MITSUBISHI LANCER EVOLUTION VI 1999 Owners Manual

ENGINE – Piston and Connecting Rod11-66
(3) Install the piston ring into the cylinder bore. Force it down
with a piston, its crown being in contact with the ring,
to correctly position it at right angles to the cylinder wall.
Then, measure the end gap with a feeler gauge. If the
ring gap is excessive, replace the piston ring.
Standard value:
No. 1 ring 0.25 – 0.35 mm
No. 2 ring 0.40 – 0.55 mm
Oil ring 0.10 – 0.40 mm
Limit:
No. 1, No. 2 ring 0.8 mm
Oil ring 1.0 mm
CRANKSHAFT PIN OIL CLEARANCE
(PLASTIC GAUGE METHOD)
(1) Remove oil from the crankshaft pin and connecting rod
bearing.
(2) Cut the Plastigage to the same length as the width of
the bearing and place it on the crankshaft pin in parallel
with its axis.
(3) Install the connecting rod cap carefully and tighten the
nuts to specified torque.
(4) Carefully remove the connecting rod cap.
(5) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.03 – 0.05 mm
Limit: 0.1 mm
Plastigage

ENGINE – Crankshaft and Flywheel11-67
CRANKSHAFT AND FLYWHEEL
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
1 2
3
4 56
78 910 11 12
13 1415
25 Nm + 9011 Nm132 Nm
9 Nm
11 Nm
32 Nm11 Nm
Removal steps
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
E5. Oil seal case
D6. Oil seal
C7. Beam bearing cap bolt
C8. Beam bearing capB9. Crankshaft bearing lower
10. Crankshaft
B11. Crankshaft bearing upper
A12. Crankshaft thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block

ENGINE – Crankshaft and Flywheel11-68
INSTALLATION SERVICE POINTS
ACRANKSHAFT THRUST BEARING INSTALLATION
(1) Install the two thrust bearing in the number 3 bearing
bore in the cylinder block. For easier installation, apply
engine oil to the bearings; this will help hold them in
position.
(2) The thrust bearings must be installed with their groove
side toward the crankshaft web.
BCRANKSHAFT BEARING INSTALLATION
(1) From the following table, select a bearing whose size
is appropriate for the crankshaft journal outside diameter.
Groove
Identification color of crankshaft journal
Bearing bore size
identification mark
Bearing bore
identification
mark
Cylinder inner
diameter size
mark
Rear face of
cylinder block Bottom of
cylinder block No. 1 No. 2No. 3
No. 4No. 5

ENGINE – Crankshaft and Flywheel11-69
Crankshaft journal outside diameterCylinder block bearing boreCrankshaft bearing
Identification colorSize mmIdentification markIdentification mark or color
Yellow56.994 – 57.00000 or Black
11 or Green
22 or Yellow
None56.988 – 56.99401 or Green
12 or Yellow
23 or None
White56.982 – 56.98802 or Yellow
13 or None
24 or Blue
For example, if the crankshaft journal outside diameter
ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “1”.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
CBEARING CAP / BEARING CAP BOLT
INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.Crankshaft bearing size
identification mark or color
Identification
mark or color
UpperGroove
Lower
9EN0477
Shank length

ENGINE – Crankshaft and Flywheel11-70
(4) Tighten the bolts to 25 Nm in the specified tightening
sequence.
(5) Make a paint mark on the head of each bolt.
(6) Make a paint mark on the bearing cap at the position
90° from the paint mark made on the bolt in the direction
of tightening the bolt.
(7) According to the specified tightening sequence, give a
90° turn to each bolt and make sure that the paint mark
on the bolt and that on the cap are in alignment.
Caution
If the bolt is turned less than 90°, proper fastening
performance may not be expected. When tightening
the bolt, therefore, be careful to give a sufficient turn
to it.
(8) After installing the bearing caps, make sure that the
crankshaft turns smoothly and the end play is correct.
If the end play exceeds the limit, replace No. 3 crankshaft
bearings.
Standard value: 0.05 – 0.25 mm
Limit: 0.4 mm
DOIL SEAL INSTALLATION
Using the special tool, knock the oil seal into the oil seal
case.
Arrow mark
6AE0299
Paint markPaint mark
90°

