MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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 -Secondary Air System and Intake Manifold11B-28
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION
1
11±1N•m
23 4 5
6
7
8
9
10 1112
13
11±1N•m24±3N•m
14±1N•m
31±3N•m5±1N•m
20±2N•m
22±4N•m
36±6N•m23±4N•m
14±1N•m
36±6N•m
36±6N•m22±4N•m
49±5N•m
Removal steps
1. Exhaust manifold heat protector
2. Vacuum hose and pipe
"DA3. Air pipe assembly
4. Air control valve gasket
5. Air control valve assembly
6. Engine hanger
"CA7. Air control valve bracket"BA8. Manifold differential pressure (MDP)
sensor
9. O-ring
"AA10. Intake manifold stay
11. Alternator brace stay
12. Intake manifold
13. Intake manifold gasket

ENGINE OVERHAUL -Secondary Air System and Intake Manifold11B-29
INSTALLATION SERVICE POINTS
"AAINTAKE MANIFOLD STAY INSTALLATION
Check that the intake manifold stay is seated against the
intake manifold and cylinder block boss, and then tighten
at the specified torque 31±3N•m.
"BAMANIFOLD DIFFERENTIAL PRESSURE (MDP)
SENSOR INSTALLATION
Caution
Make sure not to apply impact against the sensor when
installing.
Do not use a sensor that has been dropped.
"CAAIR CONTROL VALVE BRACKET INSTALLATION
1. Temporarily tighten the air control valve bracket and
engine hanger with the bolt for tightening with the intake
manifold.
2. Tighten the bolt 1 shown in the illustration at the specified
torque 23±4N•m.
3. Tighten the bolt 2 shown in the illustration at the specified
torque 36±6N•m.
4. Tighten the bolt 3 shown in the illustration with the engine
hanger at the specified torque 22±4N•m.
"DAAIR PIPE ASSEMBLY INSTALLATION
1. Temporarily tighten air pipe assembly onto the air control
valve.
2. Tighten the bolts 1 and 2 shown in the illustration to
the exhaust manifold at the specified torque 49±5N•m.
3. Tighten the bolt 3 shown in the illustration to the air control
valve at the specified torque 24±3N•m.
4. Tighten the bolt 4 shown in the illustration to the cam
position sensor support at the specified toque 11±1
N•m.
5. Tighten the bolt 5 shown in the illustration to the exhaust
manifold at the specified torque 14±1N•m.
Intake manifold stay
1
23
1
5
23
4

ENGINE OVERHAUL -Exhaust Manifold11B-30
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
1
17±2N•m
2 3
45
6
78
910
11 1213
11±1N•m
14±1N•m 59±5N•m
9±1N•m 10±1N•m 44±5N•m
31±2N•m
42±7N•m 10±1N•m
55±10 N•m59±5N•m
19±1N•m 14±1N•m
42±7N•m
19±3N•m18 19
14
15
16
17
33±6N•m
47±6N•m
Removal steps
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting bracket
5. Exhaust fitting
6. Exhaust fitting gasket
7. Air outlet fitting
"CA8. Air outlet fitting gasket
9. Oil return pipe
10. Oil return pipe gasket"BA11. Oil return pipe gasket
12. Turbocharger assembly and pipe
assembly
13. Turbocharger gasket
14. Oil pipe
15. Water pipe B
16. Water pipe A
17. Turbocharger assembly
"AA18. Exhaust manifold
19. Exhaust manifold gasket

ENGINE OVERHAUL -Exhaust Manifold11B-31
INSTALLATION SERVICE POINTS
"AAEXHAUST MANIFOLD INSTALLATION
1. Lightly tighten the installation nut for the exhaust manifold.
2. Following the tightening order shown in the illustration,
tighten the M8 nuts at the tightening torque 29 N•m.
3. Following the tightening order shown in the illustration,
tighten the M10 nuts at the tightening torque 49 N•m.
4. Following the tightening order shown in the illustration,
tighten the M8 nuts again at the tightening torque 29
N•m.
5. Finally, following the tightening order shown in the
illustration, tighten the M10 nuts at the tightening torque
55±10 N•m, and tighten the M8 nuts at the tightening
torque 33±6N•m.
"BAOIL RETURN PIPE GASKET INSTALLATION
Assembly so that the protrusion of the oil return pipe gasket
on the oil pan side is at the position shown in the illustration.
NOTE
There is no designated assembly direction for the gasket
on the turbocharger side.
"CAAIR OUTLET FITTING GASKET
Assembly so that the protrusion of the air outlet fitting gasket
is at the position shown in the illustration.
7982 13456
Protrusion
Protrusion
AA

