Mitsubishi Lancer Evolution 7. Manual — part 157
ENGINE OVERHAUL -
Specifications
11B-5
MACHINING STANDARDS
Unit: mm
Items
Standard value
Limited value
Cylinder head, valve
Cylinder head
Oversize valve guide hole diameter
0.05 O.S.
0.25 O.S.
0.50 O.S.
Oversize valve seat hole diameter
Intake
0.3 O.S.
0.6 O.S.
Exhaust
0.3 O.S.
0.6 O.S.
12.05 - 12.07
12.25 - 12.27
12.50 - 12.52
35.30 - 35.33
35.60 - 35.63
33.30 - 33.33
33.60 - 33.63
-
-
-
-
-
-
-
TIGHTENING TORQUE
Items
Tightening torque N·m
Alternator, ignition system
Oil level gauge guide bolt
13 ± 1
Water pump pulley bolt
8.8 ± 1.0
Alternator brace bolt (flange)
23 ± 3
Alternator brace bolt (washer)
22 ± 4
Alternator nut
44 ± 10
Crankshaft pulley bolt
25 ± 4
Center cover bolt
3 ± 0.5
Ignition coil bolt
10 ± 2
Spark plug
25 ± 5
Connector bracket bolt
8.8 ± 1.0
Timing belt
Timing belt cover bolt (flange)
11 ± 1
Timing belt cover bolt (washer)
9 ± 1
Power steering pump bracket bolt
49 ± 9
Tensioner pulley bolt
49 ± 6
Tensioner arm bolt
21 ± 4
Auto tensioner bolt
23 ± 3
Idler pulley bolt
35 ± 6
Crank angle sensor bolt
8.8 ± 1.0
Oil pump sprocket nut
54 ± 5
Crankshaft bolt
162 ± 5
Tensioner B bolt
19 ±3
Counter balance shaft sprocket bolt
46 ± 3
Rocker cover bolt
3.5 ± 0.5
Engine support bracket bolt
49 ± 5
ENGINE OVERHAUL -
Specifications
11B-6
Items
Tightening torque N·m
Camshaft sprocket bolt
88 ± 10
Fuel system
Throttle body bolt
19 ± 3
EGR valve bolt
20 ± 2
Fuel pressure regulator bolt
8.8 ± 2.0
Delivery pipe and injector bolt
11 ± 1
Vacuum hose and pipe bolt
11 ± 1
Solenoid assembly bolt
9 ± 1
Vacuum tank bracket bolt
9 ± 1
Secondary air system, intake manifold
Exhaust manifold heat protector bolt
14 ± 1
Vacuum hose and pipe bolt
11 ± 1
Air pipe assembly bolt (eye bolt)
49 ± 5
Air pipe assembly bolt (M6 flange)
11 ± 1
Air pipe assembly bolt (M8 flange)
24 ± 3
Air pipe assembly bolt (M8 washer)
14 ± 1
Air control valve assembly bolt
22 ± 4
Air control valve bracket bolt
22 ± 4
MDP sensor bolt
5 ± 1
Intake manifold stay bolt
31 ± 3
Intake manifold bolt (M8)
20 ± 2
Intake manifold bolt nut (M8)
36 ± 6
Exhaust manifold
Engine hanger bolt
19 ± 3
Turbocharger heat protector bolt
14 ± 1
O
2
sensor
44 ± 5
Exhaust fitting bracket bolt
47 ± 6
Exhaust fitting bolt nut
59 ± 5
Air outlet fitting bolt
19 ± 1
Oil return pipe bolt (flange)
14 ± 1
Oil return pipe bolt (washer)
9 ± 1
Turbocharger assembly and pipe bolt, nut
59 ± 5
Oil pipe bolt (M10 eye bolt)
17 ± 2
Oil pipe bolt (M12 eye bolt)
31 ± 2
Oil pipe bolt (M12 flange)
11 ± 1
Water pipe bolt (flange)
10 ± 1
Water pipe bolt (eye bolt)
42 ± 7
Exhaust manifold nut (M8)
33 ± 6
Exhaust manifold nut (M10)
55 ± 10
Water pump, water hose
Engine coolant temperature sensor
29 ± 10
Engine coolant temperature gauge unit
10.8 ± 1.0
ENGINE OVERHAUL -
Specifications
11B-7
Items
Tightening torque N·m
Water outlet fitting bolt
10 ± 1
Thermostat housing bolt
23 ± 4
Water inlet pipe bolt (M6)
10 ± 1
Water inlet pipe bolt (M8)
13 ± 2
Water pump bolt
14 ± 1
Knock sensor
23 ± 2
Rocker arm, camshaft
Cam position sensor bolt
8.8 ± 1.0
Cover bolt
10 ± 2
Cam position sensing cylinder bolt
22 ± 4
Cam position sensor support bolt
14 ± 1
Bearing cap bolt
20 ± 1
Oil delivery body bolt
11 ± 1
Cylinder head, valve
Cylinder head bolt
78 ± 2 → Completely loosen → 20 ± 2 → 90_ + 90_
Oil pump, oil pan
Drain plug
39 ± 5
Oil pan bolt
9 ± 3
Oil screen bolt
19 ± 3
Baffle plate bolt
22 ± 4
Oil pressure switch
19 ± 3
Oil cooler bypass valve
54 ± 5
Relief plug
44 ± 5
