lock MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

ENGINE OVERHAUL -Specifications11B-3
SPECIFICATIONS
SERVICE SPECIFICATIONS
Unit: mm
Items
Standard valueLimited value
Timing belt
Timing belt B
Vibration frequency Hz (during inspection)
Vibration frequency Hz (when re-tensing working belt)
Vibration frequency Hz (when mounting new belt)
Deflection amount (during inspection)
Deflection amount (when re-tensing working belt)
Deflection amount (when mounting new belt)
Auto-tensioner
Rod protrusion length (free length)
Rod protrusion length (when mounting timing belt)
Rod recess amount (when pressed at 98 to 196 N•m)
56 - 92
76 - 92
76 - 92
5-10
5-7
5-7
12.0
3.8 - 4.5
Within 1
-
-
-
Rocker arm, camshaft
Camshaft
Cam height
Intake
Exhaust
35.79
35.4935.29
34.99
Cylinder head, valve
Cylinder head
Lower surface strain
Lower surface grinding limit (in combination with combined cylinder block)
Total height
Valve
Margin
Intake
Exhaust
Total length
Intake
Exhaust
Valve spring
Free height
Squareness
Valve guide
Clearance between valve guide and valve stem
Intake
Exhaust
Total length
Intake
Exhaust
Protrusion amount
Valve seat
Contact width
Valve protrusion amount from spring seat surface
Intake
Exhaust
0.05
-
131.9 - 132.1
1.0
1.5
109.50
109.70
48.3
1.5_or less
0.02 - 0.05
0.05 - 0.09
45.5
50.5
19.2 - 19.8
0.9 - 1.3
49.20
48.400.2
0.2
-
0.5
1.0
109.00
109.20
47.3
4_
0.10
0.15
-
-
-
-
49.70
48.90

ENGINE OVERHAUL -Specifications11B-4
Unit: mm
Items
Standard valueLimited value
Oil pump, oil pan
Oil pump
Side clearance
Drive gear
Driven gear
0.08 - 0.14
0.06 - 0.12-
-
Piston, connecting rod
Piston
Press-in load N
Piston ring
Clearance between ring and ring groove
No. 1 ring
No. 2 ring
Closed gap
No. 1 ring
No. 2 ring
Oil
Connecting rod
Large end thrust clearance
Crankshaft
Pin section oil clearance
7,355 - 17,162
0.03 - 0.07
0.02 - 0.06
0.20 - 0.30
0.35 - 0.50
0.10 - 0.40
0.10 - 0.25
0.03 - 0.05-
0.1
0.1
0.8
0.8
1.0
0.4
0.1
Crankshaft, cylinder block
Crankshaft
End play
Journal section oil clearance
Cylinder block
Upper surface strain
Upper surface grinding limit (in combination with combined cylinder head)
Cylinder bore
Cylindricity
Clearance between piston and cylinder
0.05 - 0.25
0.03 - 0.04
0.05
-
85.0
0.01 or less
0.02 - 0.040.4
0.1
0.1
0.2
-
-
-
Turbocharger
Waste gate actuator operation pressure100 kPa-
Alternator
Alternator
Rotor coil resistanceΩ
Brush protrusion length
3-5
--
2
Starter motor
Starter motor
Deviation on commutator periphery
Commutator outer diameter
Undercut depth
0.05
29.4
0.50.1
28.8
0.2

ENGINE OVERHAUL -Specifications11B-7
Items Tightening torque N·m
Water outlet fitting bolt10±1
Thermostat housing bolt23±4
Water inlet pipe bolt (M6)10±1
Water inlet pipe bolt (M8)13±2
Water pump bolt14±1
Knock sensor23±2
Rocker arm, camshaft
Cam position sensor bolt8.8±1.0
Cover bolt10±2
Cam position sensing cylinder bolt22±4
Cam position sensor support bolt14±1
Bearing cap bolt20±1
Oil delivery body bolt11±1
Cylinder head, valve
Cylinder head bolt78±2→Completely loosen→20±2→90_+90_
Oil pump, oil pan
Drain plug39±5
Oil pan bolt9±3
Oil screen bolt19±3
Baffle plate bolt22±4
Oil pressure switch19±3
Oil cooler bypass valve54±5
Relief plug44±5
Oil filter bracket bolt19±3
Plug cap23±3
Flange bolt36±3
Oil pump case bolt23±3
Oil pump cover bolt17±1
Oil pump cover screw10±2
Piston, connecting rod
Connecting rod cap nut20±2+90_-94_
Crankshaft, cylinder block
Flywheel bolt132±5
Rear plate bolt11±1
Bell housing cover bolt9±1
Rear oil seal case bolt11±1
Beam bearing cap bolt25±2+90_- 100_
Check valve32±2
Throttle body
Throttle position sensor bolt2.0±0.5
Turbocharger
Waste gate actuator bolt11.3±1.5

