Engine Overhaul <2.0l Non-Turbo> - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT

Plastic region tightening bolts are used in some parts of the engine. Install these bolts according to the method described in the service information because the tightening method of these bolts are different from the conventional method. The service limit is determined for these bolts. Be sure to strictly follow the service limit described in the service information.

1. Parts to be used Cylinder head bolt Bearing cap bolt Connecting rod cap bolt
2. Tightening method After tightening to the specified torque, further tighten 45° and 90°, or 180° (90° + 90°). Follow the tightening method described in the service information because the tightening method differs from part to part.

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES

Note. The number in square brackets shows the part number.

LIQUID GASKET (FIPG)

FIPG is used for some parts in the engine. It is necessary to pay attention to an application amount, application procedure and applied surface condition for this gasket to fully achieve its purpose.

Too small amount causes leakage while too much amount squeezes out to block or narrow water and oil passages. Therefore, it is absolutely essential to apply a correct amount of liquid sealant continuously without break to eliminate leakage from joints.

FIPG used for engine parts hardens reacting with moisture in the air, and is usually used for metal flanges.

DISASSEMBLY

Parts assembled with FIPG can be easily disassembled without using a special method. In some cases, however, it is necessary to lightly tap parts with a wooden hammer or similar tool to break sealant between mating surfaces. Or lightly driving a smooth and thin gasket scraper in mating surfaces is useful, but full care must be exercised not to damage mating surfaces. As special tool oil pan FIPG cutter (MD998727) is set, use this tool.

CLEANING OF GASKET SURFACE

Completely remove all deposits from the gasket surface with a gasket scraper or wire brush. Make sure that the surface to which FIPG is applied is smooth. The gasket surface must be free from grease and foreign substances. Be sure to remove old FIPG that has entered mounting holes and screw holes.

APPLICATION PROCEDURE

Apply FIPG in a determined diameter and continuously without break. Completely enclose the periphery of mounting holes. FIPG can be wiped off if it is not hardened. Install parts in place while FIPG is still wet. Take care not to allow FIPG to adhere to other locations than necessary locations during installation. Do not pour oil or water on applied locations or do not start the engine until sufficient time (approximately one hour) passes. The application procedure of FIPG may differ depending on areas. Follow the procedure in the service information to apply FIPG.

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB991883 Flywheel stopper - Securing of drive plate and flywheel MB992106 O-ring installer - Installation of O-ring on injector injection nozzle side MB991396 Oil filter wrench - Removal and installation of oil filter MD998727 Oil pan FIPG cutter MD998727-01 Removal of oil pan MB991448 Bushing remover and installer base MB991448-01 Press fit of front oil seal MD998735 Valve spring compressor MD998735-01 Compression of valve spring MB992089 Retainer holder C MB992089-01 MB992085 Valve stem seal pliers - Extraction of valve stem seal MD998737 Valve stem seal installer MD998737-01 Installation of valve stem seal MD998780 Piston pin setting tool MIT216941 Extraction and press fit of piston pin MB991659 Guide D - MB991614 Angle gauge General service tool Installation of crankshaft bearing cap bolt and installation of balancer shaft module bolt MD998718 Rear oil seal installer MD998718-01 Press fit of rear oil seal MB991346 Top cover wrench - Removal and installation of oil pump sprocket MB991398 Spark plug wrench - Removal and installation of spark plug

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Required Special Tools

1. MB991398: Spark Plug Wrench
2. MB991883: Flywheel Stopper

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1. Use special tool MB991883 to secure the drive plate or flywheel.
2. Remove the crankshaft pulley bolt.

<< B >> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

Scheme 362

>> A << SPARK PLUGS INSTALLATION

Using special tool MB991398, tighten the spark plug to the specified torque.

Specified torque: 25 ± 5 N.m (18 ± 3 ft-lb)

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1. Use special tool MB991883 to secure the drive plate or flywheel.
2. Wipe off the dirt on the washer and on the thread hole of the crankshaft using a rag.
3. Wipe off the dirt on the crankshaft pulley and the crankshaft sprocket using a rag, and then remove the grease from the portion shown in the illustration. NOTE: Remove grease to prevent the coefficient of friction of the pressing portion from declining due to adhesion of oil.
4. Install the crankshaft pulley.
5. Apply an appropriate and minimum amount of engine oil to the threaded portion of the crankshaft and lower part of the flange.
6. With off the chamfered side on the inside of the washer facing the bolt top, install the washer to the crankshaft pulley bolt.
7. Tighten the crankshaft pulley bolt to the specified torque. Specified torque: 210 N.m (155 ft-lb)

Scheme 365

1. Temporarily tighten power steering pump bracket bolts. CAUTION: Always loosen the power steering pump bracket bolt, and temporarily install the generator. Then tighten each bolt.
2. Loosen the power steering pump bracket bolts and make the power steering pump bracket unfixed.
3. Temporarily install the generator with the generator bolts.
4. Tighten them to the specified torque according to the order as shown in illustration. Specified torque Power steering pump bracket: M8 26 ± 3 N.m (19 ± 2 ft-lb) M10 44 ± 8 N.m (32 ± 5 ft-lb) Generator: 44 ± 10 N.m (32 ± 7 ft-lb)

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>> A << MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSTALLATION

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1. Temporarily tighten each part so that the protrusion of each gasket is positioned as illustrated in figure.
2. Tighten mounting bolts to the specified torque of 20 ± 2 N.m (15 ± 1 ft-lb) in the order shown in the illustration.

>> C << EGR VALVE GASKET INSTALLATION

Install the EGR valve gasket with the diagonally shaded area used as the illustrated position in figure so as not to confuse the front with the back.

