2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

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 -Cylinder Head and Valve11B-44
2. VALVE
(1) If there is a faulty contact, one - sided contact or
improper seating with the valve seat, correct the valve
seat.
(2) Replace the valve if the margin exceeds the limit
value.
Standard value:
Intake 1.0 mm
Exhaust 1.5 mm
Limit value:
Intake 0.5 mm
Exhaust 1.0 mm
(3) Measure the total length of the valve, and replace
the valve if the length exceeds the limit value.
Standard value:
Intake 109.50 mm
Exhaust 109.70 mm
Limit value:
Intake 109.00 mm
Exhaust 109.20 mm
3. VALVE SPRING
(1) Measure the free height of the spring, and replace
the valve spring if the height exceeds the limit value.
Standard value: 48.3 mm
Limit value: 47.3 mm
(2) Measure the spring squareness, and replace the valve
spring if the inclination exceeds the limit value.
Standard value: 1.5_or less
Limit value: 4_
4. VALVE GUIDE
Measure the clearance between the valve guide and valve
stem. If the clearance exceeds the limit value, replace
the valve guide, valve or both parts.
Standard value:
Intake 0.02 - 0.05 mm
Exhaust 0.05 - 0.09 mm
Limit value:
Intake 0.10 mm
Exhaust 0.15 mm
Contact
(Must be at
centre of face)
Margin
Total valve length
Squareness
Free height
Valve
guide
Stem outer
diameter Guide inner
diameter

ENGINE OVERHAUL -Cylinder Head and Valve11B-45
5. VALVE SEAT
Assemble the valve, and measure the amount that the
valve protrudes from the valve shaft end between the
spring seat surfaces when the valve is pressed against
the valve seat. Replace the valve seat if the protrusion
amount exceeds the limit value.
Standard value:
Intake 49.20 mm
Exhaust 48.40 mm
Limit value:
Intake 49.70 mm
Exhaust 48.90 mm
Valve Seat Correction
1. Before correcting the valve seat, inspect the clearance
between the valve guide and valve, and replace the valve
guide if necessary.
2. Correct so that the seat width and seat angle are at the
specified shape.
3. After correcting, apply wrapping compound, and fit the
valve and valve seat together.
Valve Seat Replacement
1. Grind off the valve seat to be replaced from the inside
to reduce the thickness and then remove the valve seat.
2. Machine the valve seat hole on the cylinder head to match
the diameter of the oversized valve seat into which it
is to be pressed in.
Intake valve seat hole diameter:
0.3 O.S. 35.30 - 35.33 mm
0.6 O.S. 35.60 - 35.63 mm
Exhaust valve seat hole diameter:
0.3 O.S. 33.30 - 33.33 mm
0.6 O.S. 33.60 - 33.63 mm
3. When pressing in the valve seat, cool the valve seat
with liquid nitrogen, and make sure that the inner diameter
of the cylinder head is not galled.
4. Refer to the “Valve Seat Correction” procedures, and
machine the valve seat.Valve shaft end
Spring seat surface Valve protrusion
amount
10_ 65_
10_65_ 0.9 - 1.3 mm
0.9 - 1.3 mm
43.5_-44_43.5_-44_
0.5 - 1.0 mm
0.5 - 1.0 mm Grind off
Valve
seat
height
Oversized hole diameter

ENGINE OVERHAUL -Cylinder Head and Valve11B-46
Valve Guide Replacement
1. Using a press, push the valve guide to the cylinder block
side.
2. Machine the valve guide hole on the cylinder head to
match the oversized valve guide into which it is to be
pressed in.
Caution
Do not use a valve guide having the same size as
the removed valve guide.
Valve guide hole diameter:
0.05 O.S. 12.05 - 12.07 mm
0.25 O.S. 12.25 - 12.27 mm
0.50 O.S. 12.50 - 12.52 mm
3. Press in the valve guide to the dimensions shown in
the illustration.
NOTE
(1) Press in the valve guide from the top of the cylinder
head.
(2) Note that the length of the valve guides differs.
Intake 45.5 mm
Exhaust 50.5 mm
4. After pressing in the valve guide, insert a new valve,
and confirm the sliding state.
19.2 - 19.8 mm