ENGINE OVERHAUL -Water Pump and Water Hose11B-32
WATER PUMP AND WATER HOSE
REMOVAL AND INSTALLATION
1
2
3
45
67
8
9
10 11
12
13
10±1N•m
14±1N•m 23±2N•m10±1N•m
13±2N•m10.8±1.0 N•m
29±10 N•m
1415 16
23±4N•m
23±4N•m
Removal steps
1. Water hose
2. Water hose
3. Water hose
4. Water hose
"DA5. Engine coolant temperature sensor
"CA6. Engine coolant temperature gauge
unit
"BA7. Water outlet fitting
8. Thermostat9. Thermostat housing
10. Gasket
"AA11. O-ring
"AA12. Water inlet pipe
"AA13. O-ring
14. Water pump
15. Water pump gasket
16. Knock sensor

ENGINE OVERHAUL -Water Pump and Water Hose11B-33
INSTALLATION SERVICE POINTS
"AAO-RING/WATER INLET PIPE INSTALLATION
Replace the O-ring for the water inlet pipe with a new part,
and apply water on the periphery of the O-ring so that it
can be inserted easily into the water pump and thermostat
housing.
Caution
(1) Never apply grease or oil, such as engine oil, on the
O-ring.
(2) Install the water inlet pipe onto the thermostat
housing, and then fix.
"BAWATER OUTLET FITTING INSTALLATION
Squeeze out form-in-place gasket at a 3 mm width, and apply
at the position shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"CAENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION
When reusing the bolts, apply the specified sealant on the
threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"DAENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
Apply the specified sealant onto the threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8731 or equivalent
Caution
Make sure that the tool does not contact the connector
section (resin section).

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-34
ROCKER ARM AND CAMSHAFT
REMOVAL AND INSTALLATION
1 2 3
4
5 6
78
910
111213
10±2N•m
14±1N•m
22±4N•m
11±1N•m
8.8±1.0 N•m
20±1N•m
14
15
16
Apply engine oil on
all sliding sections
before installing.
17
Removal steps
1. Cam position sensor
2. O-ring
3. Cover
4. Gasket
"FA5. Cam position sensing cylinder
"EA6. Cam position sensor support
"DA7. Camshaft oil seal
"CA8. Bearing cap, rear
"CA9. Bearing cap, front"CA10. Bearing cap No. 5
"CA11. Bearing cap No. 2
"CA12. Bearing cap No. 3
"CA13. Bearing cap No. 4
"BA14. Camshaft
15. Rocker arm
AA""AA16. Lash adjuster
17. Oil delivery body

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 -Rocker Arm and Camshaft11B-36
3. Apply sealant on the contact surfaces with the head shown
in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
4. Install the bearing caps onto the cylinder head, and in
two to three steps tighten strongly.
5. Finally, tighten at the specified torque 20±1N•m.
6. Confirm that the rocker arm is correctly installed.
NOTE
Wipe off all excessive sealant.
"DACAMSHAFT OIL SEAL INSTALLATION
Install the oil seal using the special tool.
"EACAM POSITION SENSOR SUPPORT
INSTALLATION
Apply a 3 mm width of form-in-place gasket at the position
shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"FACAM POSITION SENSING CYLINDER
INSTALLATION
1. Set the exhaust camshaft at the No. 1 compression top
dead centre.
NOTE
The shaft will rotate slightly in the counterclockwise
direction by the force of the exhaust valve spring.
2. Install the cam position sensing cylinder’s vane (small)
and vane (large) at the positions shown in the illustration.
MD998713
Vane (small)
Cam position
sensorVane (large)