2007 MITSUBISHI LANCER EVOLUTION length

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 -Cylinder Head and Valve11B-42
"BAVALVE SPRING INSTALLATION
Install the valve spring so that the painted surface faces the
rocker arm.
"CARETAINER LOCK INSTALLATION
Compress the valve spring using the special tool, and install
the retainer lock.
"DACYLINDER HEAD BOLT INSTALLATION
1. Before reusing the cylinder head bolt, confirm that the
bolt’s underhead length is less than the limit value.
Replace the bolt if it exceeds the limit value.
Limit value: 99.4 mm
2. Apply engine oil on the bolt threads and washer.
NOTE
Use the special tool to tighten the cylinder head bolt.
Painted
surfaceSpring
retainer
Stem
seal
Spring
seat
MD998772
MD998735
Underhead length
MB991654

ENGINE OVERHAUL -Cylinder Head and Valve11B-44
2. VALVE
(1) If there is a faulty contact, one - sided contact or
improper seating with the valve seat, correct the valve
seat.
(2) Replace the valve if the margin exceeds the limit
value.
Standard value:
Intake 1.0 mm
Exhaust 1.5 mm
Limit value:
Intake 0.5 mm
Exhaust 1.0 mm
(3) Measure the total length of the valve, and replace
the valve if the length exceeds the limit value.
Standard value:
Intake 109.50 mm
Exhaust 109.70 mm
Limit value:
Intake 109.00 mm
Exhaust 109.20 mm
3. VALVE SPRING
(1) Measure the free height of the spring, and replace
the valve spring if the height exceeds the limit value.
Standard value: 48.3 mm
Limit value: 47.3 mm
(2) Measure the spring squareness, and replace the valve
spring if the inclination exceeds the limit value.
Standard value: 1.5_or less
Limit value: 4_
4. VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the clearance exceeds the limit value, replace
the valve guide, valve or both parts.
Standard value:
Intake 0.02 - 0.05 mm
Exhaust 0.05 - 0.09 mm
Limit value:
Intake 0.10 mm
Exhaust 0.15 mm
Contact
(Must be at
centre of face)
Margin
Total valve length
Squareness
Free height
Valve
guide
Stem outer
diameter Guide inner
diameter

ENGINE OVERHAUL -Cylinder Head and Valve11B-46
Valve Guide Replacement
1. Using a press, push the valve guide to the cylinder block
side.
2. Machine the valve guide hole on the cylinder head to
match the oversized valve guide into which it is to be
pressed in.
Caution
Do not use a valve guide having the same size as
the removed valve guide.
Valve guide hole diameter:
0.05 O.S. 12.05 - 12.07 mm
0.25 O.S. 12.25 - 12.27 mm
0.50 O.S. 12.50 - 12.52 mm
3. Press in the valve guide to the dimensions shown in
the illustration.
NOTE
(1) Press in the valve guide from the top of the cylinder
head.
(2) Note that the length of the valve guides differs.
Intake 45.5 mm
Exhaust 50.5 mm
4. After pressing in the valve guide, insert a new valve,
and confirm the sliding state.
19.2 - 19.8 mm

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-53
"JAPLUG CAP INSTALLATION
1. Install a new O-ring onto the oil pump case.
2. Lightly tighten the plug cap by hand.
3. As shown in the illustration, fit the special tool (MD998162)
into the notch on the plug cap, and while supporting with
the special tool (MD998783), tighten the plug cap at the
specified torque 23±3N•m.
"KAOIL PRESSURE SWITCH INSTALLATION
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
Caution
(1) Make sure that the sealant does not protrude to the
end of the threads.
(2) Do not tighten too far.
"LAOIL PAN INSTALLATION
1. Clean the surface of the cylinder block and oil pan onto
which gasket is to be applied.
2. Squeeze out form-in-place gasket at a 4 mm width, and
apply onto the entire periphery of the oil pan flange.
Form-in-place gasket
Specified gasket:
Mitsubishi Genuine Part No. MD970389 or
equivalent
3. Note that the lengths of the bolts shown in the illustration
differ, so take care when installing.
MD998162
MD998783
Bolt hole section Groove
Timing belt side
M6×8

