MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-37
INSPECTION
1. CAMSHAFT
Measure the cam height (length). Replace if it exceeds
the limit value.
Standard value:
Intake 35.79 mm
Exhaust 35.49 mm
Limit value:
Intake 35.29 mm
Exhaust 34.99 mm
2. LASH ADJUSTER
Caution
(1) The lash adjuster is a sophisticated part, so make
sure that foreign matter, such as dirt, does not
enter it.
(2) Do not disassemble the lash adjuster.
(3) When cleaning the lash adjuster, use clean diesel
oil.
(1) Prepare three vats and approx. five litres of diesel
oil.
Fill the vats with diesel oil so that the lash adjuster
will be submerged when placed standing in the vat.
(2) Submerge the lash adjuster in vat A, and clean the
outside.
NOTE
Use a nylon brush if the lash adjuster is heavily
contaminated.
For
preliminary
cleaningFor
cleaningFor
filling
diesel oil
ABC
Diesel oil

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-38
(3) Lightly press down on the steel ball inside using the
special tool MD998442. Remove all matter and
deteriorated oil adhered on the plunger by pressing the
tool back and forth five to ten times until the plunger
moves smoothly.
Caution
The steel ball spring’s load is extremely weak,
so if the special tool is pressed in with force,
the functions of the lash adjuster could be
damaged.
NOTE
The plunger movement must not snag at this time.
If the movement is abnormal, replace the lash adjuster.
(4) Remove the lash adjuster from the vat, and while
lightly pressing down on the steel ball, press the
plunger and removal all diesel oil, etc., inside the
pressure chamber.
Caution
Always face the oil hole on the side of the lash
adjuster toward vat A. Never face the oil hole
toward people.
(5) Submerge the lash adjuster in vat B. Lightly press
down on the steel ball inside using the special tool
MD998442. Clean the inside of the lash adjuster
pressure chamber by pressing the tool back and forth
five to ten times until the plunger moves smoothly.
Caution
The steel ball spring’s load is extremely weak,
so if the special tool is pressed in with force,
the functions of the lash adjuster could be
damaged.
(6) Remove the lash adjuster from the vat, and while
lightly pressing down on the steel ball, press the
plunger and removal all diesel oil, etc., inside the
pressure chamber.
Caution
Always face the oil hole on the side of the lash
adjuster toward vat A. Never face the oil hole
toward people.
MD998442Diesel oil
MD998442
Diesel oil
MD998442Diesel oil
MD998442
Diesel oil

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-39
(7) Submerge the lash adjuster in vat C, and lightly press
down on the steel ball inside using the special tool
MD998442.
Caution
Do not use vat C for cleaning. If vat C is used
for cleaning, foreign matter, etc., could enter the
pressure chamber when filling it with diesel oil.
(8) Stand the lash adjuster with the plunger at the top
position. Press down on the plunger with force, and
after it has reached the maximum stroke, gradually
return it. Then, release the steel ball to fill the pressure
chamber with diesel oil.
(9) Remove the lash adjuster from the vat, and stand
the lash adjuster with the plunger at the top position.
The plunger should not move when pressed down
with force.
NOTE
If the lash adjuster compresses, repeat steps (7) to
(9). Replace the lash adjuster if the same
phenomenon occurs even after diesel oil has been
filled in the pressure chamber (after the air has been
bled).
(10)Store the lash adjuster in the vertical state so that
the internal diesel oil will not spill out, and so that
foreign matter, such as dirt, will not adhere. Install
it onto the engine as soon as possible.
MD998442Diesel oil
MD998442Diesel oil

ENGINE OVERHAUL -Cylinder Head and Valve11B-40
CYLINDER HEAD AND VALVE
REMOVAL AND INSTALLATION
78±2N•m→Completely loosen
20±2N•m→90_+90_
2
1
Apply engine oil on
all sliding sections
before installing.
4
5
6
12
13
16
18
720
38
9
10
14
15
17
19
11
Removal steps
AA""DA1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AB""CA4. Retainer lock
5. Valve spring retainer
"BA6. Valve spring
7. Intake valve
AB""CA8. Retainer lock
9. Valve spring retainer
"BA10. Valve spring11. Exhaust valve
AC""AA12. Valve stem seal
13. Valve spring seat
AC""AA14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head