Oil filter bracket bolt
19 ± 3
Plug cap
23 ± 3
Flange bolt
36 ± 3
Oil pump case bolt
23 ± 3
Oil pump cover bolt
17 ± 1
Oil pump cover screw
10 ± 2
Piston, connecting rod
Connecting rod cap nut
20 ± 2 + 90_ - 94_
Crankshaft, cylinder block
Flywheel bolt
132 ± 5
Rear plate bolt
11 ± 1
Bell housing cover bolt
9 ± 1
Rear oil seal case bolt
11 ± 1
Beam bearing cap bolt
25 ± 2 + 90_ - 100_
Check valve
32 ± 2
Throttle body
Throttle position sensor bolt
2.0 ± 0.5
Turbocharger
Waste gate actuator bolt
11.3 ± 1.5
ENGINE OVERHAUL -
Specifications
11B-8
SEALANTS
Item
Specified sealant
Quantity
Engine support bracket bolt
3M
TM
AAD Part No. 8672 or equivalent
As required
Semi-circular packing
3M
TM
AAD Part No. 8672 or equivalent
As required
Rocker cover
3M
TM
AAD Part No. 8672 or equivalent
As required
Water outlet fitting
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Engine coolant temperature gauge unit
3M
TM
AAD Part No. 8672 or equivalent
As required
Engine coolant temperature sensor
3M
TM
AAD Part No. 8672 or equivalent
As required
Cylinder head (camshaft bearing cap mounting
section)
3M
TM
AAD Part No. 8672 or equivalent
As required
Cam position sensor support
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil pressure switch
3M
TM
AAD Part No. 8672 or equivalent
As required
Oil pan
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
Oil seal case
Mitsubishi Genuine Part No. MD970389 or
equivalent
As required
FORM-IN-PLACE-GASKET
FIPG is used for several members of this engine. With this gasket, caution is required to the application
amount, application procedure and state of the application surface so that the performance is sufficiently
attained.
If sufficient gasket is not applied, leaks could occur, and if too much is applied, the gasket could protrude
and plug or restrict the oil and water flow passage. Thus, to prevent leaks from the joined sections,
it is absolutely necessary to evenly apply the correct amount.
The FIPG used for the engine parts reacts with moisture in the air and hardens so use it for the normal
metal flange parts.
DISASSEMBLY
The parts assembled with FIPG can be easily disassembled without special means. However, in some
cases, the sealant on the seams must be broken by lightly tapping with a wood hammer or similar tool.
A smooth and thin gasket scraper can be lightly tapped into the seams but in this case, take care not
to damage the seams.
The special tool oil pan remover (MD998727) is set for this purpose.
WASHING THE GASKET SURFACE
Completely remove all matters adhered on the gasket surfaces with a gasket scraper or wire brush.
Confirm that the FIPG application surface is smooth. There must be no grease or foreign matter on
the gasket surface.
Always remove the old FIPG that has entered the mounting holes and screw holes.
APPLICATION PROCEDURES
Apply an even coat of FIPG within the predetermined radius. Completely cover the areas around the
mounting holes. The FIPG can be wiped off if it has not hardened. Install at the set position while the
FIPG is still wet (within 15 minutes). When installing, maker sure that the FIPG does not get on areas
other than the required areas. After installing, do not subject the application areas to oil or water or
start the engine until the FIPG has sufficiently hardened (approx. one hour). The FIPG application procedures
differ according to the member, so follow the procedures given in this manual and apply the FIPG.
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