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Required Special Tool

1. MB992106: O-ring Installer

>> A << ENGINE OIL PRESSURE SWITCH INSTALLATION

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1. Completely remove sealant adhering to the engine oil pressure switch and cylinder block threaded holes.
2. Apply sealant (Three bond 1212D, Three bond 1215 or equivalent) of 5 mm to the threaded portion of the engine oil pressure switch shown in the illustration.
3. Tighten the engine oil pressure switch to the cylinder block to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)

>> B << GENERATOR BRACKET INSTALLATION

Tighten the Generator bracket to the specified torque.

Specified torque: 44 ± 8 N.m (33 ± 5 ft-lb)

Note. Be careful when install mounting bolts as they are different in length. See illustration for bolt locations.

Scheme 373

>> C << INTAKE MANIFOLD INSTALLATION

Install the inlet manifold and temporarily tighten bolts.

>> D << INTAKE MANIFOLD STAY INSTALLATION

Make sure that the intake manifold stay is in intimate contact with the intake manifold and cylinder block boss before tightening it to the specified torque.

Specified torque: 20 ± 2 N.m (15 ± 1 ft-lb)

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>> E << O-RING INSTALLATION

When inserting an O-ring into the injector on the injection nozzle side, use special tool MB992106 to gradually expand the O-ring, and fit it in place.

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1. Apply spindle oil or gasoline to the O-ring of the injector.
2. Insert the injector into the fuel rail while rotating the injector from side to side, taking care not to damage the O-ring.
3. Check that the injector rotates smoothly. If it does not rotate smoothly, the O-ring may be caught. Remove the injector and check the O-ring for damage. Then, insert it again into the fuel rail and check.
4. Make sure that the protrusion of the injector is at the center as shown in the illustration.
5. Securely assemble the injector to the injector groove and fuel rail collar.

Scheme 378

1. Install the fuel rail assembly, bracket and injector protector on the cylinder head.
2. Tighten mounting bolts together with temporarily tightened inlet manifold mounting bolts in the order shown in the illustration.
3. Tighten the delivery pipe assembly, bracket, injector protector rear and inlet manifold in the order shown in the illustration. Temporarily torque: 3.5 ± 1.5 N.m (31 ± 13 in-lb) Specified torque: 20 ± 2 N.m (15 ± 1 ft-lb)

Scheme 379

>> A << CRANKSHAFT POSITION SENSOR INSTALLATION

Tighten the crankshaft position sensor to the specified torque.

Specified torque: 11 ± 1 N.m (98 ± 8 in-lb)

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Scheme 381

1. Assemble the thermostat housing and water pipe
2. Install the thermostat housing gasket.
3. Install a new water pipe gasket so that the tab is positioned as shown in the illustration.
4. Temporarily tighten them to the cylinder head and water pump. Then tighten them to the specified torque. Specified torque: 24 ± 3 N.m (18 ± 1 ft-lb)

>> B << THERMOSTAT INSTALLATION

Install the thermostat with the jiggle-valve facing almost straight upwards.

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>> C << WATER OUTLET FITTING GASKET INSTALLATION

Install a new gasket so that the tab is positioned as shown in the illustration.

Scheme 383

>> D << ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

Scheme 384

1. Apply an appropriate and minimum amount of sealant (Three bond 1324N, LOCTITE 262 or equivalent) to the engine coolant temperature sensor, taking care not to allow sealant to squeeze out.
2. Tighten the engine coolant temperature sensor to the cylinder block to the specified torque. Specified torque: 30 ± 9 N.m (22 ± 6 ft-lb)

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Required Special Tools

1. MB991396: Oil Filter Wrench
2. MD998727: Oil Pan FIPG Cutter
3. MB991448: Bushing remover and installer base

<< A >> OIL FILTER REMOVAL

Use special tool MB991396 to remove the oil filter.

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1. Remove oil pan tightening bolts. CAUTION: Lightly tap the oil pan FIPG cutter to drive in, taking care not to damage the ladder frame and oil pan sealed area.
2. Lightly tap special tool MD998727 to drive in the illustrated groove of the oil pan and ladder frame shown in figure.
3. Lightly tap and slide special tool MD998727 to remove the oil pan.

<< C >> TIMING CHAIN CASE REMOVAL

If the timing chain case is difficult to remove, insert a hammer handle as shown in the illustration and lightly pry it.

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>> A << TIMING CHAIN CASE INSTALLATION

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1. Completely remove the liquid gasket adhering to the timing chain case, the cylinder block and the cylinder head.
2. Completely remove the sealant remaining on the 3-plane contact surface among the cylinder head, the cylinder block and the gasket. Carry out the degreasing CAUTION: Install the timing chain case within three minutes after applying the liquid gasket.
3. Apply liquid gasket (Three bond 1217G or exact equivalent) of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) in thickness to the timing chain case. For illustrated A locations in figure, however, apply liquid gasket of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) in diameter or liquid gasket of 2.5 ± 0.5 mm (0.10 ± 0.02 inch) by putting one on top of another as shown in the illustration.
4. The engine oil staying at the cylinder gasket oozes to the 3-plane contact surface described in Step 2 and 3 . Swiftly apply the liquid gasket to this area after degreasing. Specified sealant: Three bond 1217G or exact equivalent
5. Tighten timing chain case mounting bolts to the specified tightening torque. Tightening torque A: 24 ± 4 N.m (18 ± 2 ft-lb) B: 10 ± 2 N.m (89 ± 17 in-lb) C: 10 ± 2 N.m (89 ± 17 in-lb) D: 13 ± 1 N.m (115 ± 8 in-lb)

Scheme 393

1. Apply engine oil to the internal circumference of the oil seal.
2. Use special tool MB991448 to install the front oil seal on the timing chain case.