ENGINE OVERHAUL -Cylinder Head and Valve11B-41
REMOVAL SERVICE POINTS
AA"CYLINDER HEAD BOLT REMOVAL
Remove the cylinder head bolt using the special tool.
AB"RETAINER LOCK REMOVAL
Compress the valve spring using the special tool, and remove
the retainer lock.
NOTE
Attach a tag indicating the cylinder No. and installation position
onto the parts including the removed valve and springs so
that they can be reassembled later.
INSTALLATION SERVICE POINTS
"AAVALVE STEM SEAL INSTALLATION
1. Install the valve spring seat.
2. Install the valve.
3. Apply a small amount of engine oil on the valve stem
seal.
4. Using the valve stem as a guide, press in the valve guide
using the special tool.
Caution
Improper installation of the valve stem seal can lead
to oil reduction, so always install using the special
tool.
NOTE
Note that the valve stem seals for the intake side and
exhaust side are different.
MB991654
MD998772
MD998735
MB998737
Body colour:
GreyBody colour:
Grayish-green Intake side Exhaust side

ENGINE OVERHAUL -Cylinder Head and Valve11B-42
"BAVALVE SPRING INSTALLATION
Install the valve spring so that the painted surface faces the
rocker arm.
"CARETAINER LOCK INSTALLATION
Compress the valve spring using the special tool, and install
the retainer lock.
"DACYLINDER HEAD BOLT INSTALLATION
1. Before reusing the cylinder head bolt, confirm that the
bolt’s underhead length is less than the limit value.
Replace the bolt if it exceeds the limit value.
Limit value: 99.4 mm
2. Apply engine oil on the bolt threads and washer.
NOTE
Use the special tool to tighten the cylinder head bolt.
Painted
surfaceSpring
retainer
Stem
seal
Spring
seat
MD998772
MD998735
Underhead length
MB991654

ENGINE OVERHAUL -Cylinder Head and Valve11B-43
3. Following the tightening order, tighten at 78±2N•m.
4. Completely loosen the bolts.
5. Next, following the tightening order, tighten the loosened
bolts at the torque 20±2N•m again.
6. Make paint marks on the cylinder head bolt’s head and
cylinder head.
7. Following the tightening order, tighten the cylinder head
by 90_.
8. Tighten by another 90_, and confirm that the paint mark
made on the cylinder head bolt’s head and the paint
mark on the cylinder head are positioned on the same
line.
Caution
(1) If the tightening angle is less than 90_, the
connection performance may not be attained, so
take special care to the tightening angle when
tightening.
(2) If the tightening angle is larger than the specified
value, completely loosen the bolt and start again
from step 1.
INSPECTION
1. CYLINDER HEAD
(1) Before cleaning the cylinder head, check it for water
leaks, gas leaks, damage or cracks.
(2) Completely remove the oil, water deposits, sealant
and carbon, etc. After cleaning the oil path, blow
air and confirm that there is not clogging.
(3) Using a straight edge and thickness gauge, inspect
the flatness of the bottom of the cylinder head for
strain.
If the strain exceeds the limit value, grind the end
and correct the flatness.
Standard value for lower surface strain: 0.05 mm
Limit value for lower surface strain: 0.2 mm
Grinding limit value: 0.2 mm
Cylinder head height (standard value for new part):
131.9 - 132.1 mm
Caution
The grinding limit is within 0.2 mm together with
the combined cylinder block.
Timing belt side
86139
10 4 2 5 7
90_
90_
Paint marks

