1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-56
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
KPLUG INSTALLATION
(1) Install a new O-ring to the groove of the front case.
(2) Install the plug to the front case.
(3) Fit the special tool MD998162 on the plug, and then
hold it in position with special tool MD998783.
(4) Tighten the plug to the specified torque.
(5) Remove the special tools MD998783 and MD998162.
LOIL PAN INSTALLATION
(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
NOTE
1. Be sure to install the oil pan 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.
(3) Note the difference in bolt lengths at the location shown.
MD998162
MD998783
6EN0213
Bolt hole
portionGroove
portion

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 Rod11-59
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
Apply engine oil to all
moving parts before
installation.
12 34
56
7
8
910
1112
20 Nm + 90 to 94
Removal steps
G1. Connecting rod nut
AF2. Connecting rod cap
E3. Connecting rod bearing
D4. Piston and connecting rod assem-
bly
5. Connecting rod bearing
C6. Piston ring No. 1C7. Piston ring No. 2
B8. Oil ring
BA9. Piston pin
10. Piston
11. Connecting rod
12. Bolt

ENGINE – Piston and Connecting Rod11-60
REMOVAL SERVICE POINTS
ACONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
rod big end for correct reassembly.
(2) Keep the removed connecting rods, caps, and bearings
in order according to the cylinder number.
BPISTON PIN REMOVAL
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
(3) Using a press, remove the piston pin.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.

ENGINE – Piston and Connecting Rod11-61
INSTALLATION SERVICE POINTS
APISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
(2) Obtain dimension L (to be used later) from the above
measurements by using by following formula.
L =
(A – C) – (B – D)
2
(3) Insert the special tool, Push Rod, into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
(7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 7,350 – 17,200 N
3 mm + L

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 Rod11-63
CPISTON RING NO. 2 / PISTON RING NO. 1
INSTALLATION
(1) Using piston ring expander, fit No. 2 and then No. 1 piston
ring into position.
NOTE
1. The ring end is provided with identification mark.
ItemIdentification mark
No. 1 ring1R
No. 2 ring2R
2. Install piston rings with identification mark facing up,
to the piston crown side.
3. Size marks on position rings are as follows.
SizeSize mark
StandardNone
0.50 mm oversize50
1.00 mm oversize100
DPISTON AND CONNECTING ROD ASSEMBLY
INSTALLATION
(1) Liberally coat engine oil on the circumference of the piston,
piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
(3) Rotate the crankshaft so that crank pin is on the center
of cylinder bore.
(4) Use suitable thread protectors on the connecting rod bolts
before inserting piston and connecting rod assembly into
the cylinder block.
Care must be taken not to nick the crank pin.
(5) Using a suitable piston ring compressor tool, install the
piston and connecting rod assembly into the cylinder block.
ECONNECTING ROD BEARINGS INSTALLATION
When the bearing needs replacing, select and install a proper
bearing by the following procedure.
(1) Measure the crankshaft pin diameter and confirm its
classification from the following table. In the case of a
crankshaft supplied as a service part, identification colors
of its pins are painted at the positions shown in the
illustration.
9EN0524
Identification mark
Identification mark
Side mark
No. 1
No. 2
Timing belt side