Scheme 394

1. Completely remove liquid gasket adhering to the cylinder block and oil pan.
2. Degrease the cylinder block and oil pan. CAUTION: Install the oil pan within three minutes after liquid gasket is applied.
3. Apply liquid gasket of ø2.5 ± 0.5 mm (0.10 ± 0.02 inch) of thickness in diameter to the illustrated area of the oil pan shown in figure. Specified sealant: Three bond 1217G or exact equivalent
4. Tighten the oil pan to the specified tightening torque. Tightening torque: M6:10 ± 2 N.m (89 ± 17 in-lb) M8: 29 ± 2 N.m (21 ± 1 ft-lb)

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1. Completely remove liquid gasket adhering to the cylinder head cover, timing chain case and cylinder head.
2. Degrease the cylinder head cover, timing chain case and cylinder head. CAUTION: Install the cylinder head cover immediately after liquid gasket is applied.
3. Appropriately use a minimum amount of sealant. Be careful not to allow sealant to squeeze out from the application area. Apply liquid gasket of 4 mm (0.15 inch) of thickness in diameter. Specified sealant: Three bond 1217G or exact equivalent
4. Tighten the cylinder head cover to the tightening torque in the order shown in the illustration. Tightening torque: 3.0 ± 1.0 N.m (27 ± 8 in-lb)
5. Then, tighten it to the specified tightening torque in the same order. Tightening torque: 5.5 ± 0.5 N.m (49 ± 4 in-lb)

Scheme 397

1. Clean the oil filter mounting surface of the ladder frame.
2. Apply engine oil to the O-ring of the oil filter. CAUTION: Use special tool MB991396 to install the oil filter. Tightening it by hand causes oil leakage due to lack of torque.
3. Screw in the oil filter. When the O-ring contacts the mounting surface, use a filter wrench to tighten it Specified torque: 3/4 turn (14 ± 2 N.m [124 ± 17 in-lb]).

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1. Insert a flatblade screwdriver into the release hole of the timing chain tensioner to release the latch.
2. Push the tensioner lever by hand and push in the plunger of the timing chain tensioner until it hits the bottom. Then, insert a hard wire (piano wire or the like) of ø1.5 or hexagonal bar wrench (1.5 mm [0.05 inch]) into the fixing hole of the plunger.
3. Remove the timing chain tensioner.

<< B >> EXHAUST V.V.T. SPROCKET BOLT REMOVAL

Hold the hexagonal portion of the exhaust camshaft with a wrench and loosen the exhaust V.V.T. sprocket bolt.

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<< C >> INTAKE V.V.T. SPROCKET BOLT REMOVAL

Hold the hexagonal portion of the intake camshaft with a wrench and loosen the intake V.V.T. sprocket bolt.

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1. Assemble the intake V.V.T. sprocket assembly in the following procedure. Make sure that the knock pin of the inlet camshaft assembly is positioned facing straight upward. Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the intake V.V.T. sprocket assembly and the entire circumference of the area into which the intake V.V.T. sprocket assembly is inserted. Slowly insert the intake V.V.T. sprocket assembly into the normal position of the inlet camshaft assembly with its knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into the bottom and that the V.V.T. sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench.
4. Hold the hexagonal portion of the camshaft with a wrench and tighten the intake V.V.T. sprocket bolt to the specified torque. Specified torque: 59 ± 5 N.m (44 ± 3 ft-lb)

Scheme 404

1. Assemble the exhaust V.V.T. sprocket assembly in the following procedure. Make sure that the knock pin of the exhaust camshaft assembly is positioned facing straight upward. Apply an appropriate and minimum amount of engine oil to the circumference of the tip of the exhaust V.V.T. sprocket assembly and the entire circumference of the area into which the exhaust V.V.T. sprocket assembly is inserted. Slowly insert the exhaust V.V.T. sprocket assembly into the normal position of the exhaust camshaft assembly with its knock pin hole facing straight upward.
2. Install the V.V.T. sprocket.
3. Make sure that the V.V.T. sprocket is securely inserted into the bottom and that the V.V.T. sprocket does not rotate with the hexagonal portion of the camshaft secured with a wrench.
4. Hold the hexagonal portion of the camshaft with a wrench and tighten the camshaft sprocket bolt to the specified torque. Specified torque: 59 ± 5 N.m (44 ± 3 ft-lb)

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1. Align the timing mark of the V.V.T. sprocket.
2. Align the crankshaft sprocket keys with illustrated positions shown in figure.
3. Align the link plate (Orange) with the timing mark of the exhaust V.V.T. sprocket and loop the timing chain.
4. Align the link plate (Blue) with the timing mark of the intake V.V.T. sprocket to loop the timing chain. Rotate the intake V.V.T. sprocket by one or two teeth to align with the timing mark.
5. Align the timing mark of the crankshaft sprocket with the link plate (Blue) to loop the timing chain. Because of timing chain slacks, hold it to prevent the timing mark from coming off the link plate (Blue).
6. Make sure that the timing mark of each sprocket is aligned with the link plate of the timing chain at all of three locations.
7. Install the timing chain guide and tensioner lever.

Scheme 410

1. Install the timing chain tensioner on the cylinder block and tighten it to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)
2. Remove the hard wire (piano wire or the like) of ø 1.5 or hexagonal bar wrench (1.5 mm [0.05 inch]) from the timing chain tensioner. This enables the plunger of the timing chain tensioner to push the tensioner lever to keep the timing chain tight.

INTAKE V.V.T. SPROCKET

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1. Seal with a tape all the intake camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the advanced angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the intake camshaft on a vise, install the intake V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the advanced angle, remove the stopper pin.
5. Turn the intake V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 12.5°) NOTE: The stopper pin is locked in the most retarded angle position.
6. After the check, remove the intake V.V.T. sprocket from the intake camshaft
7. Completely remove the tape sealing the intake camshaft ports for the advanced angle and for the retarded angle.

