width MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

GENERAL -Major Specifications00-17
MAJOR SPECIFICATIONS
1
234
5
6 78
9
ItemsCT9A
SNDFZL/RSNGFZL/R
Vehicle
di i
Front track11,500, 1,515*1
dimensions
mmOverall width21,770mm
Front overhang3895
Wheel base42,625
Rear overhang5935
Overall length64,455
Ground clearance
(unladen)7140
Overall height (unladen)81,450
Rear track91,500, 1,515*1
Vehicle
ihtk
Kerb weight1,3201,380
weight kgMax. gross vehicle weight1,6551,695
Max. axle weight
rating-front950970
Max. axle weight
rating-rear705725
Seating capacity5
EngineModel No.4G63g
Total displacement mL1,997
Transmis-
i
Model No.W5M51
sionType5-speed manual
Fuel systemFuel supply systemMPI
NOTE
*1: Vehicles with 17 inch wheels.

GENERAL -Support Locations for Lifting and Jacking00-27
PREPARATION OF “ATTACHMENTS”
1. Prepare the blocks (wooden) and nails as shown in the
figure.
ItemDimensions mmQuantity
Block (A)90×95×1,8002
Block (B)60×100×954
Block (C)140×40×958
Nail70 or more32
Caution
The wood selected for the blocks must be hard.
2. For the (B) blocks and (C) blocks, use a saw and chisel
or similar tool to make grooves of the dimensions shown
in the figure.
3. Make four “ATTACHMENTS” such as shown in the figure
nailing (B) and (C) blocks so that each (B) blocks is
sandwiches between (C) blocks.
Block (A)mm
1,800
90
95
Block (B) Block (C)
15
40
60
10040
2015
40
14040
20
40
Block (C)
140100
Block (C)
Nail
Block (B)
Finished attachment
Movable according
to vehicle width

ENGINE -On-vehicle Service11A-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK
1. Check that the indicator marking of the auto-tensioner
is within the range as shown in the illustration A of the
tensioner bracket.
Caution
Inspection must be carried out after turning the
crankshaft clockwise for more than once.
2. If the marking is outside the range as shown in the
illustration A, replace the drive belt.
NOTE
Due to the adoption of the auto-tensioner, no adjustment
for belt tension is required.
AUTO-TENSIONER CHECK
1. Check that the driver belt stays within the width of the
pulley of the auto-tensioner after turning off the engine
at idle.
2. Remove the drive belt.(Refer to P.11C-15.)
3. Use the 12.7sq. spinner handle and etc. to check that
the auto-tensioner is not stuck by turning it in both
directions.
4. If there is any abnormality in the above - mentioned 1
or 3, replace the auto-tensioner.
5. Install the drive belt.(Refer to P.11C-15.)

To determine whether the auto-tensioner is acceptable can
be done by checking the drive belt tension.
1. Use the following procedure to check the drive belt tension.

(1) Connect the special tool (MB991668) to the MUT-II.
(2) Connect the MUT-IIto the diagnosis connector.
Caution
Connection and disconnection of the MUT-IImust
be carried out after turning the ignition switch
to the “LOCK” (OFF) position.
(3) Turn the ignition switch to the “ON” position and select
“Belt Tension Measurement” from the menu screen.
Indicator
marking
A

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 -Timing Belt11B-24
INSPECTION
1. TIMING BELT
Inspect each section of the belt in detail, and if any of
the following type of damage is found, replace the belt
with a new part.
(1) Hardening of backface rubber.
The backface is glossy, marks are not made even
when a fingernail is run cross it, and there is no
elasticity.
(2) Cracking of backface rubber.
(3) Cracking of canvas.
(4) Cracking at root.
(5) Cracking on side of belt.
(6) Abnormal wear on side of belt.
NOTE
The state is normal if the cutting surface is neat as
if cut with a sharp knife.
(7) Abnormal wear of teeth.
First stages: Canvas is worn (canvas fibres are raised,
rubber is removed and whitish, and canvas seams
are unclear).
Latter stages: Canvas is worn off, and rubber is
exposed (face width is narrow).
(8) Teeth are missing.
2. AUTO TENSIONER
(1) Check for oil leaks. If any leaks are found, replace.
(2) Check whether the rod end is worn or damaged,
and replace if necessary.
(3) Measure the rod protrusion length. If not at the
standard value, replace the auto tensioner.
Standard value: 12 mm
Crack
Crack
Peeling of canvas
Cracking
on side
Cracking at root
Edges are rounded
Abnormal wear
(The core wires are frayed.)
Rubber exposed due to
worn canvas
Teeth are missing
12 mm

