2007 MITSUBISHI LANCER EVOLUTION light

ENGINE OVERHAUL -Timing Belt11B-18
3. Confirm that the tensioner B centre and bolt centre are
positioned as shown in the illustration.
4. Apply tension on the timing belt by lifting tensioner B
in the direction of the arrow with a finger, and tension
the tension side until it is “tight”. Fix tensioner B in this
state by tightening the bolt.
NOTE
Make sure that the tensioner B shaft does not rotate
when tightening the bolt. If the shaft rotates, the timing
belt becomes too tense.
5. Connect the special tool (MB991704) to MUT-IIand the
battery.
6. Connect the special tool (MB991668) to MUT-II.
7. Rotate the crankshaft clockwise two turns, and align each
timing mark.
8. Select “Belt Tension Measurement” from the MUT-IImenu
screen.
9. Separate the special tool (MB991668) 10 to 20 mm from
the centre back between the sprockets (shown with an
arrow), and hold so that it is vertical (inclination within
±15_) in respect to the belt.
10. Lightly tap the section shown with an arrow with fingers,
and measure the belt vibration frequency. If the results
are deviated from the standard value, loosen the bolt,
tension the belt again, and then measure the vibration
frequency again. Repeat this step until the standard value
is attained. Tighten the bolt when the standard value
is attained.
Standard value:
ItemWhen
checkWhen
adjustedWhen
replaced
Vibration frequency Hz52 - 9276 - 9276 - 92
Deflection
(Reference value) mm5-105-75-7
Tensioner
B centre
Installation
bolt centre
Timing
belt B
Belt tension side
Tensioner
B
MB991668
15_ 15_
10 - 20 mm

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 -Timing Belt11B-23
14. Using the special tool, rotate the tensioner pulley in the
counterclockwise direction to tense the timing belt, and
then fix by temporarily tightening the tensioner fixing bolt.
NOTE
Remove the deflection of the timing belt between the
intake side and exhaust side camshafts.
15. Rotate the crankshaft in the clockwise direction, and set
the timing mark at the No. 1 cylinder compression top
dead centre.
16. Set the special tool, and screw it in until the wire inserted
when the auto tensioner was installed slightly moves.
17. Loosen the tensioner pulley fixing bolt.
Caution
The timing belt will loosen at this time due to the
rotation of the intake and exhaust camshafts, so make
sure that the timing belt does not deviate.
18. Rotate the special tool and torque wrench in the
counterclockwise direction to remove the timing belt
deflection.
19. From that state, return to the position where the torque
wrench scale reads 3.5 N•m, and then tighten the fixing
bolt.
20. Remove the special tool installed in step 16.
21. Rotate the crankshaft two rotations in the clockwise
direction, and let stand for approx. 15 minutes.
22. Confirm whether the wire inserted when the auto tensioner
was installed can be pulled out easily. If it can be removed
easily, the belt tension is appropriate, so remove the wire.
If the auto tensioner rod’s protrusion amount is at the
standard value, the tension is appropriate.
Standard value: 3.8 - 4.5 mm
23. If the wire cannot be pulled out easily, repeat steps 16
to 21, and tense the belt to the appropriate tension.
Caution
When the crankshaft bolt has been rotated in the
counterclockwise direction, always check the crank-
shaft bolt’s tightening torque. If loosen, re-tighten.
MD998767
MD998738
MD998767
Protru-
sion
amount

ENGINE OVERHAUL -Exhaust Manifold11B-31
INSTALLATION SERVICE POINTS
"AAEXHAUST MANIFOLD INSTALLATION
1. Lightly tighten the installation nut for the exhaust manifold.
2. Following the tightening order shown in the illustration,
tighten the M8 nuts at the tightening torque 29 N•m.
3. Following the tightening order shown in the illustration,
tighten the M10 nuts at the tightening torque 49 N•m.
4. Following the tightening order shown in the illustration,
tighten the M8 nuts again at the tightening torque 29
N•m.
5. Finally, following the tightening order shown in the
illustration, tighten the M10 nuts at the tightening torque
55±10 N•m, and tighten the M8 nuts at the tightening
torque 33±6N•m.
"BAOIL RETURN PIPE GASKET INSTALLATION
Assembly so that the protrusion of the oil return pipe gasket
on the oil pan side is at the position shown in the illustration.
NOTE
There is no designated assembly direction for the gasket
on the turbocharger side.
"CAAIR OUTLET FITTING GASKET
Assembly so that the protrusion of the air outlet fitting gasket
is at the position shown in the illustration.
7982 13456
Protrusion
Protrusion
AA

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-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