EXHAUST V.V.T. SPROCKET

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1. Seal with a tape all the exhaust camshaft ports for the advanced angle and the retarded angle.
2. Make a hole on the port for the retarded angle. CAUTION: Fix the camshaft on a vise not to damage it.
3. Fixing the hexagonal area of the exhaust camshaft on a vise, install the exhaust V.V.T. sprocket. CAUTION: When applying air pressure, keep in mind that oil could splash.
4. By applying air pressure slowly to the holed port for the retarded angle, remove the stopper pin.
5. Turn the exhaust V.V.T. sprocket housing in the right and left directions. Check it smoothly moves in the range of A (approximately 10°) NOTE: The stopper pin is locked in the most advanced angle position.
6. After the check, remove the exhaust V.V.T. sprocket from the exhaust camshaft
7. Completely remove the tape sealing the exhaust camshaft ports for the advanced angle and for the retarded angle.

VALVE CLEARANCE ADJUSTMENT

Measure valve clearance as described in the following procedure.

Check and adjust the valve clearance with the timing chain installed.

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1. Rotate the crankshaft clockwise to align the timing mark of the V.V.T. sprocket with the top surface of the cylinder head as illustrated in figure. (Set the Number 1 piston at top dead center on the compression stroke.)
2. Valve clearance can be measured at the illustrated location shown in figure in this condition.
3. Use a thickness gauge to measure clearance between the camshaft and valve tappet. Standard value (when engine is cold): Intake side: 0.20 ± 0.03 mm (0.008 ± 0.001 inch) Exhaust side: 0.30 ± 0.03 mm (0.012 ± 0.001 inch)
4. If measured values are out of the standard value, record measured values.
5. Rotate the crankshaft by one turn clockwise to set the Number 4 piston at top dead center on the compression stroke. NOTE: The timing mark of the V.V.T. exhaust sprocket must be at the illustrated position shown in figure.
6. Valve clearance can be measured at the illustrated location shown in figure in this condition.
7. If measured values are out of the standard value, record measured values.
8. If the measured value is out of the standard value, replace the valve tappet. NOTE: There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 (0.1181 inch) and 3.690 mm (0.1453 inch).
9. Use the following procedure select a valve tappet. Measure thickness of a removed valve tappet. Calculate thickness of a valve tappet so that valve clearance meets the standard value. A: Thickness of valve tappet to be selected B: Thickness of removed valve tappet C: Measured valve clearance Formula Intake side: A = B + (C - 0.20 mm [0.008 inch]) Exhaust side: A = B + (C - 0.30 mm [0.012 inch]) Refer to " «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) " for removal, installation and inspection procedure of valve tappets.

Scheme 423

<< A >> FRONT CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

First remove a mounting bolt of the front camshaft bearing cap and then a mounting bolt of each camshaft bearing cap in the order shown in the illustration.

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<< B >> VALVE TAPPET REMOVAL

Pick out valve tappets with fingers and store removed valve tappets with tags describing the installed position attached for reassembly.

>> A << VALVE TAPPET INSTALLATION

Install valve tappets at the same position based on tags describing the installed position for reassembly.

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1. When replacing a camshaft bearing, select a bearing with the size corresponding to the identification mark in the table below.
2. Install camshaft bearings on the cylinder head. CAMSHAFT BEARING SPECIFICATIONS Camshaft Camshaft bearing Identification mark Journal diameter mm (in) Identification mark 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3
3. The identification mark of the camshaft bearing is painted at the illustrated position shown in figure.
4. Set the dowel pins of the camshaft at the illustrated positions shown in figure.
5. Camshaft bearing caps Number 1 to Number 4 are of the same shape. Install them upon checking the identification mark so as not to misidentify cap Number and to confuse the intake side with the exhaust side. Identification mark (stamped on front and Number 1 to Number 4 bearing caps) I: Intake side E: Exhaust side
6. Tighten each camshaft bearing cap mounting bolt to the specified tightening torque of 12 ± 1 N.m (107 ± 1 in-lb) in the order of number shown in the figure in two or three steps.
7. Tighten each front camshaft bearing cap mounting bolt to the temporarily torque of 17 ± 3 N.m (14 ± 2 ft-lb) in the order of number shown (1) in the illustration.
8. Tighten each front camshaft bearing cap mounting bolt to the specified tightening torque of 30 ± 2 N.m (22 ± 1 ft-lb) in the order of number shown (2) in the illustration.

Scheme 430

1. Apply a small amount of engine oil to the O-ring of the engine oil control valve.
2. Install the engine oil control valve on the cylinder head.
3. Tighten the engine oil control valve to the specified torque. Specified torque: 10 ± 2 N.m (89 ± 17 in-lb)

CAMSHAFT

Measure camshaft height (camshaft major axis). If the height is less than the limit, replace the camshaft.

Standard value

Intake: 43.25 mm (1.703 inches)

Exhaust: 45.00 mm (1.772 inches)

Limit

Intake: 42.75 mm (1.683 inches)

Exhaust: 44.50 mm (1.752 inches)

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1. Thoroughly wipe oil on the outside diameter of the camshaft and the inside diameter of the bearing.
2. Install the bearing to the camshaft.
3. Put straightly the plastigage having the length of the bearing width on the journal axis, centering the axis.
4. Carefully install the bearing cap. Tighten the bolt as instructed in «>> B << CAMSHAFT/BEARING/THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP/FRONT CAMSHAFT BEARING CAP INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) .
5. Remove the bolt and the bearing cap carefully.
6. Measure the plastigage whose width is most compressed using the scale printed on the plastigage bag. When the measured value deviates from the standard one, replace the bearing. Standard value: 0 - 0.032 mm (0 - 0.0013 inch) CAUTION: When the bearing is used again, be careful not to reverse the cylinder head side and the camshaft side during installation.

