2007 MITSUBISHI LANCER EVOLUTION timing

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 -Timing Belt11B-24
INSPECTION
1. TIMING BELT
Inspect each section of the belt in detail, and if any of
the following type of damage is found, replace the belt
with a new part.
(1) Hardening of backface rubber.
The backface is glossy, marks are not made even
when a fingernail is run cross it, and there is no
elasticity.
(2) Cracking of backface rubber.
(3) Cracking of canvas.
(4) Cracking at root.
(5) Cracking on side of belt.
(6) Abnormal wear on side of belt.
NOTE
The state is normal if the cutting surface is neat as
if cut with a sharp knife.
(7) Abnormal wear of teeth.
First stages: Canvas is worn (canvas fibres are raised,
rubber is removed and whitish, and canvas seams
are unclear).
Latter stages: Canvas is worn off, and rubber is
exposed (face width is narrow).
(8) Teeth are missing.
2. AUTO TENSIONER
(1) Check for oil leaks. If any leaks are found, replace.
(2) Check whether the rod end is worn or damaged,
and replace if necessary.
(3) Measure the rod protrusion length. If not at the
standard value, replace the auto tensioner.
Standard value: 12 mm
Crack
Crack
Peeling of canvas
Cracking
on side
Cracking at root
Edges are rounded
Abnormal wear
(The core wires are frayed.)
Rubber exposed due to
worn canvas
Teeth are missing
12 mm

ENGINE OVERHAUL -Timing Belt11B-25
(4) Measure the depression amount when the rod is
pressed with a force of 98 to 196 N. If not at the
standard value, replace the auto tensioner.
Standard value: 1 mm or less
Depression
amount 98 - 196 N

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 -Cylinder Head and Valve11B-43
3. Following the tightening order, tighten at 78±2N•m.
4. Completely loosen the bolts.
5. Next, following the tightening order, tighten the loosened
bolts at the torque 20±2N•m again.
6. Make paint marks on the cylinder head bolt’s head and
cylinder head.
7. Following the tightening order, tighten the cylinder head
by 90_.
8. Tighten by another 90_, and confirm that the paint mark
made on the cylinder head bolt’s head and the paint
mark on the cylinder head are positioned on the same
line.
Caution
(1) If the tightening angle is less than 90_, the
connection performance may not be attained, so
take special care to the tightening angle when
tightening.
(2) If the tightening angle is larger than the specified
value, completely loosen the bolt and start again
from step 1.
INSPECTION
1. CYLINDER HEAD
(1) Before cleaning the cylinder head, check it for water
leaks, gas leaks, damage or cracks.
(2) Completely remove the oil, water deposits, sealant
and carbon, etc. After cleaning the oil path, blow
air and confirm that there is not clogging.
(3) Using a straight edge and thickness gauge, inspect
the flatness of the bottom of the cylinder head for
strain.
If the strain exceeds the limit value, grind the end
and correct the flatness.
Standard value for lower surface strain: 0.05 mm
Limit value for lower surface strain: 0.2 mm
Grinding limit value: 0.2 mm
Cylinder head height (standard value for new part):
131.9 - 132.1 mm
Caution
The grinding limit is within 0.2 mm together with
the combined cylinder block.
Timing belt side
86139
10 4 2 5 7
90_
90_
Paint marks

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 -Crankshaft and Cylinder Block11B-65
INSTALLATION SERVICE POINTS
"AATHRUST BEARING INSTALLATION
1. Install the thrust bearing onto the cylinder block side of
the No. 3 bearing section. The bearing can be installed
easily by applying engine oil.
2. Install the thrust bearing so that the side with the groove
faces the crankshaft weight side.
"BACRANKSHAFT BEARING INSTALLATION
1. Measure the diameter of the crankshaft journal, and
confirm the class shown below. When using a spare part,
each identification colour is painted at the position shown
in the illustration.
2. The cylinder block bearing section bore identification mark
is stamped at the position shown in the illustration.
Crankshaft journalCylinder
block
bearing
Spare
bearing
identificaClassProduct
identifica-
tion colourSpare part
identifica-
tion colourJournal
diameter
mmbearing
section
bore iden-
tification
markidentifica-
tion mark
1NoneYellow56.994 -57 0000057.00011
22
2NoneNone56.988 -56 9940156.99412
23
3NoneWhite56.982 -56 9880256.98813
24
Groove
No. 2
No. 1No. 4
No. 5No. 3
Timing belt side
Cylinder block bearing section
bore identification mark
No. 1No. 2No. 3No. 4
No. 5
Cylinder
bore size
mark