2007 MITSUBISHI LANCER EVOLUTION engine

ENGINE OVERHAUL -Water Pump and Water Hose11B-33
INSTALLATION SERVICE POINTS
"AAO-RING/WATER INLET PIPE INSTALLATION
Replace the O-ring for the water inlet pipe with a new part,
and apply water on the periphery of the O-ring so that it
can be inserted easily into the water pump and thermostat
housing.
Caution
(1) Never apply grease or oil, such as engine oil, on the
O-ring.
(2) Install the water inlet pipe onto the thermostat
housing, and then fix.
"BAWATER OUTLET FITTING INSTALLATION
Squeeze out form-in-place gasket at a 3 mm width, and apply
at the position shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"CAENGINE COOLANT TEMPERATURE GAUGE UNIT
INSTALLATION
When reusing the bolts, apply the specified sealant on the
threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"DAENGINE COOLANT TEMPERATURE SENSOR
INSTALLATION
Apply the specified sealant onto the threads.
Sealant
Specified sealant:
3M
TMAAD Part No. 8731 or equivalent
Caution
Make sure that the tool does not contact the connector
section (resin section).

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-34
ROCKER ARM AND CAMSHAFT
REMOVAL AND INSTALLATION
1 2 3
4
5 6
78
910
111213
10±2N•m
14±1N•m
22±4N•m
11±1N•m
8.8±1.0 N•m
20±1N•m
14
15
16
Apply engine oil on
all sliding sections
before installing.
17
Removal steps
1. Cam position sensor
2. O-ring
3. Cover
4. Gasket
"FA5. Cam position sensing cylinder
"EA6. Cam position sensor support
"DA7. Camshaft oil seal
"CA8. Bearing cap, rear
"CA9. Bearing cap, front"CA10. Bearing cap No. 5
"CA11. Bearing cap No. 2
"CA12. Bearing cap No. 3
"CA13. Bearing cap No. 4
"BA14. Camshaft
15. Rocker arm
AA""AA16. Lash adjuster
17. Oil delivery body

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-35
REMOVAL SERVICE POINT
AA"LASH ADJUSTER REMOVAL
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
INSTALLATION SERVICE POINTS
"AALASH ADJUSTER INSTALLATION
Caution
When reusing the lash adjuster, always clean and inspect
it before installing. (Refer to the section on checking the
lash adjuster.)
Assembly the lash adjuster onto the rocker arm while taking
care not to spill out diesel oil in it.
"BACAMSHAFT INSTALLATION
1. Apply engine oil on the camshaft journal and cam.
2. Install the camshaft onto the cylinder head.
Caution
Do not mistake the intake and exhaust camshafts.
There is a 4 mm width slit on the back end of the
exhaust side camshaft.
"CABEARING CAP INSTALLATION
1. Set the camshaft’s dowel pin to the approximate top.
2. The bearing caps No. 2 to 5 have the same shape. Check
the identification symbol before installing to prevent
mistaking the cap No., intake side and exhaust side.
Identification symbol
(Stamped on front and on No. 2 to 5 bearing caps)
I : Intake side
E : Exhaust side
Timing belt side
Slit
Exhaust side
Dowel pins
Cap No.
Identification
of IN side and
EX side

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-36
3. Apply sealant on the contact surfaces with the head shown
in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
4. Install the bearing caps onto the cylinder head, and in
two to three steps tighten strongly.
5. Finally, tighten at the specified torque 20±1N•m.
6. Confirm that the rocker arm is correctly installed.
NOTE
Wipe off all excessive sealant.
"DACAMSHAFT OIL SEAL INSTALLATION
Install the oil seal using the special tool.
"EACAM POSITION SENSOR SUPPORT
INSTALLATION
Apply a 3 mm width of form-in-place gasket at the position
shown in the illustration.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
"FACAM POSITION SENSING CYLINDER
INSTALLATION
1. Set the exhaust camshaft at the No. 1 compression top
dead centre.
NOTE
The shaft will rotate slightly in the counterclockwise
direction by the force of the exhaust valve spring.
2. Install the cam position sensing cylinder’s vane (small)
and vane (large) at the positions shown in the illustration.
MD998713
Vane (small)
Cam position
sensorVane (large)