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1. Check the thickness stamp.
2. If the measured value in the table value is not in agreement with the value in the «VALVE TAPPET THICKNESS SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) table to the thickness stamp, replace the valve tappet. There are 47 kinds of valve tappets at intervals of 0.015 mm (0.0006 inch) in the range between 3.000 (0.1181 inch) and 3.690 mm (0.1453 inch).

VALVE TAPPET THICKNESS SPECIFICATIONS

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Required Special Tools

1. MD998735: Valve Spring Compressor
2. MB992089: Retainer Holder C
3. MB992085: Valve Stem Seal Pliers
4. MD998737: Valve Stem Seal Installer

<< A >> RETAINER LOCK REMOVAL

Use a special tool MD998735 and MB992089 to compress the valve spring and to remove the retainer lock.

Note. Store removed parts such as valves and springs with tags describing cylinder Number and installed position attached for reassembly.

Scheme 437

<< B >> VALVE STEM SEAL REMOVAL

Use special tool MB992085 to firmly pinch the base (larger external shape) of the stem seal and twist it right and left for pulling out.

Scheme 438

>> A << VALVE STEM SEAL INSTALLATION

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1. Apply a thin coat of engine oil to a new valve stem seal.
2. Use special tool MD998737 to press fit the valve stem seal into the valve guide with the valve stem used as a guide.

>> B << RETAINER LOCK INSTALLATION

Use a special tool MD998735 and MB992089 to compress the valve spring and to install the retainer lock.

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Scheme 442

1. Completely remove the liquid gasket on the upper plane of the cylinder block and the lower plane of the cylinder head. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Degrease the place specified in the illustration.
3. As shown in the illustration, apply a ø2 to 3 mm (0.079 to 0.118 inch) of sealant (Three bond 1217G or exact equivalent) to the top face of cylinder block.
4. Install the cylinder head gasket. NOTE: Check that the center of the liquid gasket is located toward the cylinder gasket in the position specified in the illustration.
5. As shown in the illustration, apply a ø2 to 3 mm (0.079 to 0.118 inch) of sealant (Three bond 1217G or exact equivalent) to the top face of cylinder head gasket.
6. Install the cylinder head assembly.

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Scheme 444

1. Install new cylinder head bolts and washers in the following procedure. NOTE: Cylinder head bolts and washers must not be reused.
2. Apply an appropriate amount of engine oil to top and bottom surfaces of washers and threaded portion of bolts.
3. Install cylinder head bolts to the cylinder head. NOTE: Bolts and washers are different parts for bolts on the timing chain side.
4. Tighten cylinder head bolts in several steps to the specified torque according to the assembly order shown in the illustration. Specified torque: 35 ± 2 N.m (26 ± 1 ft-lb)
5. Put a paint mark on all of cylinder head bolt heads and cylinder head. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
6. Tighten the cylinder head 90° according to the tightening order. Tighten it further 90° and make sure that the paint mark on the cylinder head bolt is in a straight line with that on the cylinder head.

Scheme 445

1. Check the cylinder head for water leakage, gas leakage, damage or cracks before cleaning.
2. Completely remove oil, scale, sealant, carbon, etc. After cleaning oil passages, blow air to make sure that they are not clogged. CAUTION: The grinding limit shall be within 0.2 mm (0.008 inch) in combination with the cylinder block to be assembled.
3. For the flatness on the cylinder head bottom, measure distortion using a straight edge and thickness gauge. If the distortion exceeds the limit, grind and repair it. Distortion on bottom Limit: Within 0.05 mm (0.002 inch) Grinding limit: 0.2 mm (0.008 inch) Cylinder head height: 128.5 mm (5.06 inches)

Scheme 446

Scheme 447

1. Repair the valve seat if contact with the valve seat is poor, uneven or broken.
2. Measure the margin. If the limit is exceeded, replace the valve. Standard value: Intake 1.022 mm (0.0402 inch) Exhaust 1.094 mm (0.0431 inch) Limit: Intake 0.522 mm (0.0206 inch) Exhaust 0.594 mm (0.0234 inch)
3. Measure overall length of the valve. If the limit is exceeded, replace the valve. Standard value: Intake 113.18 mm (4.456 inches) Exhaust 105.89 mm (4.169 inches) Limit: Intake 112.68 mm (4.436 inches) Exhaust 105.39 mm (4.149 inches)

Scheme 448

1. Measure free height of the spring. If the limit is exceeded, replace the spring. Standard value: 47.2 mm (1.858 inch) Limit: 46.2 mm (1.819 inch)
2. Measure squareness of the spring. If the inclination exceeds the limit, replace the spring. Standard value: 2° or less Limit: 4°

VALVE GUIDE

Measure clearance between the valve guide and valve stem. If the clearance exceeds the limit, replace the valve guide or valve, or both.

Standard value

Intake 0.020 - 0.047 mm (0.0008 - 0.0019 inch)

Exhaust 0.030 - 0.054 mm (0.0012 - 0.0021 inch)

Limit

Intake 0.10 mm (0.004 inch)

Exhaust 0.15 mm (0.006 inch)

Scheme 449

VALVE SEAT

Assemble the valve, then measure the contact width. If the measurement exceeds the specified limit, replace the valve seat.

Standard value

Intake: 1.16 - 1.46 mm (0.046 - 0.058 inch)

Exhaust: 1.35 - 1.65 mm (0.053 - 0.065 inch)

Scheme 450

Scheme 451

1. Check clearance between valve guide and valve and replace the valve guide if necessary before repairing the valve seat.
2. Repair the valve seat so that seat width and seat angle are to the specified shape.
3. Lap valve and valve seat with lapping compound after repairing valve seat.

