position the unit to the side where it will not interfere with the engine removal.
  28.  
  29. Support the engine with a garage jack. Remove tool MB991895, MB991454, MB992012 and MB992013.
    NOTE
    These special tools were needed and installed to remove the transaxle from the vehicle.

  30.  
  31. Hold the engine assembly in place with the engine lifting device. Properly position a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the front mounting bracket.
  32.  
  33. Loosen the engine front mounting bracket mounting nuts and blots. Remove the front engine mounting bracket.
  34.  
  35. After checking that all cables, hoses and wiring are disconnected from the engine, lift the engine hoist slowly and remove the engine from the vehicle.
  36.  

To install:

  1. Slowly lower the engine assembly into the vehicle.
  2.  
  3. The installation is the reverse of the removal procedure.
  4.  
  5. Place a garage jack against the engine oil pan, with a piece of wood in between. Install the engine mount while adjusting the position of the engine.
  6.  
  7. Support the engine with a garage jack, Remove the chain block (engine lifting device).
  8.  
  9. Install engine hanger tool MB991895 to the strut mounting nuts and the front end structure bar assembling bolts.

    Click image to see an enlarged view

    Fig. Special tool installation-strut mounting nuts A and B. Front end structure bar assembling bolts (C and D)-2004-2005 Galant 3.8L engine

  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Be sure to fill the engine with the proper grade and type fluids.
  14.  
  15. Be sure to fill the transaxle with the proper grade and type fluid.
  16.  
  17. Start the engine and check for leaks, correct as required.
  18.  
  19. Complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  20.  
  21. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  22.  
  23. Turn the ignition switch to the ON position.
  24.  
  25. Select -check mode- from the menu screen.
  26.  
  27. Select -erase memory- from the menu screen.
  28.  
  29. Initialize the learning value.
  30.  
  31. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  32.  
  33. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  34.  
  35. Stop the engine and place the ignition switch in the LOCK position.
  36.  
  37. After ten seconds, restart the engine.
  38.  
  39. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  40.  
  41. Roadtest the vehicle.
  42.  
  43. Check the front end alignment and correct as required.
  44.  
  45. Reprogram the radio stations and security codes, as necessary.
  46.  

Lancer Evolution
  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Remove the battery and battery tray.
  4.  
  5. Remove the engine under cover. Remove the hood. Remove the side cover.
  6.  
  7. Drain the engine oil. Drain the coolant. Drain the transaxle. Drain the transfer case.
  8.  
  9. Remove the strut tower bar. Remove the air cleaner assembly.
  10.  
  11. Remove the air cooler air pipes. Remove the accelerator cable.
  12.  
  13. Remove the rocker cover center cover. Remove the upper and lower radiator hoses. Remove the radiator.
  14.  
  15. Remove the front axle crossmember bar. Remove the front exhaust pipe. Remove the turbocharger air outlet fitting.
  16.  
  17. Disconnect the ignition coil connectors.
  18.  
  19. Disconnect the Heated Oxygen (HO 2 S) sensor connector.
  20.  
  21. Disconnect the Crankshaft Position (CKP) sensor connector.
  22.  
  23. Disconnect the manifold differential pressure sensor connector.
  24.  
  25. Disconnect the fuel pressure solenoid connector.
  26.  
  27. Disconnect the Knock Sensor (KS) connector.
  28.  
  29. Disconnect the evaporative emission purge solenoid connector.
  30.  
  31. Disconnect the Throttle Position (TP) sensor connector.
  32.  
  33. Disconnect the Idle Air Control (IAC) motor connector.
  34.  
  35. Disconnect the fuel injector connectors.
  36.  
  37. Disconnect the Camshaft Position (CMP) sensor connector.
  38.  
  39. Disconnect the Engine Coolant Temperature (ECT) gauge unit connector.
  40.  
  41. Disconnect the ECT sensor connector.
  42.  
  43. Remove the control wiring harness and transaxle wiring harness combination.
  44.  
  45. Disconnect the ground cable connection.
  46.  
  47. Disconnect the alternator wiring connectors.
  48.  
  49. Disconnect the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid valve connector.
  50.  
  51. Disconnect the engine oil pressure switch connector.
  52.  
  53. Remove the turbocharger wastegate actuator bolts.
  54.  
  55. Remove the accessory drive belt.
  56.  
  57. Disconnect the brake booster vacuum hose.
  58.  
  59. Disconnect the purge hose connection.
  60.  
  61. Disconnect the power steering oil pressure switch connector.
  62.  
  63. Remove the power steering oil pump heat protector.
  64.  
  65. Remove the power steering oil pump, mounting bracket and reservoir assembly.
  66.  
  67. Disconnect the A/C compressor connector.
  68.  
  69. Remove the A/C compressor and clutch assembly.
  70.  
  71. Disconnect the engine oil cooler feed and return hose connections.
  72.  
  73. Disconnect the heater water hose connections.
  74.  
  75. Disconnect the fuel return line and high-pressure hose connections. Discard the O-rings.
  76.  
  77. Remove the upper and lower radiator hoses.
  78.  
  79. Remove the transaxle and transfer case assemblies from the engine.
  80.  
  81. Remove the engine front roll stopper bracket and engine front mounting bracket through-bolts as follows:
    1. Support the engine with a suitable floor jack.
    2.  
    3. Remove the special tools that were installed for transaxle removal.
    4.  
    5. Support the engine with special tool MB991453 attached to a chain block or engine hoist.
    6.  
    7. Place a jack under the oil pan with a block of wood in between to protect the pan. Jack up the engine to take the weight off the engine mount insulator and bracket, then remove the front roll stopper bracket and engine front mounting bracket through-bolts.
    8.  

  82.  
  83. Make sure that all cables, hoses and harnesses are disconnected from the engine, then use the engine hose to slowly lift the engine up and out of the engine compartment.
  84.  

To install:

Click image to see an enlarged view

Fig. Front mounting bracket and related components-Lancer Evolution 2.0L engine



Click image to see an enlarged view

Fig. Engine front roll stopper bracket and related components- Lancer Evolution 2.0L engine

  1. Install the engine and secure in position. The engine mount through-bolts should not be tightened until the full weight of the engine is on the mounts. Tighten the engine front roll stopper bracket through-bolt to 34-44 ft. lbs. (45-59 Nm). Tighten the engine front mounting bracket bolt to 66-80 ft. lbs. (88-108 Nm).
  2.  
  3. Continue installation in the reverse of the removal procedure.
  4.  
  5. Be sure to fill the engine with the proper grade and type fluids.
  6.  
  7. Be sure to fill the transaxle with the proper grade and type fluid.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  
  11. Complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  12.  
  13. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  14.  
  15. Turn the ignition switch to the ON position.
  16.  
  17. Select -check mode- from the menu screen.
  18.  
  19. Select -erase memory- from the menu screen.
  20.  
  21. Initialize the learning value.
  22.  
  23. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  24.  
  25. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  26.  
  27. Stop the engine and place the ignition switch in the LOCK position.
  28.  
  29. After ten seconds, restart the engine.
  30.  
  31. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  32.  
  33. Roadtest the vehicle.
  34.  
  35. Check the front end alignment and correct as required.
  36.  
  37. Reprogram the radio stations and security codes, as necessary.
  38.  

 
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