2007 MITSUBISHI LANCER EVOLUTION engine

11B-1
ENGINE
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 3..........................
Service Specifications 3.........................
Machining Standards 5.........................
Tightening Torque 5............................
Sealants 8.....................................
Form-In-Place Gasket 8........................
SPECIAL TOOLS 9...........................
ALTERNATOR AND IGNITION SYSTEM 12....
TIMING BELT 13.............................
FUEL SYSTEM 26............................SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 28...............................
EXHAUST MANIFOLD 30.....................
WATER PUMP AND WATER HOSE 32........
ROCKER ARMS AND CAMSHAFT 34.........
CYLINDER HEAD AND VALVE 40.............
OIL PUMP AND OIL PAN 47.................
PISTON AND CONNECTING ROD 56..........
CRANKSHAFT AND CYLINDER BLOCK 64....

ENGINE OVERHAUL -General Description11B-2
GENERAL DESCRIPTION
LIST OF MODELS
Vehicle nameVehicle modelEngine modelDisplacement mLSpecifications
LANCER Evolution VIICT9A4G63 - 72000DOHC 16 valve T/C
SPECIFICATIONS
ItemsSpecifications
Bore×stroke mm85×88
Total displacement mL1,997
Combustion chamber shapePentroof type
Number of cylinders4
Valve mechanismTypeDOHC
Intake valve2
Exhaust valve2
Lash adjusterHydraulic type
Rocker armRoller follower type
Compression ratio8.8
Fuel injection deviceElectronic control MPI
Ignition device typeElectronic control type 2-coil
Alternator typeAlternating current type (IC regulator built in)
Starter motor typeDeceleration drive

ENGINE OVERHAUL -Specifications11B-3
SPECIFICATIONS
SERVICE SPECIFICATIONS
Unit: mm
Items
Standard valueLimited value
Timing belt
Timing belt B
Vibration frequency Hz (during inspection)
Vibration frequency Hz (when re-tensing working belt)
Vibration frequency Hz (when mounting new belt)
Deflection amount (during inspection)
Deflection amount (when re-tensing working belt)
Deflection amount (when mounting new belt)
Auto-tensioner
Rod protrusion length (free length)
Rod protrusion length (when mounting timing belt)
Rod recess amount (when pressed at 98 to 196 N•m)
56 - 92
76 - 92
76 - 92
5-10
5-7
5-7
12.0
3.8 - 4.5
Within 1
-
-
-
Rocker arm, camshaft
Camshaft
Cam height
Intake
Exhaust
35.79
35.4935.29
34.99
Cylinder head, valve
Cylinder head
Lower surface strain
Lower surface grinding limit (in combination with combined cylinder block)
Total height
Valve
Margin
Intake
Exhaust
Total length
Intake
Exhaust
Valve spring
Free height
Squareness
Valve guide
Clearance between valve guide and valve stem
Intake
Exhaust
Total length
Intake
Exhaust
Protrusion amount
Valve seat
Contact width
Valve protrusion amount from spring seat surface
Intake
Exhaust
0.05
-
131.9 - 132.1
1.0
1.5
109.50
109.70
48.3
1.5_or less
0.02 - 0.05
0.05 - 0.09
45.5
50.5
19.2 - 19.8
0.9 - 1.3
49.20
48.400.2
0.2
-
0.5
1.0
109.00
109.20
47.3
4_
0.10
0.15
-
-
-
-
49.70
48.90

