1999 MITSUBISHI LANCER EVOLUTION VI height

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 – 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 Camshaft11-42
(9) Remove the lash adjuster from the container, then stand
the lash adjuster with its plunger at the top. Push the
plunger firmly and check that it does not move. Also,
check that the lash adjuster’s height matches that of a
new lash adjuster.
NOTE
If lash adjuster contracts, perform the operations (7)
through (9) again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts after performing
these steps.
(10)Stand the lash adjuster upright to prevent diesel fuel from
spilling out. Do not allow the lash adjuster to become
contaminated by dirt or other foreign matter. Fit the lash
adjuster onto the engine as soon as possible.

ENGINE – Cylinder Head and Valves11-47
(6) Make paint marks on the cylinder head bolt heads and
cylinder head.
(7) Give a 90° turn to the cylinder head bolts in the specified
tightening sequence.
(8) Give another 90° turn to the cylinder head bolts and make
sure that the paint mark on the head of each cylinder
head bolt and that on the cylinder head are on the same
straight line.
Caution
1. 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.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating the
tightening procedure from step (1).
INSPECTION
CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and thickness gauge.
Standard value: 0.05 mm
Limit: 0.2 mm
(2) If the service limit is exceeded, correct to meet
specification.
Grinding limit: *0.2 mm
* Includes combined with cylinder block grinding.
Cylinder head height (Specification when new):
131.9 – 132.1 mm
6AE0297
90°
Paint mark
90°
9EN0064

ENGINE – Cylinder Head and Valves11-48
VA LV E
(1) Check the valve face for correct contact. If incorrect, reface
using a valve refacer. Valve seat contact should be
maintained uniform at the center of valve face.
(2) If the margin exceeds the service limit, replace the valve.
ItemStandard value mmLimit mm
Intake1.00.5
Exhaust1.51.0
(3) Measure valve’s total length. If measurement is less than
specified, replace the valve.
ItemStandard value mmLimit mm
Intake109.5109.0
Exhaust109.7109.2
VALVE SPRING
(1) Measure the free height of spring and, if it is smaller
than the limit, replace.
Standard value mmLimit mm
48.347.3
(2) Measure the squareness of the spring and, if the limit
is exceeded, replace.
Standard valueLimit
1.5°4°
VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide or
valve, or both.
ItemStandard value mmLimit mm
Intake0.02 – 0.050.10
Exhaust0.05 – 0.090.15
1EN0264
Free
height
Out of
square
Valve
guide

ENGINE – Cylinder Head and Valves11-49
VA LV E S E AT
Assemble the valve, then measure the valve stem projection
between the end of the valve stem and the spring seating
surface. If the measurement exceeds the specified limit,
replace the valve seat.
ItemStandard value mmLimit mm
Intake49.2049.70
Exhaust48.4048.90
VALVE SEAT RECONDITIONING PROCEDURE
(1) Before correcting the valve seat, check for clearance
between the valve guide and valve and, if necessary,
replace the valve guide.
(2) Using the seat grinder, correct to obtain the specified
seat width and angle.
(3) After correcting the valve seat, lap the valve and valve
seat using lapping compound. Then, check the valve
stem projection (refer to VALVE SEAT in INSPECTION).
VALVE SEAT REPLACEMENT PROCEDURE
(1) Cut the valve seat to be replaced from the inside to thin
the wall thickness. Then, remove the valve seat.
(2) Rebore the valve seat hole in the cylinder head to a
selected oversize valve seat diameter.
Valve seat ring hole diameter
ItemStandard value mm
Intake0.30 O.S.35.30 – 35.33
0.60 O.S.35.60 – 35.63
Exhaust0.30 O.S.33.30 – 33.33
0.60 O.S.33.60 – 33.63
(3) Before fitting the valve seat, either heat the cylinder head
up to approximately 250°C or cool the valve seat in liquid
nitrogen, to prevent the cylinder head bore from galling.
(4) Using a valve seat cutter, correct the valve seat to the
specified width and angle.
See “VALVE SEAT RECONDITIONING PROCEDURE”.
DEN0212
Valve stem end
Valve stem
projection
Spring seating
surface
6EN0491
0.9 – 1.3 mm
43.5° – 44°
0.5 – 1 mm
0.5 – 1 mm
1EN0275
Height of
seat ring
Oversize I.D.

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