wheel MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

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 – Special Handling Instruments for Towing00-20
SPECIAL HANDLING INSTRUMENTS FOR TOWING
Towing methodsRemarks
If a tow truck is used
Lifting method for 4 wheels – GoodFor 4WD models, the basic principle is that all
four wheels are to be raised before towing.
The shift lever should be set to 1st gear and
the parking brake should be applied.
Front wheels lifted – No goodThe vehicle must not be towed by placing only
its front wheels or only the rear wheels on a
rolling dolly, because to do so will result in
deterioration of the viscous coupling and result
in the viscous coupling causing the vehicle to
jump forward suddenly.
Front wheels lifted – No goodIf only the front wheels or only the rear wheels
are lifted for towing, the bumper will be damaged.
In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in heat
damage to the rear bushing of the transfer, and
so should never be done.
Rear wheels lifted – No good
Towing by rope or cable – GoodThe front and rear wheels must rotate normally.
Both running and driving systems must function
normally.
The shift lever must be set to the neutral position
and the ignition key must be set to “ACC”.

GENERAL – Brake Test00-21
BRAKE TEST
In order to stabilize the viscous coupling’s dragging force,
the brake test should always be conducted after the
speedometer test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
Caution
The rear wheels should remain on the ground.
3. If the brake dragging force exceeds the specified value,
jack up the vehicle and manually rotate each wheel to
check the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value,
the cause may be the effect of the viscous coupling’s
dragging force, so jack up the front wheels and check
the rotation condition of the wheels in this state for no
effect by the viscous coupling’s dragging force.
REAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow the
same procedures as for the front wheel measurements.
Brake tester

11-1
ENGINE
CONTENTS
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . .
Service Specifications 3. . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 5. . . . . . . . . . . . . . . . . . . . . .
New Tightening Method by Use of Bolts
to Be Tightened in Plastic Area 9. . . . . . . . . . . .
Sealants 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Form-In-Place Gasket 10. . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 11. . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR AND IGNITION SYSTEM 14.
TIMING BELT 15. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL PARTS 27
SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST MANIFOLD 31. . . . . . . . . . . . . . . . .
WATER PUMP AND WATER HOSE 34. . . . .
ROCKER ARMS AND CAMSHAFT 37. . . . . .
CYLINDER HEAD AND VALVES 43. . . . . . . .
FRONT CASE, COUNTERBALANCE
SHAFT AND OIL PAN 51. . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD 59. . . . . .
CRANKSHAFT AND FLYWHEEL 67. . . . . . . .
THROTTLE BODY 73. . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 75. . . . . . . . . . . . . . . . . . . . .
ALTERNATOR 79. . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR 83. . . . . . . . . . . . . . . . . . . . .

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 – Specifications11-8
ItemsNm
Front case and oil pan
Drain plug39
Oil pan7
Oil screen19
Buffle plate22
Oil pressure switch10
Oil cooler by-pass valve54
Relief plug44
Plug24
Front case24
Oil pump cover (Screw)10
Oil pump cover (Bolt)16
Piston and connecting rods
Connecting rod nut20 + 90° to 94°
Crankshaft and flywheel
Flywheel bolt132
Rear plate11
Bell housing cover9
Oil seal case11
Beam bearing cap bolt25 + 90°
Check valve32
Throttle body
Throttle position sensor3.5
Idle speed control body assembly3.5
Turbocharger
Waste gate actuator11

ENGINE – Special Tools11-11
SPECIAL TOOLS
ToolNumberNameUse
MD998781Flywheel stopperHolding of flywheel and drive plate
MD998778Crankshaft
sprocket pullerRemoval of crankshaft sprocket
MD998719Pulley holder pinHolding camshaft sprocket
MB990767Crankshaft pulley
holder
MD998785Sprocket stopperHolding silent shaft sprocket
MD998767Tensioner puller
socket wrenchAdjustment of timing belt tension
MD998738Set screw
MD998713Camshaft oil seal
installerInstallation of camshaft oil seal
MD998442Lash adjuster wireAir bleeding of lash adjuster

ENGINE – Timing Belt11-20
GTIMING BELT “B” INSTALLATION
(1) Align timing marks on the crankshaft sprocket “B” and
counterbalance shaft sprocket with the marks on the front
case respectively.
(2) Install the timing belt “B” on the crankshaft sprocket “B”
and counterbalance shaft sprocket. There should be no
slack on the tension side.
(3) Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
(4) Move the tensioner “B” in the direction of arrow while
lifting with a finger to give a sufficient tension to the tension
side of timing belt. In this condition, tighten bolt to secure
tensioner “B”. When the bolt is tightened, use care to
prevent shaft from turning together. If shaft is turned
together, belt will be overtensioned.
(5) Check to ensure that timing marks on sprockets and front
case are in alignment.
(6) Press with index finger the center of span on the tension
side of timing belt “B”. The bolt must deflect 5 – 7 mm.
HCRANKSHAFT BOLT TIGHTENING
(1) Using the special tool, hold the flywheel or drive plate.
(2) Install the crankshaft pulley in position.
Timing
marks
Timing
marks
(on front
case)

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