check oil MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

ENGINE -Timing Belt and Timing Belt B11A-39
"FATIMING BELT INSTALLATION
1. Check that timing marks of camshaft sprocket, crankshaft
sprocket, and oil pump sprocket are aligned with each
other.
2. After aligning the timing marks of the oil pump sprocket,
remove the cylinder block plug and insert a Phillips screw
driver with a shaft diameter of 8 mm through the plug
hole to check that the shaft of the screw driver can be
inserted for 60 mm or more. If the screw driver makes
contact with the balancer shaft and can be inserted for
only 20 - 25 mm, turn the sprocket for one round and
align timing marks again to check that screw driver can
be inserted for 60 mm or more. Do not take the screw
driver out before completing installation of the timing belt.
3. Position the timing belt without having any slack at the
tension side of the belt.
(1) Hook the timing belt to the crankshaft sprocket, the
oil pump sprocket, and the idler pulley in the sequence.
Timing Mark
Timing
Mark
Timing
Mark
Crankshaft
sprocket
Oil pump
sprocket
Camshaft
sprocket
8mm
60 mm or more
Balancer
shaft
Plug
Starter
Intake
camshaft
sprocketExhaust
camshaft
sprocket
Idler
pulley
Oil pump
sprocketCrankshaft
sprocket
Tensioner
pulley

ENGINE -Timing belt and timing belt B11A-42
INSPECTION
AUTO-TENSIONER CHECK
1. Check the sealant for oil leakage and replace if necessary.
2. Check the rod end for wear or damage and replace if
necessary.
3. Measure the deflection of the rod end pressed against
the metal (cylinder block, etc) with the force of 98 - 196
N while holding the auto-tensioner with a hand.
Standard value: Within 1 mm
A: Length in the released state
B: Length in the pressed state
A - B: Deflection
4. If the value is outside the standard value, replace the
auto-tensioner.
TIMING BELT B TENSION CHECK
1. Measure the tension of timing belt B by following
procedures.
Standard value:
ItemWhen checked
Vibration frequency Hz52 - 92
Deflection mm (Reference)5-10

Tap the center of the belt between the pulleys (arrow),
and check that the belt vibration frequency is within the
standard values.
NOTE
For the vibration frequency measurement using the
MUT-II, refer to P11A-37.

Apply a force of approx.100N to the middle (arrow part)
of pulley shown in the figure, and check that the deflection
is within the standard value.
2. If it is outside the standard value, re-adjust belt tension.
(Refer to P.11A-36.)
AB
Auto-tensioner
98 - 196 N
Deflection
Rod
MB991668
10 - 20 mm
15_
15_
Gently tap with
your finger
Deflection
Approx.
100 N

ENGINE -Engine Assembly11A-43
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched.
2. Tightening sections indicated in the mark (*) should be finally tightened with engine weight
applied on the body after lightly tightening.
Pre-removal and Post-installation Operation
DFuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.)
DFuel Leak Check
DRemoval and Installation of Hood (Refer to GROUP 42.)
DRemoval and Installation of Strut Tower Bar (Refer to GROUP 42.)
DRemoval and Installation of Under Cover (Refer to GROUP 51 - Front Bumper.)
DRemoval and Installation of Side Cover.
DDrive Belt Tension Check (Refer to P.11A - 7.)
DAccelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
DDrainage and Refilling Engine Oil(Refer to GROUP 12 - On-vehicle Service.)
DDrainage and Refilling of Engine Coolant (Refer to GROUP 14 - On-vehicle Service.)
DAir Cleaner Removal and Installation (Refer to GROUP 15)
DRemoval and Installation of Air Pipe C, Air Pipe B and Air Hose A (Refer to GROUP 15 - Intercooler.)
DBattery and Battery Tray Removal and Installation
DRemoval and Installation of Center Cover (Refer to P.11A - 17.)
DRemoval and Installation of Accelerator Cable (Refer to GROUP 17.)
DRemoval and Installation of Radiator (Refer to GROUP 14.)
DRemoval and Installation of Crossmember Bar (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DRemoval and Installation of Front Exhaust Pipe (Refer to GROUP 15.)
DRemoval and Installation of Air Outlet Fitting (Refer to GROUP 15 - Exhaust manifold.)

