lock MITSUBISHI LANCER EVOLUTION VI 1999 Owner's Manual

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-52
REMOVAL SERVICE POINTS
AOIL PAN REMOVAL
(1) Remove all oil pan bolts.
(2) Drive in the special tool between the cylinder block and
oil pan.
NOTE
Never use a screwdriver or chisel, instead of the service
tool, as a deformed oil pan flange will result in oil leakage.
BPLUG REMOVAL
(1) Fit special tool MD998162 on the plug, and then hold
it in position with special tool MD998783.
(2) Loosen the plug.
(3) Remove the special tools MD998783 and MD998162 and
then the plug.
CFLANGE BOLT REMOVAL
(1) Remove the plug on the side of cylinder block.
(2) Insert a Phillips screwdriver (shank diameter 8 mm) into
the plug hole to lock the counterbalance shaft.
(3) Loosen the flange bolt.
DCOUNTERBALANCE SHAFT FRONT BEARING
REMOVAL
Using the special tool, remove the counterbalance shaft front
bearing from the cylinder block.
NOTE
Be sure to remove the front bearing first.
If it has not been removed, the Rear Bearing Puller cannot
be used.
6EN0698
MD998727
MD998162
MD998783
6EN1026
Plug
Screwdriver
6EN0565

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-53
ECOUNTERBALANCE SHAFT REAR BEARING
REMOVAL
Using the special tool, remove the left counterbalance shaft
rear bearing from the cylinder block.
NOTE
When removing the left counterbalance shaft rear bearing,
install the special tool (MB991603) in front of the cylinder
block.
INSTALLATION SERVICE POINTS
ARIGHT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Apply engine oil to the outer surface of bearing.
(2) Using special tools, install right rear bearing. Make sure
that oil hole of bearing is aligned with oil hole of cylinder
block.
BLEFT COUNTERBALANCE SHAFT REAR
BEARING INSTALLATION
(1) Install the special tool (Guide Plate) to the cylinder block.
(2) Apply engine oil to the rear bearing outer circumference
and bearing hole in the cylinder block.
(3) Using the special tool, install the rear bearing.
NOTE
The left rear bearing has no oil holes.
MB991603
6EN1034
MD998705
MB991603
6EN0557
MB991603Rear bearing
MD998705

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-54
CCOUNTERBALANCE SHAFT FRONT BEARING
INSTALLATION
Using special tools, install front bearing.
DCOUNTERBALANCE SHAFT OIL SEAL
INSTALLATION
Using a suitable socket wrench, install the counterbalance
shaft oil seal into the front case.
EOIL PUMP OIL SEAL INSTALLATION
Using a suitable socket wrench, install the oil pump oil seal
into the front case.
FCRANKSHAFT FRONT OIL SEAL INSTALLATION
Using the special tool, install the crankshaft front oil seal
into the front case.
6EN1035
MD998705
MD998705
Bearing
Cylinder block

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-55
GOIL PUMP DRIVEN GEAR / OIL PUMP DRIVE
GEAR INSTALLATION
Apply engine oil amply to the gears and line up the alignment
marks.
HFRONT CASE ASSEMBLY INSTALLATION
(1) Set the special tool on the front end of crankshaft and
apply a thin coat of engine oil to the outer circumference
of the special tool to install the front case.
(2) Install the front case assembly through a new front case
gasket and temporarily tighten the flange bolts (other
than those for tightening the filter bracket).
ISEALANT APPLICATION TO OIL PRESSURE
SWITCH
Coat the threads of switch with sealant and install the switch
using the special tool.
Specified sealant: 3M
TM AAD Part No. 8672 or equivalent
Caution
(1) Keep the end of the thread portion clear or sealant.
(2) Avoid an overtightening.
JFLANGE BOLT INSTALLATION
(1) Insert a Phillips screwdriver into a hole in the left side
of the cylinder block to lock the silent shaft.
6EN0564

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-56
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
KPLUG INSTALLATION
(1) Install a new O-ring to the groove of the front case.
(2) Install the plug to the front case.
(3) Fit the special tool MD998162 on the plug, and then
hold it in position with special tool MD998783.
(4) Tighten the plug to the specified torque.
(5) Remove the special tools MD998783 and MD998162.
LOIL PAN INSTALLATION
(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
NOTE
1. Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
2. After installation, keep the sealed area away from
the oil and coolant for approx. one hour.
(3) Note the difference in bolt lengths at the location shown.
MD998162
MD998783
6EN0213
Bolt hole
portionGroove
portion