ENGINE OVERHAUL -Water Pump and Water Hose11B-33
INSTALLATION SERVICE POINTS
"AAO-RING/WATER INLET PIPE INSTALLATION
Replace the O-ring for the water inlet pipe with a new part,
and apply water on the periphery of the O-ring so that it
can be inserted easily into the water pump and thermostat
housing.
Caution
(1) Never apply grease or oil, such as engine oil, on the
O-ring.
(2) Install the water inlet pipe onto the thermostat
housing, and then fix.
"BAWATER OUTLET FITTING INSTALLATION
Squeeze out form-in-place gasket at a 3 mm width, and apply
at the position shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"CAENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION
When reusing the bolts, apply the specified sealant on the
threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"DAENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
Apply the specified sealant onto the threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8731 or equivalent
Caution
Make sure that the tool does not contact the connector
section (resin section).

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-35
REMOVAL SERVICE POINT
AA"LASH ADJUSTER REMOVAL
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
INSTALLATION SERVICE POINTS
"AALASH ADJUSTER INSTALLATION
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
Assembly the lash adjuster onto the rocker arm while taking
care not to spill out diesel oil in it.
"BACAMSHAFT INSTALLATION
1. Apply engine oil on the camshaft journal and cam.
2. Install the camshaft onto the cylinder head.
Caution
Do not mistake the intake and exhaust camshafts.
There is a 4 mm width slit on the back end of the
exhaust side camshaft.
"CABEARING CAP INSTALLATION
1. Set the camshaft’s dowel pin to the approximate top.
2. The bearing caps No. 2 to 5 have the same shape. Check
the identification symbol before installing to prevent
mistaking the cap No., intake side and exhaust side.
Identification symbol
(Stamped on front and on No. 2 to 5 bearing caps)
I : Intake side
E : Exhaust side
Timing belt side
Slit
Exhaust side
Dowel pins
Cap No.
Identification
of IN side and
EX side

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-45
5. VALVE SEAT
Assemble the valve, and measure the amount that the
valve protrudes from the valve shaft end between the
spring seat surfaces when the valve is pressed against
the valve seat. Replace the valve seat if the protrusion
amount exceeds the limit value.
Standard value:
Intake 49.20 mm
Exhaust 48.40 mm
Limit value:
Intake 49.70 mm
Exhaust 48.90 mm
Valve Seat Correction
1. Before correcting the valve seat, inspect the clearance
between the valve guide and valve, and replace the valve
guide if necessary.
2. Correct so that the seat width and seat angle are at the
specified shape.
3. After correcting, apply wrapping compound, and fit the
valve and valve seat together.
Valve Seat Replacement
1. Grind off the valve seat to be replaced from the inside
to reduce the thickness and then remove the valve seat.
2. Machine the valve seat hole on the cylinder head to match
the diameter of the oversized valve seat into which it
is to be pressed in.
Intake valve seat hole diameter:
0.3 O.S. 35.30 - 35.33 mm
0.6 O.S. 35.60 - 35.63 mm
Exhaust valve seat hole diameter:
0.3 O.S. 33.30 - 33.33 mm
0.6 O.S. 33.60 - 33.63 mm
3. When pressing in the valve seat, cool the valve seat
with liquid nitrogen, and make sure that the inner diameter
of the cylinder head is not galled.
4. Refer to the “Valve Seat Correction” procedures, and
machine the valve seat.Valve shaft end
Spring seat surface Valve protrusion
amount
10_ 65_
10_65_ 0.9 - 1.3 mm
0.9 - 1.3 mm
43.5_-44_43.5_-44_
0.5 - 1.0 mm
0.5 - 1.0 mm Grind off
Valve
seat
height
Oversized hole diameter

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-53
"JAPLUG CAP INSTALLATION
1. Install a new O-ring onto the oil pump case.
2. Lightly tighten the plug cap by hand.
3. As shown in the illustration, fit the special tool (MD998162)
into the notch on the plug cap, and while supporting with
the special tool (MD998783), tighten the plug cap at the
specified torque 23±3N•m.
"KAOIL PRESSURE SWITCH INSTALLATION
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
Caution
(1) Make sure that the sealant does not protrude to the
end of the threads.
(2) Do not tighten too far.
"LAOIL PAN INSTALLATION
1. Clean the surface of the cylinder block and oil pan onto
which gasket is to be applied.
2. Squeeze out form-in-place gasket at a 4 mm width, and
apply onto the entire periphery of the oil pan flange.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
3. Note that the lengths of the bolts shown in the illustration
differ, so take care when installing.
MD998162
MD998783
Bolt hole section Groove
Timing belt side
M6×8