ENGINE OVERHAUL -Specifications11B-4
Unit: mm
Items
Standard valueLimited value
Oil pump, oil pan
Oil pump
Side clearance
Drive gear
Driven gear
0.08 - 0.14
0.06 - 0.12-
-
Piston, connecting rod
Piston
Press-in load N
Piston ring
Clearance between ring and ring groove
No. 1 ring
No. 2 ring
Closed gap
No. 1 ring
No. 2 ring
Oil
Connecting rod
Large end thrust clearance
Crankshaft
Pin section oil clearance
7,355 - 17,162
0.03 - 0.07
0.02 - 0.06
0.20 - 0.30
0.35 - 0.50
0.10 - 0.40
0.10 - 0.25
0.03 - 0.05-
0.1
0.1
0.8
0.8
1.0
0.4
0.1
Crankshaft, cylinder block
Crankshaft
End play
Journal section oil clearance
Cylinder block
Upper surface strain
Upper surface grinding limit (in combination with combined cylinder head)
Cylinder bore
Cylindricity
Clearance between piston and cylinder
0.05 - 0.25
0.03 - 0.04
0.05
-
85.0
0.01 or less
0.02 - 0.040.4
0.1
0.1
0.2
-
-
-
Turbocharger
Waste gate actuator operation pressure100 kPa-
Alternator
Alternator
Rotor coil resistanceΩ
Brush protrusion length
3-5
--
2
Starter motor
Starter motor
Deviation on commutator periphery
Commutator outer diameter
Undercut depth
0.05
29.4
0.50.1
28.8
0.2

ENGINE OVERHAUL -Specifications11B-5
MACHINING STANDARDS
Unit: mm
Items
Standard valueLimited value
Cylinder head, valve
Cylinder head
Oversize valve guide hole diameter
0.05 O.S.
0.25 O.S.
0.50 O.S.
Oversize valve seat hole diameter
Intake
0.3 O.S.
0.6 O.S.
Exhaust
0.3 O.S.
0.6 O.S.
12.05 - 12.07
12.25 - 12.27
12.50 - 12.52
35.30 - 35.33
35.60 - 35.63
33.30 - 33.33
33.60 - 33.63-
-
-
-
-
-
-
TIGHTENING TORQUE
ItemsTightening torque N·m
Alternator, ignition system
Oil level gauge guide bolt13±1
Water pump pulley bolt8.8±1.0
Alternator brace bolt (flange)23±3
Alternator brace bolt (washer)22±4
Alternator nut44±10
Crankshaft pulley bolt25±4
Center cover bolt3±0.5
Ignition coil bolt10±2
Spark plug25±5
Connector bracket bolt8.8±1.0
Timing belt
Timing belt cover bolt (flange)11±1
Timing belt cover bolt (washer)9±1
Power steering pump bracket bolt49±9
Tensioner pulley bolt49±6
Tensioner arm bolt21±4
Auto tensioner bolt23±3
Idler pulley bolt35±6
Crank angle sensor bolt8.8±1.0
Oil pump sprocket nut54±5
Crankshaft bolt162±5
Tensioner B bolt19±3
Counter balance shaft sprocket bolt46±3
Rocker cover bolt3.5±0.5
Engine support bracket bolt49±5

ENGINE OVERHAUL -Specifications11B-6
Items Tightening torque N·m
Camshaft sprocket bolt88±10
Fuel system
Throttle body bolt19±3
EGR valve bolt20±2
Fuel pressure regulator bolt8.8±2.0
Delivery pipe and injector bolt11±1
Vacuum hose and pipe bolt11±1
Solenoid assembly bolt9±1
Vacuum tank bracket bolt9±1
Secondary air system, intake manifold
Exhaust manifold heat protector bolt14±1
Vacuum hose and pipe bolt11±1
Air pipe assembly bolt (eye bolt)49±5
Air pipe assembly bolt (M6 flange)11±1
Air pipe assembly bolt (M8 flange)24±3
Air pipe assembly bolt (M8 washer)14±1
Air control valve assembly bolt22±4
Air control valve bracket bolt22±4
MDP sensor bolt5±1
Intake manifold stay bolt31±3
Intake manifold bolt (M8)20±2
Intake manifold bolt nut (M8)36±6
Exhaust manifold
Engine hanger bolt19±3
Turbocharger heat protector bolt14±1
O2sensor44±5
Exhaust fitting bracket bolt47±6
Exhaust fitting bolt nut59±5
Air outlet fitting bolt19±1
Oil return pipe bolt (flange)14±1
Oil return pipe bolt (washer)9±1
Turbocharger assembly and pipe bolt, nut59±5
Oil pipe bolt (M10 eye bolt)17±2
Oil pipe bolt (M12 eye bolt)31±2
Oil pipe bolt (M12 flange)11±1
Water pipe bolt (flange)10±1
Water pipe bolt (eye bolt)42±7
Exhaust manifold nut (M8)33±6
Exhaust manifold nut (M10)55±10
Water pump, water hose
Engine coolant temperature sensor29±10
Engine coolant temperature gauge unit10.8±1.0