ENGINE OVERHAUL -Cylinder Head and Valve11B-44
2. VALVE
(1) If there is a faulty contact, one - sided contact or
improper seating with the valve seat, correct the valve
seat.
(2) Replace the valve if the margin exceeds the limit
value.
Standard value:
Intake 1.0 mm
Exhaust 1.5 mm
Limit value:
Intake 0.5 mm
Exhaust 1.0 mm
(3) Measure the total length of the valve, and replace
the valve if the length exceeds the limit value.
Standard value:
Intake 109.50 mm
Exhaust 109.70 mm
Limit value:
Intake 109.00 mm
Exhaust 109.20 mm
3. VALVE SPRING
(1) Measure the free height of the spring, and replace
the valve spring if the height exceeds the limit value.
Standard value: 48.3 mm
Limit value: 47.3 mm
(2) Measure the spring squareness, and replace the valve
spring if the inclination exceeds the limit value.
Standard value: 1.5_or less
Limit value: 4_
4. VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the clearance exceeds the limit value, replace
the valve guide, valve or both parts.
Standard value:
Intake 0.02 - 0.05 mm
Exhaust 0.05 - 0.09 mm
Limit value:
Intake 0.10 mm
Exhaust 0.15 mm
Contact
(Must be at
centre of face)
Margin
Total valve length
Squareness
Free height
Valve
guide
Stem outer
diameter Guide inner
diameter

ENGINE OVERHAUL -Cylinder Head and Valve11B-45
5. VALVE SEAT
Assemble the valve, and measure the amount that the
valve protrudes from the valve shaft end between the
spring seat surfaces when the valve is pressed against
the valve seat. Replace the valve seat if the protrusion
amount exceeds the limit value.
Standard value:
Intake 49.20 mm
Exhaust 48.40 mm
Limit value:
Intake 49.70 mm
Exhaust 48.90 mm
Valve Seat Correction
1. Before correcting the valve seat, inspect the clearance
between the valve guide and valve, and replace the valve
guide if necessary.
2. Correct so that the seat width and seat angle are at the
specified shape.
3. After correcting, apply wrapping compound, and fit the
valve and valve seat together.
Valve Seat Replacement
1. Grind off the valve seat to be replaced from the inside
to reduce the thickness and then remove the valve seat.
2. Machine the valve seat hole on the cylinder head to match
the diameter of the oversized valve seat into which it
is to be pressed in.
Intake valve seat hole diameter:
0.3 O.S. 35.30 - 35.33 mm
0.6 O.S. 35.60 - 35.63 mm
Exhaust valve seat hole diameter:
0.3 O.S. 33.30 - 33.33 mm
0.6 O.S. 33.60 - 33.63 mm
3. When pressing in the valve seat, cool the valve seat
with liquid nitrogen, and make sure that the inner diameter
of the cylinder head is not galled.
4. Refer to the “Valve Seat Correction” procedures, and
machine the valve seat.Valve shaft end
Spring seat surface Valve protrusion
amount
10_ 65_
10_65_ 0.9 - 1.3 mm
0.9 - 1.3 mm
43.5_-44_43.5_-44_
0.5 - 1.0 mm
0.5 - 1.0 mm Grind off
Valve
seat
height
Oversized hole diameter

ENGINE OVERHAUL -Cylinder Head and Valve11B-46
Valve Guide Replacement
1. Using a press, push the valve guide to the cylinder block
side.
2. Machine the valve guide hole on the cylinder head to
match the oversized valve guide into which it is to be
pressed in.
Caution
Do not use a valve guide having the same size as
the removed valve guide.
Valve guide hole diameter:
0.05 O.S. 12.05 - 12.07 mm
0.25 O.S. 12.25 - 12.27 mm
0.50 O.S. 12.50 - 12.52 mm
3. Press in the valve guide to the dimensions shown in
the illustration.
NOTE
(1) Press in the valve guide from the top of the cylinder
head.
(2) Note that the length of the valve guides differs.
Intake 45.5 mm
Exhaust 50.5 mm
4. After pressing in the valve guide, insert a new valve,
and confirm the sliding state.
19.2 - 19.8 mm