MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE OVERHAUL -Piston and Connecting Rod11B-57
REMOVAL SERVICE POINTS
AA"CONNECTING ROD CAP REMOVAL
Note the cylinder No. on the side of the connecting rod’s
large end for identification during reassembly.
AB"PISTON PIN REMOVAL
The special tool’s piston pin setting tool (MD998780) is
configured of the parts shown in the left illustration.
1. Insert the special tool’s push rod in from the front mark
(arrow) side of the piston’s front face, and install guide
C.
2. Set the piston and connecting rod assembly onto the
special tool’s piston pin setting base so that the front
mark faces upward.
3. Push out the piston pin using a press.
NOTE
After removing the piston pin, group the piston, piston
pin and connecting rod for each cylinder No.
Cylinder No.
Push rod
Guide BGuide A: 17.9 mm
Guide A: 18.9 mm
Guide A: 20.9 mm
Guide A: 21.9 mm BaseGuide C
Push rod
Front mark
Guide C
Base Front
mark

ENGINE OVERHAUL -Piston and Connecting Rod11B-58
INSTALLATION SERVICE POINTS
"AAPISTON PIN INSTALLATION
1. Measure the length of the following parts.
A : Piston pin installation section
B : Between piston boss
C : Piston pin
D : Connecting rod
2. Calculate using the following expression.
L = ((A - C) - (B - D))÷2
3. Insert the special tool’s push rod into the piston pin, and
remove guide A.
4. Align the piston and connecting rod front marks, and
assemble.
5. Apply engine oil on the periphery of the piston pin.
6. Insert the guide A side of the piston pin assembled in
step 3 into the pin hole from the front mark side of the
piston.
7. Screw guide B into guide A, and assemble so that the
clearance is the value 3 mm more than the value (L)
obtained in step 2.
8. Set onto the special tool’s piston setting base so that
the front mark faces upward.
9. Press in the piston pin using a press. If the press in
load is less than the standard value, replace the piston
pin (piston assembly), connecting rod or both parts.
Standard value: 7,355 - 17,162 N
Connecting rod
PistonPiston pin
BA DC
3mm+L
Guide B
Guide A
Push rod
Piston pin
Front mark
Front
mark
Guide A
Guide BBase

ENGINE OVERHAUL -Piston and Connecting Rod11B-59
"BAOIL RING INSTALLATION
1. Assemble the oil ring’s spacer into the piston ring groove.
Next, assemble the upper side rail, and then assemble
the lower side rail.
NOTE
(1) Install so that the side rail and spacer closed gaps
are at the position shown in the illustration.
(2) The following identification colours are applied on
the spacer and side rail (new parts) according to the
size.
SizeIdentification colour
S.T.D.None
0.50 mm O.S.Blue
1.00 mm O.S.Yellow
2. The side rail can be assembled easily by fitting one end
of the side rail into the piston groove and then pressing
on it with fingers as shown in the illustration.
Caution
The side rail’s closed gap could break if it is spread
open with a ring expander in the same manner as
the other piston rings.
3. After assembling into the piston, check that the side rail
rotates smoothly in either direction.
"CAPISTON RING NO. 2/PISTON RING NO. 1
INSTALLATION
Using a piston ring expander, assemble the ring with the
identification mark facing upward.
Identification mark
No. 1 ring 1R
No. 2 ring 2R
NOTE
The following size marks are stamped on the piston ring
according to the size.
SizeSize mark
S.T.D.(None)
0.50 mm O.S.50
1.00 mm O.S.100
Spacer closed gap Upper
side
rail
closed
gapLower
side
rail
closed
gap
Side rail edge
Piston ring expander
Identification
mark: 2RSize marks
No. 1
No. 2 Identification mark: 1R

