2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

ENGINE -Crankshaft Oil Seal11A-27
REMOVAL SERVICE POINT
AA"FLYWHEEL BOLT REMOVAL
INSTALLATION SERVICE POINTS
"AACRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply small quantity of engine oil on the circumference
of oil seal lip.
2. Use special tool to press in oil seal up to the chamfered
surface of oil seal case.
"BAFLYWHEEL BOLT INSTALLATION
Use the special tool to fix the flywheel and tighten the bolt
to the specified torque in the same way as that for removal.
Tightening Torque: 132±5 N·m
"CACRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply small quantity of engine oil on the circumference
of oil seal lip.
2. Use special tool to press in oil seal up to the chamfered
surface of oil seal case.
"DACRANKSHAFT SPROCKET B INSTALLATION
1. Clean and degrease crankshaft sprocket B and crankshaft
sprocket B mounting surface of crankshaft.
NOTE
Degrease to prevent the friction coefficient of pressed
surface from dropping by stuck oil.
2. Position crankshaft sprocket B to the direction as shown
in the illustration.
MD998781
Crankshaft
Oil Seal
MB990938
MD998776
MD998382
Oil Seal
Crankshaft
MD998285
(oil applied to the
circumference)
Crankshaft
sprocket B
Degrease
Engine FrontCrankshaft

ENGINE -Cylinder Head Gasket11A-28
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
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.
Pre-removal and Post-installation Operation
DFuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.)
DFuel Leak Check
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DDrive Belt Tension Check (Refer to P.11A-7.)
DAccelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
DDrainage and Refilling Engine Oil (Refer to GROUP 12 - On-vehicle Service.)
DDrainage and Refilling of Engine Coolant (Refer to GROUP 14 - On-vehicle Service.)
DAir Cleaner Assembly Removal and Installation (Refer to GROUP 15.)
DAir Hose E, Air Pipe C, Air hose D Removal and Installation (Refer to GROUP 15 - Intercooler.)
DBattery Removal and Installation
DCenter Cover Removal and Installation (Refer to P.11A-17.)
DAccelerator Cable Removal and Installation (Refer to GROUP 17.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DSecondary Air Control Valve Bracket Removal and Installation (Refer to GROUP 15 - Secondary Air Supply System.)
DCrossmember Bar Removal and Installation (Refer to GROUP32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15.)
DStarter Removal and Installation (Refer to GROUP 16.)
DTiming Belt Removal and Installation (Refer to P.11A-34.)

ENGINE -Cylinder Head Gasket11A-29
5.0±1.0 N·m
61
2
3 4
57
8
910
11 12
1314
13±1 N·m
15
16
17
5.0±1.0 N·m
1819
9.0±1.0 N·m
9.0±1.0 N·m
(Engine oil)
1
Removal steps
1. Ignition coil connector
2. Crank angle sensor connector
3. Oxygen sensor connector
4. Fuel pressure solenoid valve
connector
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. Throttle position sensor connector
8. Idle speed control servo connector
9. Injector connector
10. Camshaft position sensor connector
11. Engine coolant temperature gauge
unit connector12. Engine coolant temperature sensor
connector
DRocker cover (Refer to P.11A-17.)
13. EGR solenoid valve connector
14. Secondary air control solenoid valve
connector
15. Vacuum tank, solenoid valve, vacuum
pipe and hose assembly
16. Brake booster vacuum hose
connection
17. Oil level gauge and guide assembly
18. O-ring
19. Purge hose connection

ENGINE -Cylinder Head Gasket11A-30
23 31
24 26 27 28
2930
22
22±4 N·m5.0±1.0 N·m
31±3 N·m
(Engine oil)
2021
25
9.0±1.0 N·m
14±1 N·m
33 32
(Engine oil)
78±2 N·m to 0 N·m to 20±2 N·m
to +90_to +90_(cold start)
35±6 N·m44±5 N·m
34
20. Alternator brace connection
21. Intake manifold stay
22. Oil return pipe gasket
23. Oil return pipe
24. Oil return pipe gasket
"DA25. Oil return pipe gasket
26. Exhaust fitting bracket
DWater outlet fitting and thermostat
case assembly (Refer to Group 15
- Water Hose and Pipe.)27. Water hose connection
28. Heater hose connection
29. Fuel return hose connection
"CA30. Fuel high pressure hose connection
"CA31. O-ring
AA""BA32. Cylinder head bolt
33. Cylinder head assembly
"AA34. Cylinder head gasket

