2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

ENGINE OVERHAUL -Special Tools11B-11
Tool UseName Number
MD998372Silent shaft bearing
pullerRemoval of counter balance shaft rear bearing
MB991603Silent shaft
bearing installer
stopperGuide stopper when removing/pressing in
counter balance shaft rear bearing
MD998705Silent shaft bearing
installerPress in of counter balance shaft front and rear
bearings
MD998375Crankshaft front oil
seal installerInstallation of crankshaft front oil seal
MD998285Crankshaft front oil
seal guideGuide for installation of crankshaft front oil seal
MD998780Piston pin setting
toolRemoval/press in of piston pin
MD998776Crankshaft rear oil
seal installerInstallation of crankshaft rear oil seal
MD990938HandleInstallation of crankshaft rear oil seal
(Use together with MD998776.)

ENGINE OVERHAUL -Alternator and Ignition System11B-12
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
1
13±1N•m
2
3
13
4
7
6
5
89
10
1211
22±4N•m8.8±1.0 N•m
25±5N•m 3±0.5 N•m
10±2N•m
8.8±1.0 N•m
23±3N•m
25±4N•m44±10 N•m
Removal steps
1. Oil level gauge
2. O-ring
3. Oil level gauge guide
4. O-ring
5. Water pump pulley
6. Alternator brace
7. Alternator8. Crankshaft pulley
9. Center cover
10. Spark plug cable
11. Ignition coil
12. Spark plug
13. Connector bracket

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-15
AE"TIMING BELT B REMOVAL
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.
AF"COUNTER BALANCE SHAFT SPROCKET
REMOVAL
1. Fix the counter balance shaft sprocket with the special
tool.
2. Remove the installation bolt of the counter balance shaft.
AG"CRANKSHAFT SPROCKET B REMOVAL
Use the special tool to remove the sprocket if it is stuck
and hard to remove.
AH"CAMSHAFT SPROCKET BOLT REMOVAL
Hold the hexagon part of the camshaft with a wrench, and
remove the camshaft sprocket bolt.
INSTALLATION SERVICE POINTS
"AACAMSHAFT SPROCKET BOLT INSTALLATION
Hold the hexagon part of the camshaft with a wrench, and
tighten the camshaft sprocket bolt at the specified torque
88±10 N•m.
MD998785
MD998778

ENGINE OVERHAUL -Timing Belt11B-16
"BAENGINE SUPPORT BRACKET INSTALLATION
Before tightening, apply sealant on the bolt at the position
shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"CASEMI-CIRCULAR PACKING INSTALLATION
Apply sealant at the position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
"DAROCKER COVER/ROCKER COVER GASKET A
INSTALLATION
1. Apply form-in-place gasket on the rocker cover at the
position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
2. Install the rocker cover gasket A onto the rocker cover
before the form-in-place gasket hardens.
10 mm
Semi-circular
packing
Cylinder head10 mm
Timing belt side

ENGINE OVERHAUL -Timing Belt11B-17
3. Apply form-in-place gasket on the rocker cover at the
position shown in the illustration.
Sealant
Specified sealant:
3M
TMAAD Part No. 8672 or equivalent
4. Install the rocker cover onto the cylinder head before
the form-in-place gasket hardens.
"EACRANKSHAFT SPROCKET B INSTALLATION
Clean the crankshaft sprocket B installation surface before
degreasing the crankshaft sprocket B.
NOTE
Always degrease the surface to prevent a drop in the frictional
coefficient at the pressing section caused by the adherence
of oil.
"FASPACER INSTALLATION
1. Apply a slight amount of oil on the outer periphery of
the spacer (oil seal contact section).
2. Insert the spacer from the chamfered side as shown in
the illustration.
Caution
Reversed insertion of the spacer can cause damage
to the oil seal lip.
"GACOUNTER BALANCE SHAFT SPROCKET
INSTALLATION
1. Fix the counter balance shaft sprocket with the special
tool.
2. Tighten the counter balance shaft sprocket installation
bolt at the specified torque 46±3N•m.
"HATIMING BELT B INSTALLATION
1. Align the crankshaft sprocket B and counter balance shaft
sprocket timing marks with the timing mark on the oil
pump case.
2. Attach the timing belt B to the crankshaft sprocket B
and counter balance shaft sprocket.
Do not loosen the belt tension too much at this time.
Timing belt side
Crankshaft sprocket B
Crankshaft
Degrease
Spacer
Oil seal
Chamfer
MD998785
Timing
marks
Timing
marks

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