lock MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-36
3. Apply sealant on the contact surfaces with the head shown
in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
4. Install the bearing caps onto the cylinder head, and in
two to three steps tighten strongly.
5. Finally, tighten at the specified torque 20±1N•m.
6. Confirm that the rocker arm is correctly installed.
NOTE
Wipe off all excessive sealant.
"DACAMSHAFT OIL SEAL INSTALLATION
Install the oil seal using the special tool.
"EACAM POSITION SENSOR SUPPORT
INSTALLATION
Apply a 3 mm width of form-in-place gasket at the position
shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"FACAM POSITION SENSING CYLINDER
INSTALLATION
1. Set the exhaust camshaft at the No. 1 compression top
dead centre.
NOTE
The shaft will rotate slightly in the counterclockwise
direction by the force of the exhaust valve spring.
2. Install the cam position sensing cylinder’s vane (small)
and vane (large) at the positions shown in the illustration.
MD998713
Vane (small)
Cam position
sensorVane (large)

ENGINE OVERHAUL -Cylinder Head and Valve11B-40
CYLINDER HEAD AND VALVE
REMOVAL AND INSTALLATION
78±2N•m→Completely loosen
20±2N•m→90_+90_
2
1
Apply engine oil on
all sliding sections
before installing.
4
5
6
12
13
16
18
720
38
9
10
14
15
17
19
11
Removal steps
AA""DA1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AB""CA4. Retainer lock
5. Valve spring retainer
"BA6. Valve spring
7. Intake valve
AB""CA8. Retainer lock
9. Valve spring retainer
"BA10. Valve spring11. Exhaust valve
AC""AA12. Valve stem seal
13. Valve spring seat
AC""AA14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head

ENGINE OVERHAUL -Cylinder Head and Valve11B-41
REMOVAL SERVICE POINTS
AA"CYLINDER HEAD BOLT REMOVAL
Remove the cylinder head bolt using the special tool.
AB"RETAINER LOCK REMOVAL
Compress the valve spring using the special tool, and remove
the retainer lock.
NOTE
Attach a tag indicating the cylinder No. and installation position
onto the parts including the removed valve and springs so
that they can be reassembled later.
INSTALLATION SERVICE POINTS
"AAVALVE STEM SEAL INSTALLATION
1. Install the valve spring seat.
2. Install the valve.
3. Apply a small amount of engine oil on the valve stem
seal.
4. Using the valve stem as a guide, press in the valve guide
using the special tool.
Caution
Improper installation of the valve stem seal can lead
to oil reduction, so always install using the special
tool.
NOTE
Note that the valve stem seals for the intake side and
exhaust side are different.
MB991654
MD998772
MD998735
MB998737
Body colour:
GreyBody colour:
Grayish-green Intake side Exhaust side

ENGINE OVERHAUL -Cylinder Head and Valve11B-42
"BAVALVE SPRING INSTALLATION
Install the valve spring so that the painted surface faces the
rocker arm.
"CARETAINER LOCK INSTALLATION
Compress the valve spring using the special tool, and install
the retainer lock.
"DACYLINDER HEAD BOLT INSTALLATION
1. Before reusing the cylinder head 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: 99.4 mm
2. Apply engine oil on the bolt threads and washer.
NOTE
Use the special tool to tighten the cylinder head bolt.
Painted
surfaceSpring
retainer
Stem
seal
Spring
seat
MD998772
MD998735
Underhead length
MB991654

ENGINE OVERHAUL -Cylinder Head and Valve11B-43
3. Following the tightening order, tighten at 78±2N•m.
4. Completely loosen the bolts.
5. Next, following the tightening order, tighten the loosened
bolts at the torque 20±2N•m again.
6. Make paint marks on the cylinder head bolt’s head and
cylinder head.
7. Following the tightening order, tighten the cylinder head
by 90_.
8. Tighten by another 90_, and confirm that the paint mark
made on the cylinder head bolt’s head and the paint
mark on the cylinder head are positioned on the same
line.
Caution
(1) 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.
(2) If the tightening angle is larger than the specified
value, completely loosen the bolt and start again
from step 1.
INSPECTION
1. CYLINDER HEAD
(1) Before cleaning the cylinder head, check it for water
leaks, gas leaks, damage or cracks.
(2) Completely remove the oil, water deposits, sealant
and carbon, etc. After cleaning the oil path, blow
air and confirm that there is not clogging.
(3) Using a straight edge and thickness gauge, inspect
the flatness of the bottom of the cylinder head for
strain.
If the strain exceeds the limit value, grind the end
and correct the flatness.
Standard value for lower surface strain: 0.05 mm
Limit value for lower surface strain: 0.2 mm
Grinding limit value: 0.2 mm
Cylinder head height (standard value for new part):
131.9 - 132.1 mm
Caution
The grinding limit is within 0.2 mm together with
the combined cylinder block.
Timing belt side
86139
10 4 2 5 7
90_
90_
Paint marks

