lock MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat over 93C, so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B – Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

GENERAL – Precautions Before Service00-15
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Always use the designated special tools and test equipment.
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(4) Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
module and clock spring.) If faulty, replace it.
(5) Warnings labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
Sun visor
Glove box
SRS air bag control unit
Steering wheel
Steering gear and linkage
Air bag module
Clock spring
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upwards.
(7) Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle equipped
with an air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.

GENERAL – Tightening Torque00-22
TIGHTENING TORQUE
Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel
and plated with zinc.
(2) The threads and bearing surface of bolts and
nuts are all in dry condition.The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast
inserted nuts.
(4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Thread sizeTorque Nm
Bolt nominal
diameter (mm)Pitch (mm)Head mark “4”Head mark “7”Head mark “8”
M50.82.54.95.9
M61.04.98.89.8
M81.25122225
M101.25244452
M121.25418196
M141.572137157
M161.5111206235
M181.5167304343
M201.5226412481
M221.5304559647
M241.5392735853
Flange bolt and nut tightening torque
Thread sizeTorque Nm
Bolt nominal
diameter (mm)Pitch (mm)Head mark “4”Head mark “7”Head mark “8”
M61.04.99.812
M81.25132428
M101.25264957
M101.5244454
M121.254693103
M121.75428196

ENGINE – Specifications11-3
SPECIFICATIONS
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Timing belt
Auto-tensioner rod projection length mm12–
Auto-tensioner rod pushed-in amount [when pushed with a force of 98
– 196 N] mm1.0 or less–
Rocker arms and camshaft
Camshaft cam height mmIntake35.7935.29
Exhaust35.4934.99
Camshaft journal outer diameter mm26–
Cylinder head and valves
Cylinder head flatness of gasket surface mmLess than 0.050.2
Cylinder head grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block–0.2
Cylinder head overall height mm131.9 – 132.1–
Cylinder head bolt shank length mm–Maximum 99.4
Valve thickness of valve head (margin) mmIntake1.00.5
Exhaust1.51.0
Overall valve length mmIntake109.5109.0
Exhaust109.7109.2
Valve thickness to valve guide clearance
mm
Intake0.02 – 0.050.10
mmExhaust0.05 – 0.090.15
Valve face angle45° – 45.5°–
Valve spring free length mm48.347.3
Valve spring load/installed height N/mm294/40.0–
Valve spring out-of-squareness1.5° or lessMaximum 4°
Valve seat contact width mm0.9 – 1.3–
Valve guide inner diameter mm6.6–
Valve guide projection from cylinder head upper surface mm20.5–
Valve stem projection mmIntake49.2049.70
Exhaust48.4048.90
Oversize rework dimensions of valve guide
hole mm
0.05 O.S.12.05 – 12.07–
hole mm0.25 O.S.12.25 – 11.27–
0.50 O.S.12.50 – 12.52–

ENGINE – Specifications11-4
ItemsLimit Standard value
Intake oversize rework dimensions of valve
guide hole mm
0.3 O.S.35.30 – 35.33–
guide hole mm0.6 O.S.35.60 – 35.63–
Exhaust oversize rework dimensions of
valve guide hole mm
0.3 O.S.33.30 – 33.33–
valve guide hole mm0.6 O.S.33.60 – 33.63–
Front case and oil pan
Oil pump side clearance mmDrive gear0.08 – 0.14–
Driven gear0.06 – 0.12–
Oil pressure at curb idle speed kPa [Oil temperature is 75 to 90°C]78 or more–
Piston and connecting rod
Piston outer diameter mm85.0–
Piston ring side clearance mmNo. 1 ring0.04 – 0.075–
No. 2 ring0.02 – 0.06–
Piston ring end gap mmNo. 1 ring0.25 – 0.350.8
No. 2 ring0.40 – 0.550.8
Oil ring0.10 – 0.401.0
Piston pin outer diameter mm21.0–
Piston pin press-in load N (Room temperature)7,350 – 17,200–
Crankshaft pin oil clearance mm0.02 – 0.050.1
Connecting rod big end side clearance mm0.10 – 0.250.4
Crankshaft and flywheel
Crankshaft end play mm0.05 – 0.250.40
Crankshaft journal outer diameter mm57.0–
Crankshaft pin outer diameter mm44.0–
Crankshaft journal oil clearance mm0.02 – 0.040.1
Bearing cap bolt shank length mm–Maximum 71.1
Piston to cylinder clearance mm0.02 – 0.04–
Cylinder block grinding limit of gasket surface mm
Total resurfacing depth of both cylinder head and cylinder block–0.2
Cylinder block overall height mm284–
Cylinder block inner diameter mm85.0–
Cylinder block cylinder mm0.01–
Turbocharger
Waste gate actuator operation check kPa100113.3

