service MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-49
AE"COUNTER BALANCE SHAFT REAR BEARING
REMOVAL
1. Pull out the counter balance shaft rear bearing right from
the cylinder block using the special tool (MD998372).
2. When removing the counter balance shaft rear bearing
left, install the special tool (MB991603) onto the front
of the cylinder block, and then remove the bearing using
the special tool (MD998372).
INSTALLATION SERVICE POINTS
"AACOUNTER BALANCE SHAFT REAR BEARING
LEFT INSTALLATION
1. Install the special tool (MB991603) onto the cylinder block.
2. Set the counter balance shaft rear bearing left into the
special tool (MD998705).
NOTE
There is no oil hole on the counter balance shaft rear
bearing left.
3. Tap in the counter balance shaft rear bearing left.
"BACOUNTER BALANCE SHAFT REAR BEARING
RIGHT INSTALLATION
1. Install the guide pin onto the cylinder block.
2. Align the ratchet ball of the special tool with the oil hole,
and set the counter balance shaft rear bearing right.
MB991603
MD998372
MB991603
MD998705
MB991603
MD998705
Rear bearing
left
Guide pin
Ratchet ball
MD998705 Rear bearing right
Oil hole

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 -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

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 -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

13A-2
MULTIPOINT FUEL
INJECTION (MPI)
CONTENTS
GENERAL INFORMATION 3...................
SERVICE SPECIFICATIONS 6.................
SEALANT 6..................................
SPECIAL TOOLS 7...........................
TROUBLESHOOTING 9.......................
ON-VEHICLE SERVICE 125..................
Fuel Pump Connector Disconnection
(How to Reduce the Fuel Pressure) 125...........
Fuel Pump Operation Check 125.................
Throttle Body (Throttle Valve Area)
Cleaning 126..................................
Throttle Position Sensor Adjustment 126...........
Basic Idle Speed Adjustment 127.................
Fuel Pressure Test 128..........................
Component Location 131........................
Engine Control Relay Continuity Check 132........
Fuel Pump Relay 1, 2 Continuity Check 132........Fuel Pump Relay 3 Continuity Check 132..........
Fuel Pump Resistor Check 132...................
Intake Air Temperature Sensor Check 132.........
Engine Coolant Temperature Sensor Check 133....
Throttle Position Sensor Check 134...............
Oxygen Sensor Check 134......................
Injector Check 136..............................
Resistor (for Injector) Check 138..................
Idle Speed Control Servo (Stepper Motor)
Check 138.....................................
Fuel Pressure Control Solenoid Valve Check 140...
Purge Control Solenoid Valve Check 140..........
EGR Control Solenoid Valve Check 140...........
INJECTOR 141..............................
THROTTLE BODY 143.......................
ENGINE CONTROL RESISTOR, RELAY 146....
ENGINE-ECU 147...........................