1999 MITSUBISHI LANCER EVOLUTION VI oil

ENGINE – Exhaust Manifold11-31
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
1
2 3 4
5
67 8
9 1011 1213 14
15
16
17 18 19
9 Nm19 Nm41 Nm16 Nm
12 Nm59 Nm
59 Nm
59 Nm
54 Nm14 Nm 49 Nm
41 Nm
10 Nm10 Nm 11 Nm
29 Nm
30 Nm
Head mark 7: 9 Nm
Head mark 10: 13 Nm
Removal steps
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting
5. Exhaust fitting gasket
6. Air outlet fitting
C7. Air outlet fitting gasket
8. Oil return pipe
B9. Gasket
B10. Oil return pipe gasket
(Oil pan side)11. Oil return pipe gasket
(Turbocharger side)
12. Turbocharger assembly
13. Turbocharger gasket
14. Oil pipe
15. Water pipe
16. Water pipe
17. Turbocharger
A18. Exhaust manifold
19. Exhaust manifold gasket

ENGINE – Exhaust Manifold11-32
INSTALLATION SERVICE POINTS
AEXHAUST MANIFOLD INSTALLATION
Tighten the exhaust manifold mounting nuts to the specified
torque in the sequence given in the illustration.
BGASKET / OIL RETURN GASKET INSTALLATION
EVOLUTION IV AND V
Install the gasket with the silicon-printed side toward the oil
pan and with the tabbed end directed as shown.
EVOLUTION VI
(1) Install the gasket with the tabbed end directed as shown.
(2) Apply sealant to both sides of the oil return pipe gasket
and leave it for 20 minutes to dry before installing. Tighten
the mounting bolts to the specified torque.
Specified sealant:
3M
TM AAD Part No. 8731 or equivalent
NOTE
If mounting bolts with head mark 7 have been used,
be sure to replace them with bolts having head mark
10.
1234 5 6
789
Timing belt side
Oil pan
Oil return
pipe gasket Silicon print
Timing belt side
Oil pan
Oil return
pipe gasket
Oil pan
Oil return
pipe
Gasket

ENGINE – Water Pump and Water Hose11-36
INSTALLATION SERVICE POINTS
AWATER PIPE / O-RING INSTALLATION
Wet the O-ring (with water) to facilitate assembly.
Caution
Keep the O-ring free of oil or grease.
BTHERMOSTAT HOUSING INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
CWATER OUTLET FITTING INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
DSEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE GAUGE UNIT
(1) When reusing the gauge unit, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
3M
TM AAD Part No. 8672 or equivalent
ESEALANT APPLICATION TO ENGINE COOLANT
TEMPERATURE SENSOR
(1) When reusing the sensor, clean its thread.
(2) Apply the specified sealant to the thread.
Specified sealant:
3M
TM AAD Part No. 8731 or equivalent
6EN0594
Water pipe
O-ring
9EN0092
9EN0091

ENGINE – Rocker Arms and Camshaft11-37
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
1 2 3
4
5 6
78
9
1011
121314
15
16
1718
11 Nm9 Nm 10 Nm
13 Nm 21 Nm
20 Nm
Apply engine oil to all
moving parts before
installation.
Removal steps
1. Cam position sensor
2. O-ring
3. Cam position sensor support cover
4. Cam position sensor support
gasket
F5. Cam position sensing cylinder
E6. Cam position sensor support
D7. Camshaft oil seal
C8. Camshaft bearing cap rear right
C9. Camshaft bearing cap rear leftC10. Camshaft bearing cap front
C11. Camshaft bearing cap No. 5
C12. Camshaft bearing cap No. 2
C13. Camshaft bearing cap No. 3
C14. Camshaft bearing cap No. 4
B15. Camshaft
16. Rocker arm
A17. Lash adjuster
18. Oil delivery body