ENGINE OVERHAUL -Timing Belt11B-14
REMOVAL SERVICE POINTS
AA"TIMING BELT REMOVAL
1. To ensure that the timing belt is assembled in the same
direction when reused, using chalk, etc., make an arrow
showing the rotation direction on the back surface of
the timing belt.
2. Position the exhaust camshaft sprocket’s timing mark by
approx. one tooth before the No. 1 cylinder compression
top dead centre.
Caution
When removed at the compression top dead centre,
since the exhaust camshaft is at the position pressing
down on the valve, the sprocket could rotate in reverse
due to the force of the valve spring creating a
hazardous situation.
3. Loosen the lock nut for the tensioner pulley, and remove
the timing belt.
AB"OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips driver (shaft diameter 8 mm) to stop the
counter balance shaft left from rotating.
3. Loosen the flange bolt.
4. Remove the oil pump sprocket.
AC"CRANKSHAFT BOLT REMOVAL
1. Fix the flywheel with the special tool.
2. Remove the crankshaft bolt.
AD"CRANKSHAFT SPROCKET REMOVAL
Use the special tool to remove the sprocket if it is stuck
and hard to remove.
Timing marks
Phillips driver
MD998781
MD998778

ENGINE OVERHAUL -Timing Belt11B-18
3. Confirm that the tensioner B centre and bolt centre are
positioned as shown in the illustration.
4. Apply tension on the timing belt by lifting tensioner B
in the direction of the arrow with a finger, and tension
the tension side until it is “tight”. Fix tensioner B in this
state by tightening the bolt.
NOTE
Make sure that the tensioner B shaft does not rotate
when tightening the bolt. If the shaft rotates, the timing
belt becomes too tense.
5. Connect the special tool (MB991704) to MUT-IIand the
battery.
6. Connect the special tool (MB991668) to MUT-II.
7. Rotate the crankshaft clockwise two turns, and align each
timing mark.
8. Select “Belt Tension Measurement” from the MUT-IImenu
screen.
9. Separate the special tool (MB991668) 10 to 20 mm from
the centre back between the sprockets (shown with an
arrow), and hold so that it is vertical (inclination within
±15_) in respect to the belt.
10. Lightly tap the section shown with an arrow with fingers,
and measure the belt vibration frequency. If the results
are deviated from the standard value, loosen the bolt,
tension the belt again, and then measure the vibration
frequency again. Repeat this step until the standard value
is attained. Tighten the bolt when the standard value
is attained.
Standard value:
ItemWhen
checkWhen
adjustedWhen
replaced
Vibration frequency Hz52 - 9276 - 9276 - 92
Deflection
(Reference value) mm5-105-75-7
Tensioner
B centre
Installation
bolt centre
Timing
belt B
Belt tension side
Tensioner
B
MB991668
15_ 15_
10 - 20 mm

ENGINE OVERHAUL -Timing Belt11B-20
"JAOIL PUMP SPROCKET INSTALLATION
1. Stop the rotation of the counter balance shaft in the same
manner as for removal.
2. Install the oil pump sprocket.
3. Apply the minimum required amount of engine oil on the
flange nut seat surface.
4. Tighten the flange nut at the specified torque 54±5
N•m.
"KAAUTO TENSIONER INSTALLATION
1. If the auto tensioner rod is in the extended state, set
it with the following steps.
(1) Set the rod of the auto tensioner into a vice so that
it is straight and not inclined.
(2) Press in the rod gradually with the vice, and align
the rod’s set hole A with the cylinder’s set hole B.
(3) Insert a wire (diameter 1.4 mm) into the set holes.
(4) Remove the auto tensioner from the vice.
2. Install the auto tensioner.
Do not remove the wire until the timing belt has been
installed.
"LATENSIONER PULLEY INSTALLATION
Set the tensioner pulley as shown in the illustration.
"MATIMING BELT INSTALLATION
1. Set the timing mark on the exhaust side camshaft sprocket
so that it is deviated by one tooth in the counterclockwise
direction from the timing mark on the rocker cover.
NOTE
Even if the sprocket and rocker cover timing marks are
aligned, the exhaust camshaft will return in the
counterclockwise direction by the force of the valve spring
and will stabilize at a position deviated by one tooth.
Phillips driver
A
B
Tensioner pulley holes
Timing marks