ENGINE OVERHAUL -Piston and Connecting Rod11B-60
"DAPISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
1. Apply sufficient engine oil on the piston ring’s periphery,
piston ring and oil ring.
2. Align the piston ring and oil ring (side rail, spacer) closed
gap positions as shown in the illustration.
3. Insert the piston and connecting rod assembly from the
top of the cylinder so that the front mark (arrow) on the
piston’s front face faces the camshaft sprocket side.
4. Securely hold the piston ring with a ring band, and insert
the piston and connecting rod assembly.
Caution
(1) The piston ring could break if tapped in with force.
(2) Make sure not to contact the oil jet when tapping
in.
"EACONNECTING ROD BEARING INSTALLATION
When replacing the bearing, use the following procedure to
select and assemble the bearing.
1. Measure the diameter of the crankshaft pin, and confirm
the class shown below.
When using a spare part, each identification colour is
painted at the position shown in the illustration.
2. The identification marks of the connecting rod bearings
are attached at the position shown in the illustration.
Crankshaft pin sectionConnect-
ing rod
bearing
ClassProduct
identifica-
tion colourSpare
part iden-
tification
colourDiameter mmIdentifica-
tion mark
1NoneYellow44.995 - 45.0000
2NoneNone44.985 - 44.9951
3NoneWhite44.980 - 44.9852
3. Select the bearing from the above table according to
the identification confirmed in steps 1 and 2.
Example of selecting bearing
If the measured outer diameter of the crankshaft pin is
44.996 mm, Class 1 applies, and the spare part
identification colour is yellow. Thus, select a bearing with
identification mark 0.
Side rail No. 1 ring
Side rail
No. 2 ring spacer
Piston pin
No. 4
No. 2
No. 3 No. 1
Identification
mark

ENGINE OVERHAUL -Piston and Connecting Rod11B-61
4. If there is no identification, measure the oil clearance
and select.
"FACONNECTING ROD CAP INSTALLATION
1. Align the marks made during disassembly, and install
the bearing cap onto the connecting rod. When using
a new connecting rod that has no match marks, assemble
so that the bearing rotation-preventing notch comes to
the same side as shown in the illustration.
2. The plasticity range tightening method is adopted for the
connecting rod bolt and nut, so elongate and inspect
the bolt before reusing it.
Inspect that the bolt is elongated to the extent that the
nut can be screwed onto the last thread when screwed
by hand. If the nut cannot be screwed on smoothly to
the end, the bolt threads are elongated and the bolt must
be replaced.
3. Apply engine oil on the nut’s threads and seat surface
before installing the nut.
4. After installing each nut onto the bolt with fingers,
alternately tighten the nuts to assemble the cap correctly.
5. Tighten the nut at a 20 N•m torque.
6. Make a paint mark on the head of the nut.
7. Using the position of the mark painted on the nut as
reference, make paint marks on the bolt at the 90_to
94_positions in the nut tightening direction.
8. Tighten the nut between 90_and 94_, and confirm that
the paint marks on the nut and bolt match.
Caution
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.
If the tightening angle is larger than 94_, completely
loosen the nut and start again from step 1.
Cylinder No.
Rotation-
preventing
notch
Paint marks
90_-94_
Paint marks
NutBolt

ENGINE OVERHAUL -Piston and Connecting Rod11B-62
9. Check that the thrust clearance at the large end of the
connecting rod is correct.
Standard value: 0.10 - 0.25 mm
Limit value: 0.4 mm
INSPECTION
1. PISTON RING
(1) Inspect the clearance between the piston ring and
ring groove. If the limit value is exceeded, replace
the piston ring or the piston ring and piston.
Standard value:
No. 1 0.03 - 0.07 mm
No. 2 0.02 - 0.06 mm
Limit value: 0.1 mm
(2) Place the piston ring and oil ring side rail into the
cylinder bore, and contact the piston front face side,
and press in. After attaining a right angle, measure
the closed gap with a thickness gauge.
NOTE
Press in the closed gap of the piston ring and oil
ring’s side rail at the position of the piston shown
in the illustration, and measure the closed gap.
Standard value:
No. 1 0.20 - 0.30 mm
No. 2 0.35 - 0.50 mm
Oil ring 0.10 - 0.40 mm
Standard value:
No. 1 0.8 mm
No. 2 0.8 mm
Oil ring 1.0 mm
Press in with piston
Piston ringClosed gap

