2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-51
4. Align and insert the special tool into the guide pin, and
tap in the counter balance shaft front bearing.
"DAOIL PUMP OIL SEAL INSTALLATION
Install the oil pump oil seal using an appropriate socket wrench.
"EACOUNTER BALANCE SHAFT OIL SEAL
INSTALLATION
Install the counter balance shaft oil seal using an appropriate
socket wrench.
"FACRANKSHAFT FRONT OIL SEAL INSTALLATION
Install the crankshaft front oil seal using the special tool.
MD998705
Guide pin
Socket wrench
Oil pump case Oil seal
Socket wrench
Oil pump case
Oil seal
MD998375
Oil pump case Oil seal

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-52
"GAOIL PUMP DRIVE GEAR/OIL PUMP DRIVEN
GEAR INSTALLATION
Apply sufficient engine oil onto the gears, align the match
marks, and assemble.
"HAOIL PUMP CASE INSTALLATION
1. Install the special tool onto the front end of the crankshaft,
and apply a light coat of engine oil onto the periphery
of the guide. If an oil seal is installed on the oil pump
case, always use a guide.
2. Install the oil pump case through the new oil pump case
gasket, and temporarily tighten the bolts other than the
oil filter bracket tightening bolt.
3. Install the oil filter bracket through the oil filter bracket
gasket, and temporarily tighten with the bolt.
4. Tighten the oil pump case at the specified torque 23
±3N•m, and the oil filter bracket at the specified torque
19±3N•m.
"IAFLANGE BOLT INSTALLATION
1. Insert a Phillips driver (shaft diameter 8 mm) by 60 mm
or more into the hole on the left side of the cylinder block
to stop the rotation of the counter balance shaft left.
2. Tighten the flange bolt at the specified torque 36±3
N•m.
Match marks
MD998285
Counter balance
shaft left
Counter balance
shaft right
MD998285
Phillips driver

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 -Oil Pump and Oil Pan11B-54
"MADRAIN PLUG GASKET INSTALLATION
Replace the gasket with a new part, and install at the direction
shown in the illustration.
Caution
Incorrect installation direction will lead to oil leaks.
"NAOIL FILTER INSTALLATION
1. Clean the installation surface on the cylinder block side.
2. Apply engine oil on the O-ring for the oil filter.
3. Screw in the oil filter, and tighten approx. 3/4 of a rotation
(approx. 14±2N•m) from where the O-ring contacts
the installation surface.
INSPECTION
1. COUNTER BALANCE SHAFT
(1) Make sure that the oil hole is not clogged.
(2) Check the journal (bearing section) for seizure or
damage, and check the state of contact with the
bearings. If any faults are found, replace the counter
balance shaft, bearing or oil pump case assembly.
2. OIL COOLER BYPASS VALVE
(1) The valve must move smoothly.
(2) The L dimension must be at the standard value at
a constant temperature, constant humidity state.
Standard value: 34.5 mm
(3) The protruded dimensions must be at the standard
value after submerging into 100_C oil.
Standard value: 40 mm
Drain plug
Oil pan
Oil pan side Gasket
Bracket side
L
Valve

ENGINE OVERHAUL -Oil Pump and Oil Pan11B-55
3. OIL PUMP
(1) Assemble the drive gear and driven gear into the
oil pump case.
(2) Inspect the side clearance with a thickness gauge.
Standard value:
Drive gear 0.08 - 0.14 mm
Driven gear 0.06 - 0.12 mm

ENGINE OVERHAUL -Piston and Connecting Rod11B-56
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
20±2N•m+90_-94_
2
1
Apply engine oil on
all sliding sections
before installing.
4
56
12 7
3 8
910
11
Removal steps
"GA1. Connecting rod cap nut
AA""FA2. Connecting rod cap
"EA3. Connecting rod bearing
"DA4. Piston connecting rod
5. Connecting rod bearing
"CA6. Piston ring No. 1"CA7. Piston ring No. 2
"BA8. Oil ring
AB""AA9. Piston pin
10. Piston
11. Connecting rod
12. Bolt

ENGINE OVERHAUL -Piston and Connecting Rod11B-57
REMOVAL SERVICE POINTS
AA"CONNECTING ROD CAP REMOVAL
Note the cylinder No. on the side of the connecting rod’s
large end for identification during reassembly.
AB"PISTON PIN REMOVAL
The special tool’s piston pin setting tool (MD998780) is
configured of the parts shown in the left illustration.
1. Insert the special tool’s push rod in from the front mark
(arrow) side of the piston’s front face, and install guide
C.
2. Set the piston and connecting rod assembly onto the
special tool’s piston pin setting base so that the front
mark faces upward.
3. Push out the piston pin using a press.
NOTE
After removing the piston pin, group the piston, piston
pin and connecting rod for each cylinder No.
Cylinder No.
Push rod
Guide BGuide A: 17.9 mm
Guide A: 18.9 mm
Guide A: 20.9 mm
Guide A: 21.9 mm BaseGuide C
Push rod
Front mark
Guide C
Base Front
mark

ENGINE OVERHAUL -Piston and Connecting Rod11B-58
INSTALLATION SERVICE POINTS
"AAPISTON PIN INSTALLATION
1. Measure the length of the following parts.
A : Piston pin installation section
B : Between piston boss
C : Piston pin
D : Connecting rod
2. Calculate using the following expression.
L = ((A - C) - (B - D))÷2
3. Insert the special tool’s push rod into the piston pin, and
remove guide A.
4. Align the piston and connecting rod front marks, and
assemble.
5. Apply engine oil on the periphery of the piston pin.
6. Insert the guide A side of the piston pin assembled in
step 3 into the pin hole from the front mark side of the
piston.
7. Screw guide B into guide A, and assemble so that the
clearance is the value 3 mm more than the value (L)
obtained in step 2.
8. Set onto the special tool’s piston setting base so that
the front mark faces upward.
9. Press in the piston pin using a press. If the press in
load is less than the standard value, replace the piston
pin (piston assembly), connecting rod or both parts.
Standard value: 7,355 - 17,162 N
Connecting rod
PistonPiston pin
BA DC
3mm+L
Guide B
Guide A
Push rod
Piston pin
Front mark
Front
mark
Guide A
Guide BBase