ENGINE OVERHAUL -Timing Belt11B-21
2. Align the timing mark of the intake side camshaft sprocket
to the timing mark on the rocker cover.
NOTE
Even when the sprocket and rocker cover timing marks
are aligned, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
3. Shift and set the crankshaft sprocket timing mark by one
tooth in the counterclockwise direction in the same manner
as the exhaust side camshaft sprocket.
4. Align the oil pump sprocket timing marks.
5. When aligning the oil pump sprocket timing marks, remove
the cylinder block plug, and insert an 8 mm shaft diameter
Phillips driver into the plug hole, and confirm that the
driver shaft can be inserted by 60 mm or more. Do not
remove the Phillips driver until the timing belt has been
attached. If the driver shaft contacts the silent shaft and
only enters 20 to 25 mm, rotate the sprocket once, align
the timing marks again, and then confirm that the Phillips
driver can be inserted by 60 mm or more.
6. Remove the Phillips driver, and set the oil pump sprocket
at a position returned by one tooth in the counterclockwise
direction.
7. Attach the timing belt to the exhaust side camshaft
sprocket, and fix with a paper clip at the position shown
in the illustration.
Timing marks
Phillips driverPlug
Timing
marks

ENGINE OVERHAUL -Timing Belt11B-22
8. Rotate the intake side camshaft sprocket in the
counterclockwise direction. Attach the belt at a position
where the timing mark is deviated by one tooth in the
counterclockwise direction, and then fix with a paper clip.
NOTE
Even if the belt is attached at a position deviated by
one tooth, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
9. Rotate the exhaust side camshaft sprocket in the
clockwise direction, and confirm that the intake side
camshaft sprocket’s timing marks are aligned when the
timing marks are aligned.
10. Attach the timing belt in the order of the idler pulley,
oil pump sprocket and crankshaft sprocket.
NOTE
Attach the timing belt so that it is not deflected.
11. Attach the timing belt to the tensioner pulley.
NOTE
The timing belt can be attached easily to the tensioner
pulley by rotating the intake side camshaft sprocket slightly
in the counterclockwise direction.
12. Rotate the crankshaft sprocket slightly in the clockwise
direction, and remove the timing belt deflection on the
idler pulley side.
13. Confirm that the timing marks on the crankshaft, oil pump
and exhaust camshaft are each deviated by one tooth
in the counterclockwise direction.
Timing marks Timing marks
Crankshaft
sprocketOil pump
sprocket
Crankshaft
sprocket
Crankshaft sprocket

ENGINE OVERHAUL -Timing Belt11B-23
14. Using the special tool, rotate the tensioner pulley in the
counterclockwise direction to tense the timing belt, and
then fix by temporarily tightening the tensioner fixing bolt.
NOTE
Remove the deflection of the timing belt between the
intake side and exhaust side camshafts.
15. Rotate the crankshaft in the clockwise direction, and set
the timing mark at the No. 1 cylinder compression top
dead centre.
16. Set the special tool, and screw it in until the wire inserted
when the auto tensioner was installed slightly moves.
17. Loosen the tensioner pulley fixing bolt.
Caution
The timing belt will loosen at this time due to the
rotation of the intake and exhaust camshafts, so make
sure that the timing belt does not deviate.
18. Rotate the special tool and torque wrench in the
counterclockwise direction to remove the timing belt
deflection.
19. From that state, return to the position where the torque
wrench scale reads 3.5 N•m, and then tighten the fixing
bolt.
20. Remove the special tool installed in step 16.
21. Rotate the crankshaft two rotations in the clockwise
direction, and let stand for approx. 15 minutes.
22. Confirm whether the wire inserted when the auto tensioner
was installed can be pulled out easily. If it can be removed
easily, the belt tension is appropriate, so remove the wire.
If the auto tensioner rod’s protrusion amount is at the
standard value, the tension is appropriate.
Standard value: 3.8 - 4.5 mm
23. If the wire cannot be pulled out easily, repeat steps 16
to 21, and tense the belt to the appropriate tension.
Caution
When the crankshaft bolt has been rotated in the
counterclockwise direction, always check the crank-
shaft bolt’s tightening torque. If loosen, re-tighten.
MD998767
MD998738
MD998767
Protru-
sion
amount

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