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-37
INSPECTION
1. CAMSHAFT
Measure the cam height (length). Replace if it exceeds
the limit value.
Standard value:
Intake 35.79 mm
Exhaust 35.49 mm
Limit value:
Intake 35.29 mm
Exhaust 34.99 mm
2. LASH ADJUSTER
Caution
(1) The lash adjuster is a sophisticated part, so make
sure that foreign matter, such as dirt, does not
enter it.
(2) Do not disassemble the lash adjuster.
(3) When cleaning the lash adjuster, use clean diesel
oil.
(1) Prepare three vats and approx. five litres of diesel
oil.
Fill the vats with diesel oil so that the lash adjuster
will be submerged when placed standing in the vat.
(2) Submerge the lash adjuster in vat A, and clean the
outside.
NOTE
Use a nylon brush if the lash adjuster is heavily
contaminated.
For
preliminary
cleaningFor
cleaningFor
filling
diesel oil
ABC
Diesel oil

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-38
(3) Lightly press down on the steel ball inside using the
special tool MD998442. Remove all matter and
deteriorated oil adhered on the plunger by pressing the
tool back and forth five to ten times until the plunger
moves smoothly.
Caution
The steel ball spring’s load is extremely weak,
so if the special tool is pressed in with force,
the functions of the lash adjuster could be
damaged.
NOTE
The plunger movement must not snag at this time.
If the movement is abnormal, replace the lash adjuster.
(4) Remove the lash adjuster from the vat, and while
lightly pressing down on the steel ball, press the
plunger and removal all diesel oil, etc., inside the
pressure chamber.
Caution
Always face the oil hole on the side of the lash
adjuster toward vat A. Never face the oil hole
toward people.
(5) Submerge the lash adjuster in vat B. Lightly press
down on the steel ball inside using the special tool
MD998442. Clean the inside of the lash adjuster
pressure chamber by pressing the tool back and forth
five to ten times until the plunger moves smoothly.
Caution
The steel ball spring’s load is extremely weak,
so if the special tool is pressed in with force,
the functions of the lash adjuster could be
damaged.
(6) Remove the lash adjuster from the vat, and while
lightly pressing down on the steel ball, press the
plunger and removal all diesel oil, etc., inside the
pressure chamber.
Caution
Always face the oil hole on the side of the lash
adjuster toward vat A. Never face the oil hole
toward people.
MD998442Diesel oil
MD998442
Diesel oil
MD998442Diesel oil
MD998442
Diesel oil

ENGINE OVERHAUL -Rocker Arm and Camshaft11B-39
(7) Submerge the lash adjuster in vat C, and lightly press
down on the steel ball inside using the special tool
MD998442.
Caution
Do not use vat C for cleaning. If vat C is used
for cleaning, foreign matter, etc., could enter the
pressure chamber when filling it with diesel oil.
(8) Stand the lash adjuster with the plunger at the top
position. Press down on the plunger with force, and
after it has reached the maximum stroke, gradually
return it. Then, release the steel ball to fill the pressure
chamber with diesel oil.
(9) Remove the lash adjuster from the vat, and stand
the lash adjuster with the plunger at the top position.
The plunger should not move when pressed down
with force.
NOTE
If the lash adjuster compresses, repeat steps (7) to
(9). Replace the lash adjuster if the same
phenomenon occurs even after diesel oil has been
filled in the pressure chamber (after the air has been
bled).
(10)Store the lash adjuster in the vertical state so that
the internal diesel oil will not spill out, and so that
foreign matter, such as dirt, will not adhere. Install
it onto the engine as soon as possible.
MD998442Diesel oil
MD998442Diesel oil

ENGINE OVERHAUL -Cylinder Head and Valve11B-40
CYLINDER HEAD AND VALVE
REMOVAL AND INSTALLATION
78±2N•m→Completely loosen
20±2N•m→90_+90_
2
1
Apply engine oil on
all sliding sections
before installing.
4
5
6
12
13
16
18
720
38
9
10
14
15
17
19
11
Removal steps
AA""DA1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
AB""CA4. Retainer lock
5. Valve spring retainer
"BA6. Valve spring
7. Intake valve
AB""CA8. Retainer lock
9. Valve spring retainer
"BA10. Valve spring11. Exhaust valve
AC""AA12. Valve stem seal
13. Valve spring seat
AC""AA14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head