Scheme 452

Scheme 453

1. Scrape the valve seat to be replaced from inside to make its wall thickness thin before pulling out.
2. Repair the valve seat hole of the cylinder head to match it with the diameter of the oversize valve seat to be press fitted. Intake valve seat bore diameter: 0.3 Over size: 36.22 - 36.24 mm (1.426 - 1.427 inches) Exhaust valve seat bore diameter: 0.3 Over size: 30.22 - 30.24 mm (1.190 - 1.191 inches)
3. Press fit the valve seat, taking care not to score the cylinder head bore at room temperature.
4. Ream the valve seat. Refer to " «REPAIR PROCEDURE OF VALVE SEAT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) ."

Scheme 454

1. Pull out the valve guide with a press toward the cylinder block side.
2. Ream the valve guide hole of the cylinder head to match it with the diameter of the oversize valve guide to be press fitted. CAUTION: Do not use a valve guide with the same size as that of the pulled out valve guide because it cannot be press fitted. Valve guide bore diameter 0.25 Over size: 11.23 - 11.25 mm (0.442 - 0.443 inch)
3. Press fit the valve guide to the illustrated dimension shown in figure. Standard value: 14.6 - 15.2 mm (0.57 - 0.60 inch) NOTE: Press fit the valve guide from the cylinder head top surface.
4. After pressing fit the valve guide, insert a new valve to check for sliding.

Scheme 455

Required Special Tools

1. MB991346: Top cover wrench
2. MB991883: Flywheel Stopper
3. MD998718: Rear Oil Seal Installer

<< A >> DRIVE PLATE BOLT/FLYWHEEL BOLT REMOVAL

1. Use special tool MB991883 to secure the drive plate or flywheel.
2. Remove the drive plate bolts or flywheel bolts.

<< B >> OIL PUMP SPROCKET REMOVAL

Fix the oil pump sprocket with a special tool MB991346, loosen a center bolt, and remove the oil pump sprocket.

Scheme 456

Scheme 457

Scheme 458

1. Pry the illustrated position shown in figure with a screwdriver or tap the boss with a hammer.
2. If the ladder frame does not come off, insert a flatblade screwdriver into the gap between the ladder frame and bearing cap as shown in the illustration and lightly pry it to remove the ladder frame.

>> A << LADDER FRAME INSTALLATION

Scheme 459

Scheme 460

1. Completely remove liquid gasket adhering to the cylinder block and ladder frame. CAUTION: Sufficiently check that there is no residual oil on the place where degreasing is performed. If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
2. Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.
3. Squeeze liquid gasket (Three bond 1217G or exact equivalent) of ø2 to 3 mm (0.08 to 0.12 inch) in thickness and apply it to the illustrated position of the ladder frame shown in figure.
4. Tighten the ladder frame to the specified torque in the order shown in the illustration. Specified torque: 26 ± 1 N.m (19 ± 1 ft-lb)

Scheme 461

1. Wipe off the dirt on the crankshaft sprocket and the crankshaft using a rag, and then remove the grease from the portion shown in the illustration. NOTE: Remove grease to prevent a drop in the coefficient of friction of the pressing portion caused by adhesion of oil.
2. Set the Number 1 piston at top dead center on the compression stroke.
3. Install the crankshaft sprocket to the crankshaft.

>> C << OIL PUMP SPROCKET/OIL PUMP CHAIN/OIL PUMP CHAIN GUIDE/OIL PUMP TENSIONER LEVER INSTALLATION

1. Set the Number 1 piston at top dead center on the compression stroke.
2. Using the special tools MB991346, install the oil pump sprocket to the oil pump case.
3. Install the oil pump chain to the crankshaft sprocket.
4. Install the oil pump chain to the oil pump sprocket.

>> D << REAR OIL SEAL INSTALLATION

After applying a small amount of engine oil to the oil seal lip, use special tool MD998718 to press fit the oil seal.

Scheme 462

Scheme 463

Scheme 464

Scheme 465

1. Clean off sealant and oil of thread of crankshaft and flywheel bolt.
2. Use special tool MB991883 to secure the flywheel.
3. Apply engine oil to thread of crankshaft and bolt seat area of flywheel or drive plate.
4. Apply the sealant (Three bond 1324 or equivalent) to the thread of flywheel bolt or drive plate bolt.
5. Tighten flywheel bolts to temporary torque 40 N.m (30 ft-lb) in the order shown to illustration.
6. Tighten flywheel bolts or drive plate bolt to specified torque in the order shown in the illustration. Specified torque: 130 N.m (96 ft-lb)

Scheme 466

Required Special Tools

1. MD998780: Piston Pin Setting Tool
2. MB991659: Guide D

<< A >> CONNECTING ROD/CONNECTING ROD CAP REMOVAL

Mark the connecting rod on the big end with the cylinder number it is being removed from.

Scheme 467

<< B >> PISTON PIN REMOVAL

Special tool MD998780 consists of parts shown in the illustration. Also use special tool MB991659 to remove the piston pin.