ENGINE OVERHAUL -Cylinder Head and Valve11B-46
Valve Guide Replacement
1. Using a press, push the valve guide to the cylinder block
side.
2. Machine the valve guide hole on the cylinder head to
match the oversized valve guide into which it is to be
pressed in.
Caution
Do not use a valve guide having the same size as
the removed valve guide.
Valve guide hole diameter:
0.05 O.S. 12.05 - 12.07 mm
0.25 O.S. 12.25 - 12.27 mm
0.50 O.S. 12.50 - 12.52 mm
3. Press in the valve guide to the dimensions shown in
the illustration.
NOTE
(1) Press in the valve guide from the top of the cylinder
head.
(2) Note that the length of the valve guides differs.
Intake 45.5 mm
Exhaust 50.5 mm
4. After pressing in the valve guide, insert a new valve,
and confirm the sliding state.
19.2 - 19.8 mm

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-48
REMOVAL SERVICE POINTS
AA"OIL PAN REMOVAL
1. Remove the oil pan tightening bolts.
2. Tap the special tool between the oil pan and cylinder
block.
3. Tap on the edge of the special tool, slide the tool and
remove the oil pan.
AB"PLUG CAP REMOVAL
Fit the special tool (MD998162) into the notch on the plug
cap as shown in the illustration. Loosen the plug cap while
supporting with the special tool (MD998783).
AC"FLANGE BOLT REMOVAL
1. Remove the plug on the left side of the cylinder block,
and insert a Phillips driver (shaft diameter 8 mm) by 60
mm or more to stop the rotation of the counter balance
shaft left.
2. Loosen the flange bolt.
AD"COUNTER BALANCE SHAFT FRONT BEARING
REMOVAL
Pull out the counter balance shaft front bearing from the
cylinder block using the special tool.
Caution
Always remove the counter balance shaft front bearing
first. Otherwise, the counter balance shaft rear bearing
cannot be removed.MD998727
MD998162
MD998783
Plug
Phillips driver
MD998371Front bearing

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 -Oil Pump and Oil Pan11B-50
3. Align and insert the special tool into the guide pin, and
tap in the counter balance shaft rear bearing right.
"CACOUNTER BALANCE SHAFT FRONT BEARING
INSTALLATION
1. Remove the part for tapping in the rear bearing from
the special tool.
2. Install the guide pin onto the cylinder block.
3. Align the ratchet ball of the special tool with the oil hole,
and set the counter balance shaft front bearing.
MD998705
Guide pin
MD998705
Part for tapping in
the rear bearing
Guide pin
Ratchet ball
MD998705 Front bearing
Oil hole

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-52
"GAOIL PUMP DRIVE GEAR/OIL PUMP DRIVEN
GEAR INSTALLATION
Apply sufficient engine oil onto the gears, align the match
marks, and assemble.
"HAOIL PUMP CASE INSTALLATION
1. Install the special tool onto the front end of the crankshaft,
and apply a light coat of engine oil onto the periphery
of the guide. If an oil seal is installed on the oil pump
case, always use a guide.
2. Install the oil pump case through the new oil pump case
gasket, and temporarily tighten the bolts other than the
oil filter bracket tightening bolt.
3. Install the oil filter bracket through the oil filter bracket
gasket, and temporarily tighten with the bolt.
4. Tighten the oil pump case at the specified torque 23
±3N•m, and the oil filter bracket at the specified torque
19±3N•m.
"IAFLANGE BOLT INSTALLATION
1. Insert a Phillips driver (shaft diameter 8 mm) by 60 mm
or more into the hole on the left side of the cylinder block
to stop the rotation of the counter balance shaft left.
2. Tighten the flange bolt at the specified torque 36±3
N•m.
Match marks
MD998285
Counter balance
shaft left
Counter balance
shaft right
MD998285
Phillips driver