ENGINE – Piston and Connecting Rod11-63
CPISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
1. The ring end is provided with identification mark.
ItemIdentification mark
No. 1 ring1R
No. 2 ring2R
2. Install piston rings with identification mark facing up,
to the piston crown side.
3. Size marks on position rings are as follows.
SizeSize mark
StandardNone
0.50 mm oversize50
1.00 mm oversize100
DPISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate the crankshaft so that crank pin is on the center
of cylinder bore.
(4) Use suitable thread protectors on the connecting rod bolts
before inserting piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
ECONNECTING ROD BEARINGS INSTALLATION
When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.
9EN0524
Identification mark
Identification mark
Side mark
No. 1
No. 2
Timing belt side

ENGINE – Piston and Connecting Rod11-64
(2) The connecting rod bearing identification mark is stamped
at the position shown in the illustration.
Crankshaft pinConnecting rod bearing
Classi-
ficationIdentifica-
tion markIdentifi-
cation
colorO. D. mmIdenti-
fication
markThickness mm
Produc-
tion partService
part
1NoneYellow44.995 – 45.00001.483 – 1.487
2NoneNone44.985 – 44.99511.487 – 1.491
3NoneWhite44.980 – 44.98521.491 – 1.495
Connecting rod I.D.: 48.000 – 48.015 mm
(3) Select a proper bearing from the above table on the basic
of the identification data confirmed under items (1) and
(2).
[Example]
If the measured value of a crankshaft pin outer diameter
is 44.996 mm, the pin is classified as “1” in the table.
In case the crankshaft is also replaced by a spare part,
check the identification colors of the pins painted on the
new crankshaft. If the color is yellow, for example, the
pin is classified as “1”. In the above cases, select the
connection rod bearing having identification mark “0”.
FCONNECTING ROD CAP INSTALLATION
(1) Verifying the mark made during disassembly, install the
bearing cap to the connecting rod. If the connecting rod
is new with no index mark, make sure that the bearing
locking notches come on the same side as shown.
(2) Make sure that the connecting rod big end side clearance
meets the specification.
Standard value: 0.10 – 0.25 mm
Limit: 0.4 mm
Identification mark

ENGINE – Crankshaft and Flywheel11-67
CRANKSHAFT AND FLYWHEEL
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
1 2
3
4 56
78 910 11 12
13 1415
25 Nm + 9011 Nm132 Nm
9 Nm
11 Nm
32 Nm11 Nm
Removal steps
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
E5. Oil seal case
D6. Oil seal
C7. Beam bearing cap bolt
C8. Beam bearing capB9. Crankshaft bearing lower
10. Crankshaft
B11. Crankshaft bearing upper
A12. Crankshaft thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block

ENGINE – Crankshaft and Flywheel11-68
INSTALLATION SERVICE POINTS
ACRANKSHAFT THRUST BEARING INSTALLATION
(1) Install the two thrust bearing in the number 3 bearing
bore in the cylinder block. For easier installation, apply
engine oil to the bearings; this will help hold them in
position.
(2) The thrust bearings must be installed with their groove
side toward the crankshaft web.
BCRANKSHAFT BEARING INSTALLATION
(1) From the following table, select a bearing whose size
is appropriate for the crankshaft journal outside diameter.
Groove
Identification color of crankshaft journal
Bearing bore size
identification mark
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Rear face of
cylinder block Bottom of
cylinder block No. 1 No. 2No. 3
No. 4No. 5

ENGINE – Crankshaft and Flywheel11-69
Crankshaft journal outside diameterCylinder block bearing boreCrankshaft bearing
Identification colorSize mmIdentification markIdentification mark or color
Yellow56.994 – 57.00000 or Black
11 or Green
22 or Yellow
None56.988 – 56.99401 or Green
12 or Yellow
23 or None
White56.982 – 56.98802 or Yellow
13 or None
24 or Blue
For example, if the crankshaft journal outside diameter
ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “1”.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
CBEARING CAP / BEARING CAP BOLT
INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.Crankshaft bearing size
identification mark or color
Identification
mark or color
UpperGroove
Lower
9EN0477
Shank length