lock MITSUBISHI LANCER EVOLUTION 2007 Service Workshop 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 -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-37

(1) Connect the special tool (MB991668) to the MUT-II.
(2) Connect the special tool (MB991704) to the MUT-II
and the battery.
(3) Rotate the crankshaft clockwise for two rounds to
position No.1 cylinder at compression TDC and check
that timing marks of each sprocket are aligned with
each other.
(4) Select “Belt Tension Measurement” from the menu
screen of the MUT-II.
(5) Hold the special tool (MB991668) to the middle of
the belt between sprockets (at the place indicated
by the arrow) as shown in the illustration about 10
- 20 mm away from the rear surface of the belt and
so that it is perpendicular to the belt (within an angle
of±15_).
(6) Gently tap the middle of the belt between sprockets
(the place indicated by the arrow) with your finger
as shown in the illustration and check that the vibration
frequency of the belt is within the standard value.
Caution
1) If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
2) If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.

Apply a force of approx.100N to the middle (arrow part)
of pulley shown in the figure, and check that the deflection
is within the standard value.
3. If it is outside the standard value, re-adjust belt tension.
MB991668
10 - 20 mm
15_
15_
Gently tap with
your finger
Deflection
Approx.
100 N

ENGINE -Timing Belt and Timing Belt B11A-39
"FATIMING BELT INSTALLATION
1. Check that timing marks of camshaft sprocket, crankshaft
sprocket, and oil pump sprocket are aligned with each
other.
2. After aligning the timing marks of the oil pump sprocket,
remove the cylinder block plug and insert a Phillips screw
driver with a shaft diameter of 8 mm through the plug
hole to check that the shaft of the screw driver can be
inserted for 60 mm or more. If the screw driver makes
contact with the balancer shaft and can be inserted for
only 20 - 25 mm, turn the sprocket for one round and
align timing marks again to check that screw driver can
be inserted for 60 mm or more. Do not take the screw
driver out before completing installation of the timing belt.
3. Position the timing belt without having any slack at the
tension side of the belt.
(1) Hook the timing belt to the crankshaft sprocket, the
oil pump sprocket, and the idler pulley in the sequence.
Timing Mark
Timing
Mark
Timing
Mark
Crankshaft
sprocket
Oil pump
sprocket
Camshaft
sprocket
8mm
60 mm or more
Balancer
shaft
Plug
Starter
Intake
camshaft
sprocketExhaust
camshaft
sprocket
Idler
pulley
Oil pump
sprocketCrankshaft
sprocket
Tensioner
pulley

ENGINE -Timing Belt and Timing Belt B11A-40
(2) Hook the timing belt with exhaust side of the camshaft
sprocket and retain the specified position indicated
in the figure with paper clips.
(3) Use two wrenches to hook the timing belt to the intake
side of the camshaft sprocket while aligning the timing
marks on the rocker cover and camshaft sprocket.
(4) Retain timing belt at the specified positions with paper
clips according to the figure.
(5) Hook the timing bolt to the tensioner pulley.
(6) Remove two paper clips.
Caution
After hooking the timing belt, apply force to the
camshaft sprocket counterclockwise(in left turn)
and reconfirm that each timing mark is in the
proper position while the belt is being stretched.
4. Use the special tool to rotate the tensioner pulley in the
direction indicated in the figure, tighten the timing belt,
and temporarily tighten the mounting bolt of the tensioner
pulley for fixing.
5. Check that each timing mark is properly aligned.
6. Remove the screw driver and install a plug.
7. Adjust timing belt tension.
"GATIMING BELT TENSION ADJUSTMENT
1. After removal of the rubber plug of the timing belt rear
cover, prepare the special tool to insert the special tool
into the position where a wire or a pin inserted during
installation of automatic tensioner can be moved easily.
Caution
Be sure to pressfit the special tool with a hand because
pressfitting the special tool with tools, such as
spanner, and etc. could damage a wire or a pin inserted
into the automatic tensioner.
Paper
clip
Timing Mark
Timing Mark
Paper
clip
MD998767
MD998738
Timing belt
rear cover

ENGINE -Timing Belt and Timing Belt B11A-41
2. Rotate the crankshaft counterclockwise for 1/4 round.
3. Rotate the crankshaft clockwise and mate timing marks
with each other to position No.1 cylinder at compression
TDC.
4. Loosen the temporarily tightened tensioner pulley
mounting bolt.
5. Use the special tool and torque wrench to apply tension
torque (3.5 Nm) to the timing belt in the direction indicated
in the figure and tighten the tensioner pulley mounting bolt
to the specified torque.
Tightening Torque: 48±5 N·m
Caution
Be careful not to let the tensioner pulley rotate together
when tightening the mounting bolt. If the tensioner
rotates together, belt tension becomes too loose.
6. Remove a wire or a pin inserted during installation of
the automatic tensioner.
7. Remove the special tool installed in the above - mentioned
1 with a hand.
8. Rotate the crankshaft clockwise for two rounds and leave
it alone for approximately 15 minutes.
9. Insert the removed wire or pin in the above - mentioned
6 again to check that it can be removed easily.
If either wire or pin can be removed easily, the timing
belt tension is correct and remove a wire or a pin. Then,
check that projection of the automatic tensioner rod is
within the standard value.
Standard value (A): 3.8 - 4.5 mm
10. If a wire or a pin cannot be easily removed, repeat the
above-mentioned operations 1 - 8 to obtain the correct
timing belt tension.
11. Check that timing marks of each sprocket are aligned
with each other.
Caution
After turning the crankshaft bolt counterclockwise,
always check the tightening torque of the crankshaft
bolt and tighten it again if it becomes loose.
MD998767
A

ENGINE -Timing belt and timing belt B11A-42
INSPECTION
AUTO-TENSIONER CHECK
1. Check the sealant for oil leakage and replace if necessary.
2. Check the rod end for wear or damage and replace if
necessary.
3. Measure the deflection of the rod end pressed against
the metal (cylinder block, etc) with the force of 98 - 196
N while holding the auto-tensioner with a hand.
Standard value: Within 1 mm
A: Length in the released state
B: Length in the pressed state
A - B: Deflection
4. If the value is outside the standard value, replace the
auto-tensioner.
TIMING BELT B TENSION CHECK
1. Measure the tension of timing belt B by following
procedures.
Standard value:
ItemWhen checked
Vibration frequency Hz52 - 92
Deflection mm (Reference)5-10

Tap the center of the belt between the pulleys (arrow),
and check that the belt vibration frequency is within the
standard values.
NOTE
For the vibration frequency measurement using the
MUT-II, refer to P11A-37.

Apply a force of approx.100N to the middle (arrow part)
of pulley shown in the figure, and check that the deflection
is within the standard value.
2. If it is outside the standard value, re-adjust belt tension.
(Refer to P.11A-36.)
AB
Auto-tensioner
98 - 196 N
Deflection
Rod
MB991668
10 - 20 mm
15_
15_
Gently tap with
your finger
Deflection
Approx.
100 N

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....