ENGINE -Engine Assembly11A-47
AD"ENGINE ASSEMBLY REMOVAL
After checking that all the cables, hoses, and harness
connectors have been disconnected, lift the engine with a
chain block slowly and remove the engine assembly located
at the upper engine room.
INSTALLATION SERVICE POINTS
"AAENGINE ASSEMBLY INSTALLATION
Install the engine assembly while checking that none of cables,
hoses, or harness connectors, etc. has been engaged.
"BAENGINE MOUNTING BRACKET AND STOPPER
ASSEMBLY INSTALLATION
1. Support the engine oil pan with a garage jack via a block
of wood cut adjusting the engine position and install the
engine mounting bracket and stopper assembly. Position
the engine mounting stopper so that a mark indicated
by an arrow can face the direction shown in the illustration.
2. Support engine with garage jack.
3. Remove the chain block and hold the engine assembly
with the special tool.(Tool used for removal of transmission
assembly)
"CAO-RING/FUEL HIGH PRESSURE HOSE
INSTALLATION
1. Apply small quantity of new engine oil on O-ring.
Caution
Do not let engine oil get into the delivery pipe.
2. Install the fuel high pressure pipe to the delivery pipe
rotating in both directions without damaging the O-ring
and check that it rotates smoothly.
3. In case of not rotating smoothly, remove the fuel high
pressure hose and insert it to the delivery pipe again
after checking damage of the O-ring since there is a
possibility of O-ring engagement.
4. Tighten fuel high pressure hose mounting bolt to the
specified torque.
Tightening Torque: 5.0±1.0 N·m
Engine mounting stopper
Engine side

Engine side

ENGINE OVERHAUL -Specifications11B-7
Items Tightening torque N·m
Water outlet fitting bolt10±1
Thermostat housing bolt23±4
Water inlet pipe bolt (M6)10±1
Water inlet pipe bolt (M8)13±2
Water pump bolt14±1
Knock sensor23±2
Rocker arm, camshaft
Cam position sensor bolt8.8±1.0
Cover bolt10±2
Cam position sensing cylinder bolt22±4
Cam position sensor support bolt14±1
Bearing cap bolt20±1
Oil delivery body bolt11±1
Cylinder head, valve
Cylinder head bolt78±2→Completely loosen→20±2→90_+90_
Oil pump, oil pan
Drain plug39±5
Oil pan bolt9±3
Oil screen bolt19±3
Baffle plate bolt22±4
Oil pressure switch19±3
Oil cooler bypass valve54±5
Relief plug44±5
Oil filter bracket bolt19±3
Plug cap23±3
Flange bolt36±3
Oil pump case bolt23±3
Oil pump cover bolt17±1
Oil pump cover screw10±2
Piston, connecting rod
Connecting rod cap nut20±2+90_-94_
Crankshaft, cylinder block
Flywheel bolt132±5
Rear plate bolt11±1
Bell housing cover bolt9±1
Rear oil seal case bolt11±1
Beam bearing cap bolt25±2+90_- 100_
Check valve32±2
Throttle body
Throttle position sensor bolt2.0±0.5
Turbocharger
Waste gate actuator bolt11.3±1.5

ENGINE OVERHAUL -Timing Belt11B-24
INSPECTION
1. TIMING BELT
Inspect each section of the belt in detail, and if any of
the following type of damage is found, replace the belt
with a new part.
(1) Hardening of backface rubber.
The backface is glossy, marks are not made even
when a fingernail is run cross it, and there is no
elasticity.
(2) Cracking of backface rubber.
(3) Cracking of canvas.
(4) Cracking at root.
(5) Cracking on side of belt.
(6) Abnormal wear on side of belt.
NOTE
The state is normal if the cutting surface is neat as
if cut with a sharp knife.
(7) Abnormal wear of teeth.
First stages: Canvas is worn (canvas fibres are raised,
rubber is removed and whitish, and canvas seams
are unclear).
Latter stages: Canvas is worn off, and rubber is
exposed (face width is narrow).
(8) Teeth are missing.
2. AUTO TENSIONER
(1) Check for oil leaks. If any leaks are found, replace.
(2) Check whether the rod end is worn or damaged,
and replace if necessary.
(3) Measure the rod protrusion length. If not at the
standard value, replace the auto tensioner.
Standard value: 12 mm
Crack
Crack
Peeling of canvas
Cracking
on side
Cracking at root
Edges are rounded
Abnormal wear
(The core wires are frayed.)
Rubber exposed due to
worn canvas
Teeth are missing
12 mm

