MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-67
8. After installing the beam bearing cap, inspect the end
play of the crankshaft. If the end play exceeds the limit
value, replace the crankshaft bearing.
Standard value: 0.05 - 0.25 mm
Limit value: 0.4 mm
"DAREAR OIL SEAL INSTALLATION
Press in the rear oil seal using the special tool.
"EAREAR OIL SEAL CASE INSTALLATION
1. Apply form-in-place gasket onto the rear oil seal case
at the position shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
Caution
Evenly squeeze out the form-in-place gasket so that
it is not insufficient or excessive.
2. Apply an appropriate amount of engine oil on the entire
periphery of the oil seal lip, and install on the cylinder
block.
MB990938
MD998776

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-68
INSPECTION
1. CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The oil clearance can be measured easily by using the
“plastic gauge”.
Use the following steps to use the “plastic gauge”.
(1) Wipe off all oil from the crankshaft’s outer diameter
and bearing’s inner diameter.
(2) Assemble the crankshaft.
(3) Set a plastic gauge as long as the bearing width
on the journal shaft so that straightly aligned with
the shaft centre.
(4) Carefully install the beam bearing cap, and tighten
the bolt at the specified torque 25±2N•m+90_
to 100_.
(5) Remove the bolt, and carefully remove the beam
bearing cap.
(6) 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 - 0.04 mm
Limit value: 0.1 mm
2. CYLINDER BLOCK
(1) Visually check for the presence of scratches, rusting,
or corrosion, and using flaw detection agent, etc.,
check for cracks. If any faults are found, repair or
replace the part.
(2) Using a straight edge and thickness gauge, measure
the flatness of the cylinder block’s upper surface.
Make sure that no gasket pieces, etc., are adhered
to the upper surface of the cylinder block when
measuring.
Standard value: 0.05 mm
Limit value: 0.1 mm
(3) Check for the presence of scratches or seizure on
the cylinder wall. If any faults are found, repair (over
size) or replace the part.
(4) Using a cylinder gauge, measure the inner diameter
and cylindricity of the cylinder. If greatly worn, repair
the cylinder to the over size, and replace the piston
ring.
Standard value: 85.0 mm
Cylindricity: 0.01 mm
Plastic gauge
12 mm

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

NOTES

12-1
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
LUBRICANTS 3..............................
SPECIAL TOOL 3............................ON-VEHICLE SERVICE 4.....................
Engine Oil Check 4............................
Engine Oil Replacement 4.......................
Oil Filter Replacement 5........................
Oil Pressure Check 5..........................
ENGINE OIL COOLER 7......................

ENGINE LUBRICATION -General Information12-2
GENERAL INFORMATION
The lubrication method is a fully force-fed, full-flow
filtration type. The oil pump is a gear type which
is driven by the crankshaft via the timing belt.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentiallyharmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example
by using enclosed systems for handling used engine
oil and by degreasing components, where
practicable, before handling them.
Other precautions:
DAvoid prolonged and repeated contact with oils,
particularly used engine oils.
DWear protective clothing, including impervious
gloves where practicable.
DAvoid contaminating clothes, particularly
underpants, with oil.
DDo not put oily rags in pockets, the use of
overalls without pockets will avoid this.
DDo not wear heavily soiled clothing and
oil - impregnated foot - wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.DWhere there is a risk of eye contact, eye
protection should be worn, for example,
chemical goggles or face shields; in addition
an eye wash facility should be provided.
DObtain First Aid treatment immediately for open
cuts and wounds.
DWash regularly with soap and water to ensure
all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin
oils is advised.
DDo not use petrol, kerosine, diesel fuel, gas
oil, thinners or solvents for cleaning skin.
DUse barrier creams, applying them before each
work period, to help the removal of oil from
the skin after work.
DIf skin disorders develop, obtain medical advice
without delay.

ENGINE LUBRICATION -Service Specifications/Sealant/Lubricants/Special Tool12-3
SERVICE SPECIFICATIONS
ItemsStandard value
Oil pressure kPaat idle29 or more
at 3,500 r/min294 - 686
SEALANT
ItemsSpecified sealantRemark
Oil pressure switch3M ATD Part No. 8660 or equivalentSemi-drying sealant
LUBRICANTS
ItemsSpecifications
Engine oil ACEA classificationFor EuropeA1, A2, A3
Engine oil API classificationFor EuropeSG or higher
For General ExportSE or higher
Engine oil quantity LOil filter0.3
Oil cooler0.3
Total5.1
SPECIAL TOOL
ToolNumberNameUse
MD998054Oil pressure switch
wrenchRemoval and installation of oil pressure switch

ENGINE LUBRICATION -On-vehicle Service12-4
ON-VEHICLE SERVICE
ENGINE OIL CHECK
1. Pull out the level gauge slowly and check that the oil
level is in the illustrated range.
2. Check that the oil is not excessively dirty, that there is
no coolant or petrol mixed in, and that it has sufficient
viscosity.
ENGINE OIL REPLACEMENT
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80_Cto90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Install a new drain plug gasket so that it faces in the
direction shown in the illustration, and then tighten the
drain plug to the specified torque.
Tightening torque: 39±5 N·m
NOTE
Install the drain plug gasket so it faces in the direction
shown in the illustration.
5. Refill with specified quantity of oil.
Specified Engine Oil (ACEA and API classification):

ACEA A1, A2, A3 / API SG or higher

API SE or higher
Total quantity
(Includes volume inside oil filter and oil cooler):
5.1 L
NOTE
SAE 5W-30 can be only used at the area where the
lowest temperature is lower than the applicable
temperature of SAE 5W-30.
6. Install the engine oil filler cap.
7. Check oil level.
Drain plug
gasket
Oil pan side
Barometric temperature

ENGINE LUBRICATION -On-vehicle Service12-5
OIL FILTER REPLACEMENT
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80_Cto90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Remove the under cover.
5. Use the respective tool in the following table to remove
the engine oil filter.
6. Clean the filter bracket side mounting surface.
7. Apply a small amount of engine oil to the O-ring of the new
oil filter.
8. Once the O-ring of the oil filter is touching the flange,
use the generic tool to turn for approximately 3/4 round
and tighten to (14±2 N·m).
9. Install the drain plug and refill the engine oil.
(Refer to Engine Oil Replacement P.12-4.)
10. Race the engine 2 - 3 times, and check to be sure that
no engine oil leaks from installation section of the oil
filter.
OIL PRESSURE CHECK
1. Check engine oil quantity.
2. Remove the oil pressure switch terminal.
3. Use the special tool (oil pressure switch wrench) to remove
the oil pressure switch.
Caution
Since sealant is applied to the thread of oil pressure
switch, take care not to damage the oil pressure switch
when removing it.
Commercially-
available tool
O-ring
Oil pressure switch
Oil filter bracket
MD998054

ENGINE LUBRICATION -On-vehicle Service12-6
4. Install the oil pressure gauge.
NOTE
Use a adapter of PT 1/8 thread.
5. Run the engine to warm it.
6. After the engine has been warmed up, check that oil
pressure is within the standard value.
Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 - 686 kPa
7. Remove the oil pressure gauge.
8. Apply the specified sealant to the thread of oil pressure
switch.
Specified sealant: 3M ATD Part No. 8660 or equivalent
9. Use the special tool to tighten the oil pressure switch
to the specified torque.
Tightening torque: 10±2 N·m
Caution
Do not start the engine within one hour after the oil
pressure switch has been installed.
10. Install the oil pressure switch terminal.
MD998054