ENGINE -Cylinder Head Gasket11A-31
REMOVAL SERVICE POINT
AA"CYLINDER HEAD BOLTS REMOVAL
Use the special tool to loosen the bolt in 2 to 3 times in
the order of the numbers shown in the illustration for removal.
INSTALLATION SERVICE POINTS
"AACYLINDER HEAD GASKET INSTALLATION
1. Remove residual gasket attached on the mounting surface
of the gasket.
Caution
Do not let contaminants get into engine coolant, oil
passage or cylinder.
2. With individual holes of cylinder head aligned on individual
holes of cylinder head gasket, install cylinder head gasket
on cylinder head.
"BACYLINDER HEAD BOLTS INSTALLATION
1. Ensure that the length under head of cylinder head bolts
is under the limit value. When the measured value exceeds
the limit value, replace the bolt with new one.
Limit (A): 99.4 mm
2. Apply small quantity of engine oil at the threads of cylinder
head bolts and the washers.
1
5
4
2
7
38
69
10
Engine Front
MB991654
A
(Engine oil)

ENGINE -Cylinder Head Gasket11A-32
3. Use special tool to tighten bolts according to the following
procedure (tightening for plastic zone)
(1) According to the sequence specified in the figure,
tighten the bolt to the specified torque 78±2 N·m.
(2) In the reverse sequence of the figure, fully loosen
bolts.
(3) According to the sequence specified in the figure,
tighten bolts to the specified torque 20±2 N·m.
(4) Indicate paint markings on the heads of cylinder head
bolts and cylinder head, and tighten bolts at the angle
of 90 degree in the sequence specified in the figure.
(5) When bolts are tightened at the angle of 90 degree
according to the figure, ensure that the paint markings
on the heads of cylinder head bolts and cylinder head
are standing in line.
Caution
1) When the tightening angle is under 90 degree,
the bolt is not sufficiently tightened.
2) When the tightening angle exceeds the
specified value, remove the bolt and repeat
the same procedure beginning with Step 1.
"CAO-RING/FUEL HIGH PRESSURE HOSE
INSTALLATION
1. Apply small quantity of new engine oil on O-ring.
Caution
Do not let engine oil get into the delivery pipe.
2. Install the fuel high pressure pipe to the delivery pipe
rotating in both directions without damaging the O-ring
and check that it rotates smoothly.
1
5427
3869
10
Engine Front
MB991654
Step (4)Step (5)
Paint Marking
90_
Paint Marking
90_

ENGINE -Cylinder Head Gasket11A-33
3. In case of not rotating smoothly, remove the fuel high
pressure hose and insert it to the delivery pipe again
after checking damage of the O-ring since there is a
possibility of O-ring engagement.
4. Tighten fuel high pressure hose mounting bolts to the
specified torque.
Tightening Torque: 5.0±1.0 N·m
"DAOIL RETURN PIPE GASKET INSTALLATION
Gasket should be replaced with a new one, and set the convex
part to the position as shown in the illustration for installation.
NOTE
There is no specific direction indicated for installing the
turbocharger side of the oil return pipe gasket.
Convex part

ENGINE -Timing Belt and Timing Belt B11A-34
TIMING BELT AND TIMING BELT B
REMOVAL AND INSTALLATION
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.
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DSide Cover Removal and Installation
DDrive Belt Tension Check (Refer to P.11A-7.)
DCrankshaft Pulley Removal and Installation (Refer to P.11A-15.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15.)
DEngine Mounting Removal and Installation (Refer to GROUP 32.)
1
2
3
4 5
67 89
10
11±1 N·m
8.8±1.0 N·m
44±10 N·m
24±4 N·m
11±1 N·m
9.0±1.0 N·m64±5 N·m 11±1 N·m48±5 N·m21±4 N·m
23±3 N·m
11
35±6 N·m
Removal steps
1. Timing belt front upper cover
2. Water pump pulley
3. Timing belt front center cover
4. Idler pulley
5. Drive belt auto-tensioner
6. Timing belt front lower cover"GADTiming belt tension adjustment
AA""FA7. Timing belt
"EA8. Tensioner pulley
9. Tensioner arm
"DA10. Auto-tensioner
11. Idler pulley