ENGINE OVERHAUL -Piston and Connecting Rod11B-58
INSTALLATION SERVICE POINTS
"AAPISTON PIN INSTALLATION
1. Measure the length of the following parts.
A : Piston pin installation section
B : Between piston boss
C : Piston pin
D : Connecting rod
2. Calculate using the following expression.
L = ((A - C) - (B - D))÷2
3. Insert the special tool’s push rod into the piston pin, and
remove guide A.
4. Align the piston and connecting rod front marks, and
assemble.
5. Apply engine oil on the periphery of the piston pin.
6. Insert the guide A side of the piston pin assembled in
step 3 into the pin hole from the front mark side of the
piston.
7. Screw guide B into guide A, and assemble so that the
clearance is the value 3 mm more than the value (L)
obtained in step 2.
8. Set onto the special tool’s piston setting base so that
the front mark faces upward.
9. Press in the piston pin using a press. If the press in
load is less than the standard value, replace the piston
pin (piston assembly), connecting rod or both parts.
Standard value: 7,355 - 17,162 N
Connecting rod
PistonPiston pin
BA DC
3mm+L
Guide B
Guide A
Push rod
Piston pin
Front mark
Front
mark
Guide A
Guide BBase

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-66
3. Select the bearing from the above table according to
the identification confirmed in steps 1 and 2.
[Example of selecting bearing]
(1) If the measured outer diameter of the crankshaft
journal is 57.000 mm, Class 1 applies, and the
identification colour is yellow.
(2) If the cylinder block bearing bore identification mark
is 0, select identification mark 0 in consideration of
step (1).
4. Install the grooved bearing on the cylinder block side.
5. Install the bearing with no oil groove onto the beam bearing
cap side.
"CABEAM BEARING CAP/BEARING CAP BOLT
INSTALLATION
1. Install the beam bearing cap with the arrow facing the
timing belt side.
2. Before installing the bearing cap bolt, confirm that the
bolt’s underhead length is less than the limit value.
Replace the bolt if it exceeds the limit value.
Limit value: 71.1 mm
3. Apply engine oil on the bolt threads and bolt surface.
4. Following the tightening order, tighten the bearing cap
bolt at 25±2N•m.
5. Make paint marks on the bolt head.
6. Using the position of the mark painted on the bolt head
as reference, make paint marks on the seat surface at
the 90_to 100_positions in the tightening direction.
7. Following the tightening order, tighten the bolt by 90_
to 100_, and confirm that the paint marks made on the
bolt and seat surface match.
Caution
(1) If the tightening angle is less than 90_, the
connection performance may not be attained, so
take special care when tightening.
(2) If the tightening angle exceeds 100_, completely
loosen the nut, and start again from step 1.Crankshaft bearing side
identification mark position
Identification
mark
Groove
Upper bearing
Lower bearing
Underhead length
Arrow
84159
732610
Paint marksPaint marks
90°- 100°

ENGINE COOLING -Water Pump14-13
WATER PUMP
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
REMOVAL AND INSTALLATION
Pre-remobal and Post-installation Operation
DEngine Coolant Draining and Supplying (Refer to P.14-6.)
DTiming Belt Removal and installation (Refer to GROUP 11A.)
1
Bolt specifications
28×22
2
23±3 N·m
14±1 N·m
Nominal diameter×Nominal length mm
8×70
8×14
8×22 8×25
3 4
22±4 N·m
Removal steps
1. Alternator brace
2. Water pump
3. Water pump Gasket
"AA4. O-ring
INSTALLATION SERVICE POINT
"AAO-RING INSTALLATION
Fit an O-ring into the O-ring groove located at the end of
the water inlet pipe and apply water to the O-ring or the
inside of the mounting surface of the water pump for insertion.
CAUTION
Do not let the O-ring get contaminated with grease, such
as engine oil.Water pump
O-ring
Water inlet pipe