2007 MITSUBISHI LANCER EVOLUTION engine valve

ENGINE OVERHAUL -Timing Belt11B-13
TIMING BELT
REMOVAL AND INSTALLATION
1
11±1N•m
2
3
4 56
7
8
910
11 1213
14 15
16 1718
192021 2223
2425
26
27
2829
30
313233
34
35
49±6N•m
21±4N•m
23±3N•m
11±1N•m11±1N•m
88±10 N•m
35±6N•m
54±5N•m 19±3N•m 46±3N•m 9±1N•m162±5N•m3.5±0.5 N•m
49±9N•m
8.8±1.0 N•m 49±5N•m
Removal steps
1. Timing belt front upper cover
2. Timing belt front center cover
3. Timing belt front lower cover
4. Power steering pump bracket
AA""MA5. Timing belt
"LA6. Tensioner pulley
7. Tensioner arm
"KA8. Auto tensioner
9. Idler pulley
10. Crank angle sensor
AB""JA11. Oil pump sprocket
AC""IA12. Crankshaft bolt
AD""IA13. Crankshaft sprocket
"IA14. Crankshaft sensing blade
15. Tensioner B
AE""HA16. Timing belt B
AF""GA17. Counter balance shaft sprocket
"FA18. SpacerAG""EA19. Crankshaft sprocket B
20. Crankshaft key
21. Breather hose
22. PCV hose
23. PCV valve
24. PCV valve gasket
25. Oil filler cap
"DA26. Rocker cover
"DA27. Rocker cover gasket A
28. Rocker cover gasket B
"CA29. Semi-circular packing
"BA30. Engine support bracket
AH""AA31. Camshaft sprocket bolt
32. Camshaft sprocket
33. Timing belt rear right cover
34. Timing belt rear left upper cover
35. Timing belt rear left lower cover

ENGINE OVERHAUL -Timing Belt11B-14
REMOVAL SERVICE POINTS
AA"TIMING BELT REMOVAL
1. To ensure that the timing belt is assembled in the same
direction when reused, using chalk, etc., make an arrow
showing the rotation direction on the back surface of
the timing belt.
2. Position the exhaust camshaft sprocket’s timing mark by
approx. one tooth before the No. 1 cylinder compression
top dead centre.
Caution
When removed at the compression top dead centre,
since the exhaust camshaft is at the position pressing
down on the valve, the sprocket could rotate in reverse
due to the force of the valve spring creating a
hazardous situation.
3. Loosen the lock nut for the tensioner pulley, and remove
the timing belt.
AB"OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of the cylinder block.
2. Insert a Phillips driver (shaft diameter 8 mm) to stop the
counter balance shaft left from rotating.
3. Loosen the flange bolt.
4. Remove the oil pump sprocket.
AC"CRANKSHAFT BOLT REMOVAL
1. Fix the flywheel with the special tool.
2. Remove the crankshaft bolt.
AD"CRANKSHAFT SPROCKET REMOVAL
Use the special tool to remove the sprocket if it is stuck
and hard to remove.
Timing marks
Phillips driver
MD998781
MD998778

ENGINE OVERHAUL -Timing Belt11B-20
"JAOIL PUMP SPROCKET INSTALLATION
1. Stop the rotation of the counter balance shaft in the same
manner as for removal.
2. Install the oil pump sprocket.
3. Apply the minimum required amount of engine oil on the
flange nut seat surface.
4. Tighten the flange nut at the specified torque 54±5
N•m.
"KAAUTO TENSIONER INSTALLATION
1. If the auto tensioner rod is in the extended state, set
it with the following steps.
(1) Set the rod of the auto tensioner into a vice so that
it is straight and not inclined.
(2) Press in the rod gradually with the vice, and align
the rod’s set hole A with the cylinder’s set hole B.
(3) Insert a wire (diameter 1.4 mm) into the set holes.
(4) Remove the auto tensioner from the vice.
2. Install the auto tensioner.
Do not remove the wire until the timing belt has been
installed.
"LATENSIONER PULLEY INSTALLATION
Set the tensioner pulley as shown in the illustration.
"MATIMING BELT INSTALLATION
1. Set the timing mark on the exhaust side camshaft sprocket
so that it is deviated by one tooth in the counterclockwise
direction from the timing mark on the rocker cover.
NOTE
Even if the sprocket and rocker cover timing marks are
aligned, the exhaust camshaft will return in the
counterclockwise direction by the force of the valve spring
and will stabilize at a position deviated by one tooth.
Phillips driver
A
B
Tensioner pulley holes
Timing marks

ENGINE OVERHAUL -Timing Belt11B-21
2. Align the timing mark of the intake side camshaft sprocket
to the timing mark on the rocker cover.
NOTE
Even when the sprocket and rocker cover timing marks
are aligned, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
3. Shift and set the crankshaft sprocket timing mark by one
tooth in the counterclockwise direction in the same manner
as the exhaust side camshaft sprocket.
4. Align the oil pump sprocket timing marks.
5. When aligning the oil pump sprocket timing marks, remove
the cylinder block plug, and insert an 8 mm shaft diameter
Phillips driver into the plug hole, and confirm that the
driver shaft can be inserted by 60 mm or more. Do not
remove the Phillips driver until the timing belt has been
attached. If the driver shaft contacts the silent shaft and
only enters 20 to 25 mm, rotate the sprocket once, align
the timing marks again, and then confirm that the Phillips
driver can be inserted by 60 mm or more.
6. Remove the Phillips driver, and set the oil pump sprocket
at a position returned by one tooth in the counterclockwise
direction.
7. Attach the timing belt to the exhaust side camshaft
sprocket, and fix with a paper clip at the position shown
in the illustration.
Timing marks
Phillips driverPlug
Timing
marks