ENGINE OVERHAUL -Specifications11B-7
Items Tightening torque N·m
Water outlet fitting bolt10±1
Thermostat housing bolt23±4
Water inlet pipe bolt (M6)10±1
Water inlet pipe bolt (M8)13±2
Water pump bolt14±1
Knock sensor23±2
Rocker arm, camshaft
Cam position sensor bolt8.8±1.0
Cover bolt10±2
Cam position sensing cylinder bolt22±4
Cam position sensor support bolt14±1
Bearing cap bolt20±1
Oil delivery body bolt11±1
Cylinder head, valve
Cylinder head bolt78±2→Completely loosen→20±2→90_+90_
Oil pump, oil pan
Drain plug39±5
Oil pan bolt9±3
Oil screen bolt19±3
Baffle plate bolt22±4
Oil pressure switch19±3
Oil cooler bypass valve54±5
Relief plug44±5
Oil filter bracket bolt19±3
Plug cap23±3
Flange bolt36±3
Oil pump case bolt23±3
Oil pump cover bolt17±1
Oil pump cover screw10±2
Piston, connecting rod
Connecting rod cap nut20±2+90_-94_
Crankshaft, cylinder block
Flywheel bolt132±5
Rear plate bolt11±1
Bell housing cover bolt9±1
Rear oil seal case bolt11±1
Beam bearing cap bolt25±2+90_- 100_
Check valve32±2
Throttle body
Throttle position sensor bolt2.0±0.5
Turbocharger
Waste gate actuator bolt11.3±1.5

ENGINE OVERHAUL -Specifications11B-8
SEALANTS
ItemSpecified sealantQuantity
Engine support bracket bolt3MTMAAD Part No. 8672 or equivalentAs required
Semi-circular packing3MTMAAD Part No. 8672 or equivalentAs required
Rocker cover3MTMAAD Part No. 8672 or equivalentAs required
Water outlet fittingMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Engine coolant temperature gauge unit3MTMAAD Part No. 8672 or equivalentAs required
Engine coolant temperature sensor3MTMAAD Part No. 8672 or equivalentAs required
Cylinder head (camshaft bearing cap mounting
section)3MTMAAD Part No. 8672 or equivalentAs required
Cam position sensor supportMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Oil pressure switch3MTMAAD Part No. 8672 or equivalentAs required
Oil panMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Oil seal caseMitsubishi Genuine Part No. MD970389 or
equivalentAs required
FORM-IN-PLACE-GASKET
FIPG is used for several members of this engine. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil and water flow passage. Thus, to prevent leaks from the joined sections,
it is absolutely necessary to evenly apply the correct amount.
The FIPG used for the engine parts reacts with moisture in the air and hardens so use it for the normal
metal flange parts.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the seams must be broken by lightly tapping with a wood hammer or similar tool.
A smooth and thin gasket scraper can be lightly tapped into the seams but in this case, take care not
to damage the seams.
The special tool oil pan remover (MD998727) is set for this purpose.
WASHING THE GASKET SURFACE
Completely remove all matters adhered on the gasket surfaces with a gasket scraper or wire brush.
Confirm that the FIPG application surface is smooth. There must be no grease or foreign matter on
the gasket surface.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius. Completely cover the areas around the
mounting holes. The FIPG can be wiped off if it has not hardened. Install at the set position while the
FIPG is still wet (within 15 minutes). When installing, maker sure that the FIPG does not get on areas
other than the required areas. After installing, do not subject the application areas to oil or water or
start the engine until the FIPG has sufficiently hardened (approx. one hour). The FIPG application procedures
differ according to the member, so follow the procedures given in this manual and apply the FIPG.