ENGINE OVERHAUL -Piston and Connecting Rod11B-63
2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC
GAUGE METHOD)
(1) Wipe off the oil from the crankshaft pin and connecting
rod bearing.
(2) Set a plastic gauge as long as the bearing width
on the pin shaft so that straightly aligned with the
shaft centre.
(3) Carefully set the connecting rod cap, and tighten the
nut at the specified torque 20±2N•m+90_to
94_
(4) Remove the nut, and carefully remove the connecting
rod cap.
(5) Measure the width of the crushed plastic gauge (at
the section crushed the most) with the scale printed
on the plastic gauge bag.
Standard value: 0.03 - 0.05 mm
Limit value: 0.1 mm

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-64
CRANKSHAFT AND CYLINDER BLOCK
REMOVAL AND INSTALLATION
25±2N•m+90_- 100_
21
Apply engine oil on
all sliding sections
before installing.
4
5 6
73
8 9 1011
132±5N•m 11±1N•m
11±1N•m9±1N•m
32±2N•m
14
1312 15
Removal steps
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
"EA5. Rear oil seal case
"DA6. Rear oil seal
"CA7. Bearing cap bolt
"CA8. Beam bearing cap"BA9. Crankshaft bearing lower
10. Crankshaft
"BA11. Crankshaft bearing upper
"AA12. Thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-65
INSTALLATION SERVICE POINTS
"AATHRUST BEARING INSTALLATION
1. Install the thrust bearing onto the cylinder block side of
the No. 3 bearing section. The bearing can be installed
easily by applying engine oil.
2. Install the thrust bearing so that the side with the groove
faces the crankshaft weight side.
"BACRANKSHAFT BEARING INSTALLATION
1. Measure the diameter of the crankshaft journal, and
confirm the class shown below. When using a spare part,
each identification colour is painted at the position shown
in the illustration.
2. The cylinder block bearing section bore identification mark
is stamped at the position shown in the illustration.
Crankshaft journalCylinder
block
bearing
Spare
bearing
identificaClassProduct
identifica-
tion colourSpare part
identifica-
tion colourJournal
diameter
mmbearing
section
bore iden-
tification
markidentifica-
tion mark
1NoneYellow56.994 -57 0000057.00011
22
2NoneNone56.988 -56 9940156.99412
23
3NoneWhite56.982 -56 9880256.98813
24
Groove
No. 2
No. 1No. 4
No. 5No. 3
Timing belt side
Cylinder block bearing section
bore identification mark
No. 1No. 2No. 3No. 4
No. 5
Cylinder
bore size
mark

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-66
3. Select the bearing from the above table according to
the identification confirmed in steps 1 and 2.
[Example of selecting bearing]
(1) If the measured outer diameter of the crankshaft
journal is 57.000 mm, Class 1 applies, and the
identification colour is yellow.
(2) If the cylinder block bearing bore identification mark
is 0, select identification mark 0 in consideration of
step (1).
4. Install the grooved bearing on the cylinder block side.
5. Install the bearing with no oil groove onto the beam bearing
cap side.
"CABEAM BEARING CAP/BEARING CAP BOLT
INSTALLATION
1. Install the beam bearing cap with the arrow facing the
timing belt side.
2. Before installing the bearing cap bolt, confirm that the
bolt’s underhead length is less than the limit value.
Replace the bolt if it exceeds the limit value.
Limit value: 71.1 mm
3. Apply engine oil on the bolt threads and bolt surface.
4. Following the tightening order, tighten the bearing cap
bolt at 25±2N•m.
5. Make paint marks on the bolt head.
6. Using the position of the mark painted on the bolt head
as reference, make paint marks on the seat surface at
the 90_to 100_positions in the tightening direction.
7. Following the tightening order, tighten the bolt by 90_
to 100_, and confirm that the paint marks made on the
bolt and seat surface match.
Caution
(1) If the tightening angle is less than 90_, the
connection performance may not be attained, so
take special care when tightening.
(2) If the tightening angle exceeds 100_, completely
loosen the nut, and start again from step 1.Crankshaft bearing side
identification mark position
Identification
mark
Groove
Upper bearing
Lower bearing
Underhead length
Arrow
84159
732610
Paint marksPaint marks
90°- 100°