ENGINE – Crankshaft and Flywheel11-71
ESEALANT APPLICATION TO OIL SEAL CASE
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
NOTE
(1) Be sure to install the case quickly while the sealant is
wet (within 15 minutes).
(2) After installation, keep the sealed area away from the
oil and coolant for approx. one hour.
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD)
(1) Remove oil from the crankshaft journal and the crankshaft
bearing.
(2) Install the crankshaft.
(3) Cut the Plastigage to the same length as the width of
the bearing and place it on the journal in parallel with
its axis.
(4) Install the crankshaft bearing cap carefully and tighten
the bolts to the specified torque.
(5) Carefully remove the crankshaft bearing cap.
(6) Measure the width of the Plastigage at its widest part
by using a scale printed on the Plastigage package.
Standard value: 0.02 – 0.04 mm
Limit: 0.1 mm
CYLINDER BLOCK
(1) Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects
are evident, correct, or replace.
(2) Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard value: 0.05 mm
Limit: 0.1 mm
(3) If the distortion is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
Includes/combined with cylinder head grinding
Cylinder block height (when new): 284 mm
(4) Check cylinder walls for scratches and seizure. If defects
are evident, correct (bored to oversize) or replace.
Plastigage
Plastigage

ENGINE – Crankshaft and Flywheel11-72
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D. 85.00 – 85.03 mm
Cylindricity 0.01 mm or less
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
SizeIdentification mark
0.50 O.S.50
1.00 O.S.100
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) – 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, working from No.
2, No. 4, No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 – 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.

ENGINE – Throttle Body11-73
THROTTLE BODY
DISASSEMBLY AND REASSEMBLY
1
2
34
5 6
73.5 Nm
3.5 Nm
Disassembly steps
AA1. Throttle position sensor (with built-
in closed throttle position switch)
2. Idle speed control body assembly
3. O-ring
B4. Throttle body
5. Fixed SAS
6. Speed adjusting screw
8. O-ringNOTE
1. The fixed SAS and the speed adjusting screw are
correctly adjusted at the factory and should not be
removed.
2. If the fixed SAS should happen to have been
removed, carry out fixed SAS adjustment.
3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment.

ENGINE – Throttle Body11-74
DISASSEMBLY SERVICE POINTS
ATHROTTLE POSITION SENSOR AND IDLE AIR
CONTROL MOTOR REMOVAL
(1) Do not disassemble the sensor and motor.
(2) Do not immerse solvent to clean the sensor and motor.
Clean then with shop towel.
BTHROTTLE BODY REMOVAL
(1) Do not remove the throttle body.
(2) Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
ATHROTTLE POSITION SENSOR INSTALLATION
(1) Install the throttle position sensor to the throttle body
as shown in the diagram.
(2) Turn throttle position sensor 90° clockwise to set it, and
tighten screws.
(3) Check the continuity between terminal No. 3 (Idle throttle
position switch) and No. 4 (Earth).
Throttle valve conditionContinuity
Fully closedConductive
Fully openNo conductive
If there is no continuity with the throttle valve fully closed,
turn the throttle position sensor counterclockwise, and
then check again.
Throttle position sensor
Earth TPS power supply
TPS outputIdle position switch

ENGINE – Turbocharger11-75
TURBOCHARGER
DISASSEMBLY AND REASSEMBLY
1 2 3
4567
8
11 Nm
Disassembly steps
F
Inspection of turbocharger waste gate
actuator operation
1. Snap pin
2. Waste gate actuator
E3. CouplingD4. Turbine housing
AC5. Snap ring
BB6. Turbine wheel assembly
7. Compressor cover
A8. O-ring