engine oil MITSUBISHI LANCER EVOLUTION VI 1999 Repair Manual

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 – Turbocharger11-76
DISASSEMBLY SERVICE POINTS
ASNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
BTURBINE WHEEL ASSEMBLY REMOVAL
Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
CLEANING
(1) Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
(2) Use a plastic scraper or hard brush to clean aluminum
parts.
REASSEMBLY SERVICE POINTS
AO-RING INSTALLATION
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
BTURBINE WHEEL ASSEMBLY
(1) Apply a light coat of engine oil to the periphery of the
O-ring.
(2) Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
Snap ring
Turbine
wheel
assembly
O-ring
Dowel pin hole
Dowel pin

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 – Alternator11-80
DISASSEMBLY SERVICE POINTS
AFRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.
BALTERNATOR PULLEY REMOVAL
Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
CSTATOR / REGULATOR ASSEMBLY REMOVAL
(1) Unsolder the stator with a soldering iron (180 to 250
W). Complete this work within four seconds not to transfer
heat to the diode.
(2) When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Caution
1. Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.
REASSEMBLY SERVICE POINTS
AREGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
Soldered
Rear bracket
Brush
WireWire

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

ENGINE – Alternator11-82
RECTIFIERS CHECK
(1) Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(2) Inspect the (–) heat sink by checking the continuity
between the (–) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(3) Check the diode trio by connecting an ohmmeter to both
ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the recitifier.
BRUSH CHECK
(1) Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Limit: 2 mm or less
(2) The brush can be removed if the solder of the brush
lead wire is removed.
(3) When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
Protrusion
length
Soldered

ENGINE – Starter Motor11-84
DISASSEMBLY SERVICE POINTS
AMAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
BARMATURE / BALL REMOVAL
Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
CSNAP RING / STOP RING REMOVAL
(1) Press stop ring off snap ring with a suitable socket.
(2) Remove snap ring with snap ring pliers and then remove
stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
(1) Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
(2) Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch.
(3) The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
Magnetic
switch“S” terminal
“B” terminal
Field coil wire “M” terminal
Stop ringSocket
Pinion gear
Overrunning
clutch
Armature
Snap ring
Pinion gear
Overrunning
clutchSnap ring pliers
Armature

ENGINE – Starter Motor11-86
OVERRUNING CLUTCH CHECK
(1) While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
properly, replace overrunnig clutch assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING CHECK
Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
BRUSH AND SPRING REPLACEMENT
(1) Brushes that are worn beyond wear limit line, or oil-soaked,
should be replaced.
(2) When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
(1) Place armature in a growler.
(2) Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
ARMATURE COIL EARTH TEST
Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
Free
Lock
Wear limit line
Growler