dimensions MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

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

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

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-69
3. CYLINDER BORING
(1) Select the oversized piston to be used using the
maximum inner diameter cylinder as a reference.
(2) There are two types of oversized pistons (0.50 mm,
1.00 mm), so bore so that the clearance is at the
specified value that matches the piston’s outer
diameter. The reference points for measuring the
piston’s outer diameter are shown in the illustration.
(3) Calculate the boring finish dimensions based on the
piston outer diameter measurement value.
Boring finish dimension = Piston outer diameter +
0.02 to 0.04 mm (clearance with cylinder) - 0.02 mm
(honing margin)
(4) Bore each cylinder to the boring finish dimensions
calculated above.
Caution
To prevent strain caused by a temperature rise
during boring, bore in the order of the No. 2→
No. 4→No. 1→No. 3 cylinders.
(5) Hone to the final finish dimension (piston outer
diameter + clearance with cylinder).
(6) Confirm the clearance between the piston and
cylinder.
Standard value: 0.02 - 0.04 mm
Piston outer diameter 11.65 mm

MANUAL TRANSMISSION OVERHAUL -Input Shaft22B-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
Accurately tap in the oil seal to the dimensions shown in
the illustration.
"BABALL BEARING INSTALLATION
Using the special tool, install the ball bearing onto the input
shaft.
"CASNAP RING INSTALLATION
Select and install the snap ring so that the input shaft front
bearing clearance is at the standard value.
Standard value: 0.01 mm tight to 0.12 mm loose
"DASYNCHRONIZER SPRING INSTALLATION
Accurately install the synchronizer spring onto the position
of the synchronizer ring shown in the illustration.
"EA3RD-4TH SPEED SYNCHRONIZER HUB
INSTALLATION
Install the 3rd-4th speed synchronizer hub onto the input
shaft at the direction shown in the illustration.Oil seal3.5 mm
MD998812
MD998813
MD998818 MD998801
Snap ring
Synchronizer spring
Identification mark3rd
speed
side
4th speed
side Installation
direction

MANUAL TRANSMISSION OVERHAUL -Output Shaft22B-31
AF"1ST SPEED GEAR SLEEVE REMOVAL
Using the special tool, remove the 1st speed gear sleeve
from the output shaft.
AG"TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing from
the output shaft.
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
Accurately tap in the oil seal to the dimensions shown in
the illustration.
"BATAPER ROLLER BEARING INSTALLATION
Using the special tool, install the roller bearing onto the output
shaft.
"CA1ST SPEED GEAR SLEEVE INSTALLATION
Using the special tool, install the 1st speed gear sleeve onto
the output shaft.
MD998801
Sleeve
MD998801Taper roller
bearing
Oil seal3.5 mm
MD998801MD998812
MD998819
Taper roller
bearing
MD998364SleeveMD998812
MD998814
MD998824

MANUAL TRANSMISSION OVERHAUL -Control Housing22B-41
DISASSEMBLY SERVICE POINT
AA"LOCK PIN REMOVAL
Tap out the lock pin from the direction shown in the illustration.
REASSEMBLY SERVICE POINTS
"AANEEDLE BEARING INSTALLATION
Press the needle bearing into the dimensions shown in the
illustration so that the type stamp side faces the indicated
direction.
"BAOIL SEAL INSTALLATION
Apply transmission oil on the oil seal lip section.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"CAAIR BREATHER INSTALLATION
(1) Apply sealant on the periphery of the insertion section.
Sealant
Specified sealant:
3M SUPER WEATHERSTRIP No.8001 or
equivalent
(2) Install so that the protrusion faces the direction shown
in the illustration.
Lock pin
Control
finger
Control
housing
Needle
bearing
2mm Type
stamp
side

REAR AXLE -Differential Carrier 27B-46
4. Clean the side bearing hub.
5. Place special tool between the side bearing hub of the
gear carrier, and position the notch as shown in the
illustration. Then tighten side bearing mounting bolt.
6. Use a thickness gauge to measure the clearance (A)
between special tools.
7. Remove special tools (MB990835, MB990326).
8. Use a micrometer to measure the shown dimensions (B,
C) of special tools.
9. Install the bearing cap, and then use a cylinder gauge
to measure inside diameter (D) of the bearing cap.
10. Calculate thickness (F) of the required drive pinion rear
shim twice by the following formula. Select a shim which
most closely matches this thickness.
F = A + B + C - 1/2D - 86.00 mm
11. Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using special tool.
"EADRIVE PINION TURNING TORQUE ADJUSTMENT
/OIL SEAL INSTALLATION
1. Insert the drive pinion into the gear carrier, and then install
the following parts in sequence from the carrier rear side.
Drive pinion spacer, drive pinion front shim and drive
pinion front bearing inner race, companion flange.
NOTE
Do not install the oil seal.
2. Tighten the companion flange to the specified torque by
using special tool.
Thickness
gauge
MB990392
(MB990835)Notch
MB990836
(MB990835)A
BC
Cylinder
gauge
Drive pinion
rear shim
MB990728
MB990850
186±29 N·m

INTERIOR -Special Tool/Instrument Panel52A-3
SPECIAL TOOL
ToolNumberNameApplication
MB990784Ornament removerRemoval of switches and trims
INSTRUMENT PANEL
REMOVAL AND INSTALLATION
The following bolts and screws are used for installing the instrument panel.
Bolts and screws are indicated as marks shown in the illustration in the sections of “Removal and Installation”
and “Disassembly and Reassembly.”
NameMarkDimensions mm
(screw diameter x
screw length)ColorShape
Tapping screwa5×16Black
b5×16-
c5×12-
Bolt with washerd6×16-
e6×12-