ENGINE – Rocker Arms and Camshaft11-38
INSTALLATION SERVICE POINTS
ALASH ADJUSTER INSTALLATION
Caution
If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto rocker arm without allowing diesel
fuel to spill out.
BCAMSHAFT INSTALLATION
(1) Apply engine oil to the journals and cams of the camshafts.
Install the camshafts on the cylinder head.
Use care not to confuse the intake camshaft with the
exhaust one. The intake camshaft has a slit on its rear
end for driving the crankshaft position sensor.
(2) Install the crankshaft sprocket B or spacer and flange
to one end of the crankshaft, and turn the crankshaft
until the timing marks are lined up, setting No. 1 cylinder
to the TDC.
(3) Set the camshafts so that their dowel pins are positioned
at top.
CBEARING CAP INSTALLATION
(1) According to the identification mark stamped on the top
of each bearing cap, install the caps to the cylinder head.
Only “L” or “R” is stamped on front bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing caps. Rear
bearing cap has no stamping.
I: For intake camshaft side
E: For exhaust camshaft side
(2) Tighten the bearing caps in the order shown two to three
times by torquing progressively.
Tighten to the specification in the final sequence.
(3) Check to ensure that the rocker arm is positioned correctly
on the lash adjuster and valve stem end.
Camshaft sprocket side
Slit
Intake side
camshaft
Dowel pin
Cam number
Symbol identifying
intake or exhaust
Timing belt side

ENGINE – Rocker Arms and Camshaft11-39
DCAMSHAFT OIL SEAL INSTALLATION
(1) Apply engine oil to lib area of the oil seal and the front
end outside diameter of the camshaft.
(2) Using special tool install the camshaft oil seals.
ECAMSHAFT POSITION SENSOR SUPPORT
INSTALLATION
Apply 3 mm diameter of form-in-place gasket (FIPG) to the
location shown in the illustration.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
FCAMSHAFT POSITION SENSING CYLINDER
INSTALLATION
(1) Set the No. 1 cylinder to the compression top dead center
position (so that dowel pin of the exhaust camshaft is
at the top).
(2) Install the camshaft position sensing cylinder so that the
white paint mark is facing in the direction shown in the
illustration.
INSPECTION
CAMSHAFT
Measure the cam height.
ItemStandard value mmLimit mm
Intake35.7935.29
Exhaust35.4934.99
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure is evident,
replace the rocker arm.
MD998713
Camshaft
position
sensorPaint mark
Roller
Tip

ENGINE – Rocker Arms and Camshaft11-40
LASH ADJUSTER
Caution
(1) The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign substances.
(2) Do not attempt to disassemble the lash adjusters.
(3) Use only fresh diesel fuel to clean the lash adjusters.
(1) Prepare three containers and approximately five liters
of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.
(2) Place the lash adjuster in container A and clean its outside
surface.
NOTE
Use a nylon brush if deposits are hard to remove.
(3) While gently pushing down the internal steel ball using
wire (0.5 mm in diameter) or special tool MD998442,
move the plunger through 5 to 10 strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
this operation will remove dirty oil.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
NOTE
If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.
Outside
cleaningInside
cleaningFilling with
diesel fuel
A
B
C
Diesel
fuel
MD998442Diesel fuel

ENGINE – Rocker Arms and Camshaft11-41
(4) Removal the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.
(5) Place the lash adjuster in container B. Then, gently push
down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442 and move the plunger through
5 to 10 strokes until it slides smoothly. This operation
will clean the lash adjuster’s pressure chamber.
Caution
The steel ball spring is extremely weak, so the lash
adjuster’s functionality may be lost if the air bleed
wire is pushed in hard.
(6) Remove the lash adjuster from the container. Then, push
down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.
Caution
Make sure the oil hole in the side of the body is pointing
toward container A. Do not point the oil hole at yourself
or other people.
(7) Place the lash adjuster in container C. Then, gently push
down the internal steel ball using wire (0.5 mm in diameter)
or special tool MD998442.
Caution
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter
the pressure chamber when chamber is filled with
diesel fuel.
(8) Stand the lash adjuster with its plunger at the top, then
push the plunger downward firmly until it moves through
its greatest possible stroke. Return the plunger slowly,
then release the steel ball and allow the pressure chamber
to fill with diesel fuel.
MD998442
Diesel fuel
MD998442Diesel fuel
MD998442
Diesel fuel
MD998442
Diesel fuel
MD998442Diesel fuel