service MITSUBISHI LANCER EVOLUTION 2007 Service Service Manual

ENGINE -Oil Pan11A-25
INSTALLATION SERVICE POINTS
"AAOIL PAN INSTALLATION
1. Remove sealant remained on the oil pan and the cylinder
block.
2. Apply sealant on the mounting surface of oil pan without
any gap as indicated in the figure, and install oil pan
on cylinder block.
Specified sealant:
MITSUBISHI GENUINE PART MD970389 or
equivalent
3. Tighten the mounting bolt of oil pan to the specified torque.
Be careful not to use a wrong bolt when tightening the
bolt as shown in the illustration.
Tightening Torque: 9.0±3.0 N·m
"BADRAIN PLUG GASKET INSTALLATION
Gasket should be replaced with a new one, and install it
in the direction specified in the figure.
"CAOIL RETURN PIPE GASKET INSTALLATION
Gasket should be replaced with a new one, and set the convex
part to the position as shown in the illustration for installation.
NOTE
There is no specific direction indicated for installing the
turbocharger side of the oil return pipe gasket.
INSPECTION
DCheck oil pan for cracks.
DCheck oil pan sealant - coated surface for damage and
deformation.
DCheck oil screen for cracked, clogged or damaged wire
net and pipe.
ø4 mm
at the groove
at the bolt hole
M6×8mm
Gasket
Oil Pan Side
Convex part

ENGINE -Crankshaft Oil Seal11A-27
REMOVAL SERVICE POINT
AA"FLYWHEEL BOLT REMOVAL
INSTALLATION SERVICE POINTS
"AACRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply small quantity of engine oil on the circumference
of oil seal lip.
2. Use special tool to press in oil seal up to the chamfered
surface of oil seal case.
"BAFLYWHEEL BOLT INSTALLATION
Use the special tool to fix the flywheel and tighten the bolt
to the specified torque in the same way as that for removal.
Tightening Torque: 132±5 N·m
"CACRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply small quantity of engine oil on the circumference
of oil seal lip.
2. Use special tool to press in oil seal up to the chamfered
surface of oil seal case.
"DACRANKSHAFT SPROCKET B INSTALLATION
1. Clean and degrease crankshaft sprocket B and crankshaft
sprocket B mounting surface of crankshaft.
NOTE
Degrease to prevent the friction coefficient of pressed
surface from dropping by stuck oil.
2. Position crankshaft sprocket B to the direction as shown
in the illustration.
MD998781
Crankshaft
Oil Seal
MB990938
MD998776
MD998382
Oil Seal
Crankshaft
MD998285
(oil applied to the
circumference)
Crankshaft
sprocket B
Degrease
Engine FrontCrankshaft

ENGINE -Cylinder Head Gasket11A-28
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Caution
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.
Pre-removal and Post-installation Operation
DFuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.)
DFuel Leak Check
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
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 Assembly Removal and Installation (Refer to GROUP 15.)
DAir Hose E, Air Pipe C, Air hose D Removal and Installation (Refer to GROUP 15 - Intercooler.)
DBattery Removal and Installation
DCenter Cover Removal and Installation (Refer to P.11A-17.)
DAccelerator Cable Removal and Installation (Refer to GROUP 17.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DSecondary Air Control Valve Bracket Removal and Installation (Refer to GROUP 15 - Secondary Air Supply System.)
DCrossmember Bar Removal and Installation (Refer to GROUP32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15.)
DStarter Removal and Installation (Refer to GROUP 16.)
DTiming Belt Removal and Installation (Refer to P.11A-34.)

ENGINE -Cylinder Head Gasket11A-31
REMOVAL SERVICE POINT
AA"CYLINDER HEAD BOLTS REMOVAL
Use the special tool to loosen the bolt in 2 to 3 times in
the order of the numbers shown in the illustration for removal.
INSTALLATION SERVICE POINTS
"AACYLINDER HEAD GASKET INSTALLATION
1. Remove residual gasket attached on the mounting surface
of the gasket.
Caution
Do not let contaminants get into engine coolant, oil
passage or cylinder.
2. With individual holes of cylinder head aligned on individual
holes of cylinder head gasket, install cylinder head gasket
on cylinder head.
"BACYLINDER HEAD BOLTS INSTALLATION
1. Ensure that the length under head of cylinder head bolts
is under the limit value. When the measured value exceeds
the limit value, replace the bolt with new one.
Limit (A): 99.4 mm
2. Apply small quantity of engine oil at the threads of cylinder
head bolts and the washers.
1
5
4
2
7
38
69
10
Engine Front
MB991654
A
(Engine oil)

