check oil MITSUBISHI LANCER EVOLUTION VI 1999 User Guide

ENGINE – Cylinder Head and Valves11-46
BVALVE SPRING INSTALLATION
Direct the valve spring end with identification color toward
the spring retainer.
CRETAINER LOCK INSTALLATION
The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and damage,
the stem seal.
DCYLINDER HEAD BOLT INSTALLATION
(1) When installing the cylinder head bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm
(2) Apply engine oil to the bolt threads and to the washers.
(3) Using the special tool (MB991654) and according to the
tightening sequence, tighten the bolts to the specified
torque.
Tightening torque: 78 Nm
(4) Loosen all bolts fully.
(5) Retighten the loosened bolts to a torque of 20 Nm in
the specified tightening sequence.
MD998772
MD998735
6EN0782
Shank length
Timing belt side

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-57
MOIL FILTER INSTALLATION
(1) Clean the installation surfaces of the filter bracket.
(2) Apply engine oil to the O-ring of the oil filter.
(3) Screw the oil filter in until the O-ring contacts the bracket.
Then tighten 3/4 turn (tightening torque: 16 Nm).
NDRAIN PLUG GASKET INSTALLATION
Caution
Fitting the gasket in a wrong way will result in oil leakage.
Install the drain plug gasket in the direction shown.
INSPECTION
FRONT CASE
(1) Check oil holes for clogging and clean if necessary.
(2) Check the left counterbalance shaft front bearing section
for wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
(3) Check the front case for cracks and other damage.
Replace cracked or damaged front case.
OIL SEAL
(1) Check the oil seal lip for wear and damage. Replace
oil seal if necessary.
(2) Check the oil seal lip for deterioration. Replace oil seal
if necessary.
6EN0591
Bracket side
Oil pan
side Drain plug
GasketOil pan

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-58
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with
bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.
OIL COOLER BY-PASS VALVE (ENGINE WITH AIR
COOLING TYPE OIL COOLER)
(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension (L) measures the standard
valve under normal temperature and humidity.
Standard value (L): 34.5 mm
(3) The dimension must be the standard value when
measured after the valve has been dipped in 100°C oil.
Standard value (L): 40 mm or more
OIL PUMP
(1) Assemble the oil pump gear to the front case and rotate
it to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
(3) Check the side clearance.
Standard value:
Drive gear 0.08 – 0.14 mm
Driven gear 0.06 – 0.12 mm
Valve

ENGINE – Piston and Connecting Rod11-62
(10)Check that the piston moves smoothly
BOIL RING INSTALLATION
(1) Fit the oil ring spacer into the piston ring groove.
NOTE
1. The side rails and spacer may be installed in either
direction.
2. New spacers and side rails are colored for
identification of their sizes.
SizeIdentification color
StandardNone
0.50 mm oversizeRed
1.00 mm oversizeYellow
(2) Install the upper side rail.
To install the side rail, first fit one end of the rail into
the piston groove, then press the remaining portion into
position by finger. See illustration.
Use of ring expander to expand the side rail end gap
can break the side rail, unlike other piston rings.
Caution
Do not use piston ring expander when installing side
rail.
(3) Install the lower side rail in the same procedure as
described in step (2).
(4) Make sure that the side rails move smoothly in either
direction.
6EN1237
Lower side railSpacer
Upper
side rail
1EN0269
Side rail gap

ENGINE – Piston and Connecting Rod11-65
GCONNECTING ROD CAP NUT INSTALLATION
Caution
If the cylinder head has been installed before installing
the connecting rod cap nut, be sure to remove the spark
plugs.
(1) Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should
be examined BEFORE reuse. If the bolt threads are
“necked down”, the bolt should be replaced.
Necking can be checked by running a nut with fingers
to the full length of the bolt threads. If the nut does not
run down smoothly, the bolt should be replaced.
(2) Before installation of each nut, apply engine oil to the
thread portion and bearing surface of the nut.
(3) Install each nut to the bolt and tighten it with fingers.
Then tighten the nuts alternately to install the cap properly.
(4) Tighten the nuts to a torque of 20 Nm.
(5) Make a paint mark on the head of each nut.
(6) Make a paint mark on the bolt end at the position 90°
to 94° from the paint mark made on the nut in the direction
of tightening the nut.
(7) Give a 90° to 94° turn to the nut and make sure that
the paint mark on the nut and that on the bolt are in
alignment.
Caution
1. If the nut is turned less than 90°, proper fastening
performance may not be expected. When
tightening the nut, therefore, be careful to give
a sufficient turn to it.
2. If the nut is overtightened (exceeding 94°), loosen
the nut completely and then retighten it by
repeating the tightening procedure from step (1).
INSPECTION
PISTON RING
(1) Check the piston ring for damage, excessive wear, and
breakage and replace if defects are evident. If the piston
has been replaced with a new one, the piston rings must
also be replaced with new ones.
(2) Check for the clearance between the piston ring and
ring groove. If the limit is exceeded, replace the ring or
piston, or both.
Standard value:
No. 1 ring 0.04 – 0.075 mm
No. 2 ring 0.02 – 0.06 mm
Limit: 0.1 mm
6AE0298
90° to 94°Paint mark
Paint
mark
NutBolt

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 Flywheel11-69
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 Flywheel11-71
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 – Turbocharger11-78
COMPRESSOR COVER
Check the compressor cover for traces of contact with the
compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
(1) Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
(2) Check the oil passage of the turbine wheel assembly
for deposit and clogging.
(3) In the case of water cooled type, check also the water
passage for deposit and clogging.
(4) Check the turbine wheel and compressor wheel for light
and smooth turning.Oil passage
Turbine wheel
Compressor
wheelWater passage

ENGINE – Alternator11-81
BROTOR INSTALLATION
After installing the rotor, remove the wire used to fix the brush.
INSPECTION
ROTOR CHECK
(1) Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 – 5 Ω
(2) Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
STATOR CHECK
(1) Check the continuity between the coil leads, and if there
is continuity, replace the stator.
(2) Check the continuity between the coil and core, and if
there is continuity, replace the stator.
Wire