ENGINE OVERHAUL -Timing Belt11B-22
8. Rotate the intake side camshaft sprocket in the
counterclockwise direction. Attach the belt at a position
where the timing mark is deviated by one tooth in the
counterclockwise direction, and then fix with a paper clip.
NOTE
Even if the belt is attached at a position deviated by
one tooth, the intake camshaft will rotate slightly in the
clockwise direction by the force of the valve spring and
will stabilize.
9. Rotate the exhaust side camshaft sprocket in the
clockwise direction, and confirm that the intake side
camshaft sprocket’s timing marks are aligned when the
timing marks are aligned.
10. Attach the timing belt in the order of the idler pulley,
oil pump sprocket and crankshaft sprocket.
NOTE
Attach the timing belt so that it is not deflected.
11. Attach the timing belt to the tensioner pulley.
NOTE
The timing belt can be attached easily to the tensioner
pulley by rotating the intake side camshaft sprocket slightly
in the counterclockwise direction.
12. Rotate the crankshaft sprocket slightly in the clockwise
direction, and remove the timing belt deflection on the
idler pulley side.
13. Confirm that the timing marks on the crankshaft, oil pump
and exhaust camshaft are each deviated by one tooth
in the counterclockwise direction.
Timing marks Timing marks
Crankshaft
sprocketOil pump
sprocket
Crankshaft
sprocket
Crankshaft sprocket

ENGINE OVERHAUL -Fuel System11B-26
FUEL SYSTEM
REMOVAL AND INSTALLATION
1
11±1N•m
2
3
4 5
678
9 10
11 12 13
14 15
16
1718 1920 21
22
23
2425
11±1N•m
20±2N•m 19±3N•m
9±1N•m8.8±2.0 N•m
9±1N•m 9±1N•m
9±1N•m
Removal steps
1. Throttle body assembly
"CA2. Throttle body gasket
3. EGR valve
4. EGR gasket
5. Fuel hose
"BA6. Fuel pressure regulator
7. O-ring
8. Delivery pipe and injector
9. Insulator
10. Fuel return pipe
11. Insulator
"AA12. Injector
13. O-ring14. Grommet
15. Delivery pipe
16. Vacuum hose
17. Vacuum hose
18. Vacuum hose
19. Solenoid valve assembly
20. Solenoid valve assembly
21. Vacuum hose and pipe
22. Solenoid valve assembly
23. Vacuum tank bracket
24. Vacuum tank
25. Vacuum tank hose assembly

ENGINE OVERHAUL -Secondary Air System and Intake Manifold11B-28
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION
1
11±1N•m
23 4 5
6
7
8
9
10 1112
13
11±1N•m24±3N•m
14±1N•m
31±3N•m5±1N•m
20±2N•m
22±4N•m
36±6N•m23±4N•m
14±1N•m
36±6N•m
36±6N•m22±4N•m
49±5N•m
Removal steps
1. Exhaust manifold heat protector
2. Vacuum hose and pipe
"DA3. Air pipe assembly
4. Air control valve gasket
5. Air control valve assembly
6. Engine hanger
"CA7. Air control valve bracket"BA8. Manifold differential pressure (MDP)
sensor
9. O-ring
"AA10. Intake manifold stay
11. Alternator brace stay
12. Intake manifold
13. Intake manifold gasket

ENGINE OVERHAUL -Secondary Air System and Intake Manifold11B-29
INSTALLATION SERVICE POINTS
"AAINTAKE MANIFOLD STAY INSTALLATION
Check that the intake manifold stay is seated against the
intake manifold and cylinder block boss, and then tighten
at the specified torque 31±3N•m.
"BAMANIFOLD DIFFERENTIAL PRESSURE (MDP)
SENSOR INSTALLATION
Caution
Make sure not to apply impact against the sensor when
installing.
Do not use a sensor that has been dropped.
"CAAIR CONTROL VALVE BRACKET INSTALLATION
1. Temporarily tighten the air control valve bracket and
engine hanger with the bolt for tightening with the intake
manifold.
2. Tighten the bolt 1 shown in the illustration at the specified
torque 23±4N•m.
3. Tighten the bolt 2 shown in the illustration at the specified
torque 36±6N•m.
4. Tighten the bolt 3 shown in the illustration with the engine
hanger at the specified torque 22±4N•m.
"DAAIR PIPE ASSEMBLY INSTALLATION
1. Temporarily tighten air pipe assembly onto the air control
valve.
2. Tighten the bolts 1 and 2 shown in the illustration to
the exhaust manifold at the specified torque 49±5N•m.
3. Tighten the bolt 3 shown in the illustration to the air control
valve at the specified torque 24±3N•m.
4. Tighten the bolt 4 shown in the illustration to the cam
position sensor support at the specified toque 11±1
N•m.
5. Tighten the bolt 5 shown in the illustration to the exhaust
manifold at the specified torque 14±1N•m.
Intake manifold stay
1
23
1
5
23
4