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-47
OIL PUMP AND OIL PAN
REMOVAL AND INSTALLATION
2
1
Apply engine oil on
all sliding sections
before installing.
4 56
12 13
16187 20
38
9
10 1415
1719
1139±5N•m 54±5N•m19±3N•m
36±3N•m23±3N•m 17±1N•m 10±2N•m
9±3N•m 22±4N•m 23±3N•m
19±3N•m
44±5N•m 23±3N•m
25
24232221
26272930
31
28
19±3N•m
Removal steps
1. Drain plug
"NA2. Drain plug gasket
"MA3. Oil filter
AA""LA4. Oil pan
5. Oil screen
6. Oil screen gasket
7. Baffle plate
"KA8. Oil pressure switch
9. Oil cooler bypass valve
10. Relief plug
11. Gasket
12. Relief spring
13. Relief plunger
14. Oil filter bracket
15. Oil filter bracket gasket
AB""JA16. Plug cap
17. O-ringAC""IA18. Flange bolt
"HA19. Oil pump case
20. Oil pump case gasket
21. Oil pump cover
"GA22. Oil pump driven gear
"GA23. Oil pump drive gear
"FA24. Crankshaft front oil seal
"EA25. Counter balance shaft oil seal
"DA26. Oil pump oil seal
27. Counter balance shaft, right
28. Counter balance shaft, left
AD""CA29. Counter balance shaft front bearing
AE""BA30. Counter balance shaft rear bearing,
right
AE""AA31. Counter balance shaft rear bearing,
left

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-48
REMOVAL SERVICE POINTS
AA"OIL PAN REMOVAL
1. Remove the oil pan tightening bolts.
2. Tap the special tool between the oil pan and cylinder
block.
3. Tap on the edge of the special tool, slide the tool and
remove the oil pan.
AB"PLUG CAP REMOVAL
Fit the special tool (MD998162) into the notch on the plug
cap as shown in the illustration. Loosen the plug cap while
supporting with the special tool (MD998783).
AC"FLANGE BOLT REMOVAL
1. Remove the plug on the left side of the cylinder block,
and insert a Phillips driver (shaft diameter 8 mm) by 60
mm or more to stop the rotation of the counter balance
shaft left.
2. Loosen the flange bolt.
AD"COUNTER BALANCE SHAFT FRONT BEARING
REMOVAL
Pull out the counter balance shaft front bearing from the
cylinder block using the special tool.
Caution
Always remove the counter balance shaft front bearing
first. Otherwise, the counter balance shaft rear bearing
cannot be removed.MD998727
MD998162
MD998783
Plug
Phillips driver
MD998371Front bearing

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-49
AE"COUNTER BALANCE SHAFT REAR BEARING
REMOVAL
1. Pull out the counter balance shaft rear bearing right from
the cylinder block using the special tool (MD998372).
2. When removing the counter balance shaft rear bearing
left, install the special tool (MB991603) onto the front
of the cylinder block, and then remove the bearing using
the special tool (MD998372).
INSTALLATION SERVICE POINTS
"AACOUNTER BALANCE SHAFT REAR BEARING
LEFT INSTALLATION
1. Install the special tool (MB991603) onto the cylinder block.
2. Set the counter balance shaft rear bearing left into the
special tool (MD998705).
NOTE
There is no oil hole on the counter balance shaft rear
bearing left.
3. Tap in the counter balance shaft rear bearing left.
"BACOUNTER BALANCE SHAFT REAR BEARING
RIGHT INSTALLATION
1. Install the guide pin onto the cylinder block.
2. Align the ratchet ball of the special tool with the oil hole,
and set the counter balance shaft rear bearing right.
MB991603
MD998372
MB991603
MD998705
MB991603
MD998705
Rear bearing
left
Guide pin
Ratchet ball
MD998705 Rear bearing right
Oil hole

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-50
3. Align and insert the special tool into the guide pin, and
tap in the counter balance shaft rear bearing right.
"CACOUNTER BALANCE SHAFT FRONT BEARING
INSTALLATION
1. Remove the part for tapping in the rear bearing from
the special tool.
2. Install the guide pin onto the cylinder block.
3. Align the ratchet ball of the special tool with the oil hole,
and set the counter balance shaft front bearing.
MD998705
Guide pin
MD998705
Part for tapping in
the rear bearing
Guide pin
Ratchet ball
MD998705 Front bearing
Oil hole