Scheme 468

Scheme 469

1. Insert the push rod into the piston pin from the front mark side of the piston top surface, and attach special tool MB991659.
2. Set the piston and connecting rod assembly on the base so that the front mark of the piston faces upward.
3. Use a press to push the push rod and pull out the piston pin. NOTE: After pulling out the piston pin, organize pistons, piston pins and connecting rods by cylinder Number

Scheme 470

Scheme 471

Scheme 472

1. When replacing a piston, check the cylinder bore size mark stamped on the illustrated position of the cylinder block shown in figure, and select a corresponding piston from the «CYLINDER BORE SIZE MARKS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) table below. CYLINDER BORE SIZE MARKS Cylinder bore size mark Piston size mark A A B B C C NOTE: The piston size mark is indicated on the piston top face.
2. Insert the push rod into the piston pin and attach guide A.
3. Align the front mark of the piston with that of the connecting rod to assemble.
4. Apply engine oil to the circumference of the piston pin.
5. Insert the guide A side of the piston pin assembled in section 1 into the pin hole from the front mark side of the piston.
6. Screw guide B into guide A and open clearance between guide A and guide B by 3 mm (0.12 inch) (make the base in line with flushed surface) to assemble.
7. Set the piston on special tool piston setting base so that its front mark faces upward.
8. Use a press to press fit the piston pin. If the press fit load is below the standard value, replace the piston pin (piston assembly) or connecting rod, or both. Standard value: 7,500 - 17,500 N (1,686 - 3,934 lbf)

Scheme 473

Scheme 474

1. Assemble the spacer of the oil ring into the piston ring groove. Then, assemble the upper side rail, and after this assemble the lower side rail. NOTE: Install the side rail and end gap of the spacer so that they are at the position as shown in the illustration. CAUTION: The side rail may be broken if its end gap is widened by a ring expander as in other piston rings.
2. When assembling the side rail, push it by fingers, after fitting one end of the side rail into the piston groove, for easy assembly.
3. After assembling the oil ring into the piston, make sure that the side rail turns smoothly to either direction.

>> C << PISTON RING NUMBER 2/PISTON RING NUMBER 1 INSTALLATION

Use a piston ring expander to assemble piston rings with their identification marks facing upward. Piston rings can be assembled by hand without using the piston ring expander.

Scheme 475

Identification mark

Number 1 ring: 1T

Number 2 ring: 2T

Scheme 476

Scheme 477

Scheme 478

1. Apply a sufficient amount of engine oil to the circumference of the piston, piston rings and oil ring.
2. Arrange end gap positions of piston rings and oil ring (side rail and spacer) as shown in the illustration.
3. Insert the piston and connecting rod assembly from the top surface of the cylinder block with the front mark of the piston top face facing toward the timing chain side. CAUTION: Driving it in hard causes breakage of piston rings and damage to the crank pin.
4. Firmly tighten the piston ring with a ring band and insert the piston and connecting rod assembly.

Scheme 479

Scheme 480

1. When replacing a connecting rod bearing, select the bearing corresponding to the crankshaft pin outside diameter according to the crankshaft pin identification in the «CRANKSHAFT PIN SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) table below. CRANKSHAFT PIN SPECIFICATIONS Crankshaft pin Connecting rod bearing Identification mark Journal diameter mm (in) Identification mark 1 47.966 - 47.972 (1.8884 - 1.8887) 1 2 47.960 - 47.966 (1.8882 - 1.8884) 2 3 47.954 - 47.960 (1.8880 - 1.8882) 3
2. An identification mark of a crankshaft is stamped at the illustrated position by Number shown in figure.
3. A connecting rod bearings an identification color or identification mark at the illustrated position shown in figure.

>> F << CONNECTING ROD CAP INSTALLATION

Note. The connecting rod resulting from the breaking process has the high insertion force. The new connecting rod assembly may possibly be difficult to remove the connecting rod. If difficult to remove it, alternately strike the two bolt heads with a plastic hammer while the connecting rod bolt is slightly loosened, or strike the center of the cap shaft's inside diameter slightly and outward. If the outside of the cap is directly struck, the lateral force is added to the broken-out section. Thus, pay attention to the broken-out section that might be difficult to be separated or might fall. Clean the broken-out section before the installation to the engine, using compression air.

Scheme 481

Scheme 482

1. Assemble the bearing cap on the connecting rod by aligning it with the mark put during removal. If a new connecting rod without a mating mark is used, assemble so that the detent notch of the bearing is on the same side as illustrated in the figure.
2. Make sure that clearance of the thrust of the connecting rod big end is appropriate. Standard value: 0.10 - 0.25 mm (0.004 - 0.010 inch) Limit: 0.4 mm (0.016 inch)

Scheme 483

Scheme 484

1. Check in the following procedure before reusing the connecting rod bolt. Measure the outside diameter "A." Measure the smallest outside diameter "B" within the range "X" shown in the illustration. If the difference of outside diameter of thread exceeds the limit, replace the connecting rod bolt. Limit: 0.1 mm
2. Apply engine oil to the threaded portion and seat surface of the bolt before installing it.
3. After installing each bolt and tightening it by fingers, tighten bolts alternately to properly assemble the cap.
4. Tighten the bolt in several steps until the torque reaches 5.0 N.m (44 in-lb).
5. Tighten the bolt in several steps until the torque reaches 20 N.m (15 ft-lb).
6. Put a paint mark on the bolt head as illustrated in figure.
7. Put a paint mark on the connecting rod at 90° position in the tightening direction of the bolt with reference to the paint mark position of the bolt. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
8. Tighten the bolt 90°, and make sure that the paint mark of the connecting rod is aligned with that of the bolt.