ENGINE – Specifications11-7
ItemsNm
OIl return pipe (Turbocharger side)9
Oil return pipe (Oil pan side – Head mark 7)9
Oil return pipe (Oil pan side – Head mark 10)13
Oil pipe11
Oil pipe eye bolt (Cylinder head side)16
Oil pipe eye bolt (Turbocharger side)30
Water pipe11
Water pipe eye bolt41
Exhaust manifold (M8)29
Exhaust manifold (M10)49
Exhaust manifold (Turbocharger side)59
Water pump and water hose
Water temperature sensor29
Water temperature gauge unit11
Water inlet fitting24
Water outlet fitting (M6)10
Water outlet fitting (M8)13
Thermostat housing24
Thermostat housing (Clamp)11
Water inlet pipe (Cylinder block)13
Water inlet pipe (Outlet fitting)10
Water pump14
Knock sensor22
Rocker arms and camshaft
Camshaft position sensor9
Camshaft position sensor cover10
Camshaft position sensing cylinder21
Camshaft position sensing support13
Camshaft bearing cap20
Oil delivery body11
Cylinder head and valves
Cylinder head bolt [Tighten to 78 Nm and then completely before tightening to final torque
specification]20
90° + 90°

ENGINE – Specifications11-10
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

ENGINE – Timing Belt11-16
REMOVAL SERVICE POINTS
ATIMING BELT REMOVAL
(1) If the timing belt is to be reused, chalk an arrow mark
on the back surface of the belt so that the belt can be
reinstalled in the same direction.
(2) Place the exhaust camshaft sprocket in a position where
the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.
Caution
The camshaft sprocket on the exhaust side can turn
very easily because of the valve spring tension. Use
care not to allow your fingers to get caught by the
sprocket.
(3) Loosen the lock nut of the tensioner pulley, then remove
the timing belt.
BOIL PUMP SPROCKET REMOVAL
(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the
counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.
CCRANKSHAFT BOLT LOOSENING
(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.
DCRANKSHAFT SPROCKET REMOVAL
If it is difficult to remove the sprocket, use the special tool.
Timing mark

ENGINE – Timing Belt11-19
DSEALANT APPLICATION TO ROCKER COVER
Apply sealant to the areas indicated in the illustration.
Specified sealant: 3M
TM AAD Part No. 8672 or equivalent
Apply sealantApply sealant
Apply sealant 10 mm
10 mm
10 mm
10 mm
Apply sealant
ESPACER INSTALLATION
Install the spacer with the chamfered end toward the oil seal.
FCOUNTERBALANCE SHAFT SPROCKET
INSTALLATION
(1) Install the counterbalance shaft sprocket and screw the
bolt.
(2) Install special tool MD998785 as shown in the illustration
to lock the counterbalance shaft.
(3) Tighten the bolt, and then remove the special tool.
Counter-
balance
shaft
Sharp
edge
MD998785

ENGINE – Timing Belt11-21
IOIL PUMP SPROCKET INSTALLATION
(1) Insert a Phillips screwdriver (shank diameter 8 mm shaft)
through the plug hole on the left side of the cylinder
block to block the left counterbalance shaft.
(2) Install the oil pump sprocket.
(3) Apply a proper amount of engine oil to the bearing surfaces
of the nuts.
(4) Tighten the nuts to the specified torque.
JAUTO TENSIONER INSTALLATION
(1) If the auto tensioner rod is in its fully extended position,
reset it as follows.
(2) Clamp the auto-tensioner in the vise with soft jaws.
(3) Push in the rod little by little with the vise until the set
hole A in the rod is aligned with the hole B in the cylinder.
(4) Insert a wire (1.4 mm in diameter) into the set holes.
(5) Unclamp the auto tensioner from the vise.
(6) Install the auto tensioner to front case and tighten to
the specified torque.
Caution
Leave the wire installed in the auto tensioner.
KTENSIONER PULLEY INSTALLATION
Install the tensioner pulley in such direction that its two small
holes are arranged vertically.
6EN0564
A
B
6EN1323
Small holes