ENGINE OVERHAUL -Fuel System11B-27
INSTALLATION SERVICE POINTS
"AAINJECTOR INSTALLATION
1. Apply a small amount of new engine oil on the O-ring.
2. While rotating the injector to the left and right, insert the
O-ring into the delivery pipe while taking care not to
damage it.
Caution
Make sure that the engine oil does not enter the
delivery pipe.
3. Confirm that the injector rotates smoothly. If it does not
rotate smoothly, the O-ring may be biting in. Remove
the injector, check the O-ring for damage, and then insert
it into the delivery pipe. Check the rotation again.
"BAFUEL PRESSURE REGULATOR INSTALLATION
1. Apply a small amount of new engine oil on the O-ring.
2. While rotating the fuel pressure regulator to the left and
right, insert the O-ring into the delivery pipe while taking
care not to damage it.
Caution
Make sure that the engine oil does not enter the
delivery pipe.
3. Confirm that the fuel pressure regulator rotates smoothly.
If it does not rotate smoothly, the O-ring may be biting
in. Remove the fuel pressure regulator, check the O-ring
for damage, and then insert it into the delivery pipe. Check
the rotation again.
"CATHROTTLE BODY GASKET INSTALLATION
Assembly so that the protrusion on the throttle body gasket
is at the position shown in the illustration.
Protrusion

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-35
REMOVAL SERVICE POINT
AA"LASH ADJUSTER REMOVAL
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
INSTALLATION SERVICE POINTS
"AALASH ADJUSTER INSTALLATION
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
Assembly the lash adjuster onto the rocker arm while taking
care not to spill out diesel oil in it.
"BACAMSHAFT INSTALLATION
1. Apply engine oil on the camshaft journal and cam.
2. Install the camshaft onto the cylinder head.
Caution
Do not mistake the intake and exhaust camshafts.
There is a 4 mm width slit on the back end of the
exhaust side camshaft.
"CABEARING CAP INSTALLATION
1. Set the camshaft’s dowel pin to the approximate top.
2. The bearing caps No. 2 to 5 have the same shape. Check
the identification symbol before installing to prevent
mistaking the cap No., intake side and exhaust side.
Identification symbol
(Stamped on front and on No. 2 to 5 bearing caps)
I : Intake side
E : Exhaust side
Timing belt side
Slit
Exhaust side
Dowel pins
Cap No.
Identification
of IN side and
EX side

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 -Oil Pump and Oil Pan11B-54
"MADRAIN PLUG GASKET INSTALLATION
Replace the gasket with a new part, and install at the direction
shown in the illustration.
Caution
Incorrect installation direction will lead to oil leaks.
"NAOIL FILTER INSTALLATION
1. Clean the installation surface on the cylinder block side.
2. Apply engine oil on the O-ring for the oil filter.
3. Screw in the oil filter, and tighten approx. 3/4 of a rotation
(approx. 14±2N•m) from where the O-ring contacts
the installation surface.
INSPECTION
1. COUNTER BALANCE SHAFT
(1) Make sure that the oil hole is not clogged.
(2) Check the journal (bearing section) for seizure or
damage, and check the state of contact with the
bearings. If any faults are found, replace the counter
balance shaft, bearing or oil pump case assembly.
2. OIL COOLER BYPASS VALVE
(1) The valve must move smoothly.
(2) The L dimension must be at the standard value at
a constant temperature, constant humidity state.
Standard value: 34.5 mm
(3) The protruded dimensions must be at the standard
value after submerging into 100_C oil.
Standard value: 40 mm
Drain plug
Oil pan
Oil pan side Gasket
Bracket side
L
Valve