Scheme 485

Scheme 486

1. Check clearance between piston rings and ring grooves. If the limit is exceeded, replace piston rings or piston, or both. Standard value: Number 1 ring: 0.03 - 0.07 mm (0.001 - 0.003 inch) Number 2 ring: 0.03 - 0.07 mm (0.001 - 0.003 inch) Limit: 0.1 mm (0.004 inch)
2. Put piston rings into the cylinder bore, press them against the piston top face, and push them in. After achieving squareness, measure the end gap with a thickness gauge. If the end gap is excessive, replace piston rings. Standard value: Number 1 ring: 0.15 - 0.28 mm (0.006 - 0.011 inch) Number 2 ring: 0.25 - 0.40 mm (0.010 - 0.016 inch) Oil ring: 0.10 - 0.35 mm (0.004 - 0.014 inch) Limit: Number 1 ring: 0.8 mm (0.03 inch) Number 2 ring: 0.8 mm (0.03 inch) Oil ring: 1.0 mm (0.04 inch)

Scheme 487

Scheme 488

1. Wipe oil off the crankshaft pin and connecting rod bearing.
2. Place a plastigage in length equal to the bearing width on the pin shaft straight in alignment with the shaft center.
3. Carefully install the connecting rod cap and tighten bolts to the specified torque of 5.0 N.m (44 in-lb) --> 20 N.m (15 ft-lb) --> +90°.
4. Remove bolts and gently remove the connecting rod cap.
5. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag. Standard value: 0.018 - 0.045 mm (0.0007 - 0.0018 inch) Limit: 0.1 mm (0.004 inch)

Scheme 489

Required Special Tool

1. MB991614: Angle Gauge

<< A >> CRANKSHAFT REMOVAL

After removing the crankshaft with the crankshaft sensing ring attached, temporarily place it on a V-block to prevent teeth of the sensing ring from deforming.

Note. If a tooth bends, be sure to replace the crankshaft sensing ring with a new one.

>> A << CRANKSHAFT SENSING RING INSTALLATION

Tighten crankshaft sensing ring bolts to the torque of 11 ± 1 N.m (98 ± 8 in-lb) in the tightening order shown in the illustration.

Scheme 490

Scheme 491

1. Install the thrust bearing on the Number 3 bearing on the cylinder block side. Application of engine oil makes the installation easier.
2. Install the thrust bearing so that the grooved side is on the crankshaft weight side.

Scheme 492

Scheme 493

1. When replacing the crankshaft bearing upper, select a bearing with the size corresponding to the crankshaft journal diameter in the «CRANKSHAFT BEARING UPPER SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-overhaul-20l-non-turbo-except-lancer-evolution) table below.
2. The crankshaft bearing upper has an identification color or identification mark at the illustrated position shown in figure. CRANKSHAFT BEARING UPPER SPECIFICATIONS Cylinder block Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark 1 56.000 - 56.006 (2.2047 - 2.2050) 1 2 56.006 - 56.012 (2.2050 - 2.2052) 2 3 56.012 - 56.018 (2.2052 - 2.2054) 3
3. Install the selected crankshaft bearing upper.

Scheme 494

Scheme 495

1. When replacing the crankshaft bearing lower, select a bearing with the size corresponding to the crankshaft journal diameter in the table below.
2. The crankshaft bearing lower has an identification color or identification mark at the illustrated position shown in figure. CRANKSHAFT BEARING LOWER SPECIFICATIONS Crankshaft Crankshaft bearing Identification mark Journal diameter mm (in) Identification mark 0 51.985 - 51.988 (2.0467 - 2.0468) 0 1 51.982 - 51.985 (2.0465 - 2.0467) 1 2 51.979 - 51.982 (2.0464 - 2.0465) 2 3 51.976 - 51.979 (2.0463 - 2.0464) 3 4 51.973 - 51.976 (2.0462 - 2.0463) 4
3. Install the selected crankshaft bearing lower.

Scheme 496

Scheme 497

Scheme 498

Scheme 499

1. Install the crankshaft bearing cap with reference to the identification mark as illustrated in figure.
2. Make sure that the underhead length of the bolt is at or below the limit before installing the crankshaft bearing cap bolt. If the length exceeds the limit, replace the bolt with a new one. Limit: 75.5 - 76.5 mm (2.972 - 3.012 inch)
3. Apply engine oil to the threaded portion and seat surface of the bolt.
4. Tighten crankshaft bearing cap bolts to the torque of 26.5 ± 2.0 N.m (20 ± 1 ft-lb) according to the tightening order. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
5. Use special tool MB991614 to tighten bolts 45° according to the tightening order.
6. Check end play of the crankshaft after installing the crankshaft bearing cap. If the end play exceeds the limit, replace the thrust bearing. Standard value: 0.05 - 0.25 mm (0.002 - 0.010 inch) Limit: 0.4 mm (0.016 inch)

CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)

Oil clearance can be easily measured by using a "plastigage." When using a "plastigage," perform measurement in the following procedure.

Scheme 500

Scheme 501

1. Fully wipe oil off the outside diameter of the crankshaft and inside diameter of the bearing.
2. Assemble the crankshaft.
3. Place a plastigage in length equal to the bearing width on the journal shaft straight in alignment with the shaft center.
4. Carefully install the bearing cap and tighten the bolt according to the main point of installation >> B <<.
5. Remove the bolt, and then carefully remove the crankshaft bearing cap.
6. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag. Standard value: 0.012 - 0.030 mm (0.0005 - 0.0012 inch) Limit: 0.1 mm (0.004 inch)

Scheme 502

Scheme 503

1. Visually check the cylinder block for scratch, rust and corrosion. Use a flaw detecting agent to check for cracks. If it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block using a straight edge and thickness gauge. If distortion exceeds the limit, grind and repair it. A gasket or the like must not be adhered to the top surface of the cylinder block during measurement. Distortion on bottom Standard value: Within 0.05 mm (0.0020 inch) Limit: 0.2 mm (0.008 inch) Grinding limit: 0.2 mm (0.008 inch)
3. Check the cylinder wall for scratch or seizure. If there is any defect, replace the cylinder block.
4. Measure the bore and cylindricity of the cylinder using a cylinder gauge. If the cylinder is excessively worn, repair the cylinder and replace the piston and piston rings. Measuring points are as shown in the illustration. Standard value Cylinder bore: 86.0 mm (3.39 inches) Cylindricity: 0.15 mm (0.006 inch)

See also:
• REMOVAL AND INSTALLATION