ENGINE -Timing Belt and Timing Belt B11A-35
12
1314 1516
8.8±1.0 N·m
162±5 N·m 19±3 N·m
(Engine oil)
12. Crank angle sensor
AB""CA13. Crankshaft sprocket
"CA14. Crankshaft sensing blade"BADTiming belt B tension adjustment
"AA15. Timing belt B tensioner
AC""AA16. Timing belt B
REMOVAL SERVICE POINTS
AA"TIMING BELT REMOVAL
1. Rotate the crankshaft clockwise and mate timing marks
with each other to position No.1 cylinder at compression
TDC.
Caution
Ensure that the crankshaft always rotates clockwise.
2. Loosen the mounting bolt of the tensioner pulley and
remove the timing belt.
Caution
When the timing belt is reused, use a chalk to indicate
an arrow of rotation direction on the back of the belt
so that it can be re-assembled in the same direction
as before.
AB"CRANKSHAFT SPROCKET REMOVALTiming Mark
MB991367
Crankshaft
sprocket
MB991385

ENGINE -Timing Belt and Timing Belt B11A-36
AC"TIMING BELT B REMOVAL
Caution
When the timing belt B is reused, use a chalk to indicate
an arrow of rotation direction on the back of the belt
so that it can be re-assembled in the same direction as
before.
INSTALLATION SERVICE POINTS
"AATIMING BELT B/TIMING BELT B TENSIONER
INSTALLATION
1. Check that timing marks of crankshaft sprocket B and
balancer shaft sprocket are aligned with each other.
2. Install timing belt B to crankshaft sprocket B and balancer
shaft sprocket. Prevent the tension side of the belt from
sagging.
3. Position the center of the timing belt tensioner B at the
center or upper left of the mounting bolt and flange pulley
at the engine front to assemble and fix them temporarily.
4. Adjust the tension of timing belt B.
"BATIMING BELT B TENSION ADJUSTMENT
1. Apply force to the timing belt B tensioner in the direction
indicated by the arrow to give tension torque (3.0±0.4
N·m) to the timing belt B so that the tension side of the
timing belt B can become tense. Maintaining the condition,
tighten the mounting bolt to the specified torque for fixing.
Tightening Torque: 19±3 N·m
Caution
Be careful not to let the tensioner rotate together when
tightening the mounting bolt. If the tensioner rotates
together, belt tension becomes too much.
2. Measure the tension of timing belt B by following
procedures.
Standard value:
ItemWhen adjustedWhen replaced
Vibration frequency
Hz76 - 9276 - 92
Deflection mm
(Reference)5-75-7
Crankshaft
sprocket B
Timing
mark
Timing Mark
Belt Tension Side
Balancer shaft
sprocket
Center of
the pulley
Center of the
mounting bolt

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-46
REMOVAL SERVICE POINTS
AA"DRIVE BELT REMOVAL
Due to the adoption of the Serpentine drive system with the
auto-tensioner, the following operation is required:
1. Insert the 12.7sq. spinner handle into the tool hole of
the auto-tensioner and rotate it counterclockwise until
the auto-tensioner reaches to the stopper.
2. Align hole A with hole B for fixing by inserting the L
shaped-hexagon wrench, then remove the drive belt.
Caution
When the drive belt is reused, use a chalk to indicate
an arrow of rotation direction on the back of the belt
so that it can be re-assembled in the same direction
as before.
AB"POWER STEERING OIL PUMP, BRACKET AND
OIL RESERVOIR ASSEMBLY / A/C COMPRESSOR
REMOVAL
Remove the power steering oil pump, bracket, oil reservoir
and A/C compressor with the hose attached from the bracket.
NOTE
Tie the removed oil pump and A/C compressor with a rope
and set aside where they cannot hinder the removal of the
engine assembly.
AC"ENGINE MOUNTING BRACKET AND STOPPER
ASSEMBLY REMOVAL
1. Support the engine with a garage jack.
2. Remove special tool (MZ203827).
(Tool used for removal of transmission assembly)
3. Hold the engine assembly with a chain block.
4. Support the engine oil pan with a garage jack via a block
of wood cut without applying the weight of the engine
and remove the engine mounting bracket and stopper
assembly.
Bore A
L-shaped
hexagon
wrench
Bore B
MZ203827
MB991453
MB991453

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

11B-1
ENGINE
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 3..........................
Service Specifications 3.........................
Machining Standards 5.........................
Tightening Torque 5............................
Sealants 8.....................................
Form-In-Place Gasket 8........................
SPECIAL TOOLS 9...........................
ALTERNATOR AND IGNITION SYSTEM 12....
TIMING BELT 13.............................
FUEL SYSTEM 26............................SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 28...............................
EXHAUST MANIFOLD 30.....................
WATER PUMP AND WATER HOSE 32........
ROCKER ARMS AND CAMSHAFT 34.........
CYLINDER HEAD AND VALVE 40.............
OIL PUMP AND OIL PAN 47.................
PISTON AND CONNECTING ROD 56..........
CRANKSHAFT AND CYLINDER BLOCK 64....