Mitsubishi Lancer Evolution IX. Manual - part 91

OIL PAN AND OIL PUMP

ENGINE OVERHAUL

11B-55

CAUTION

Too much FIPG will squeeze out, blocking cool-
ant or oil passages, while too thin a bead could 
result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange 

surface all around the oil pan.

Specified sealant:

Mitsubishi Genuine Part No.MD970389 or 

equivalent

NOTE: In the grooved areas on the oil pan flange, 
apply FIPG bead along the centre of the groove.

3. Install the shorter bolts in the locations indicated 

in the drawing.

>>M<< OIL FILTER INSTALLATION

1. Clean the installation surface of the filter bracket.
2. Apply engine oil to the o-ring of the oil filter.
3. Install the oil filter to the bracket and tighten it to 

the specified torque.

Tightening torque: 14 

± 2 N⋅m

4. If no torque wrench can be used for tightening, 

use the following procedure:
(1) Screw in the oil filter until its o-ring contacts 

the oil filter bracket.

(2) Tighten the oil filter 3/4 turn.

>>N<< DRAIN PLUG GASKET 
INSTALLATION

CAUTION

Installing the gasket with the wrong side facing 
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install 
it with the side indicated in the drawing toward the oil 
pan.

AK202694

Timing belt side

Bolt hole 
area

Grooved
area

AB

AK202693

Timing belt side

M6 × 8

AC

AK202556

Bracket side

Engine oil

AB

AK300601AE

Drain plug

Oil pan

Gasket

Oil pan 
side

OIL PAN AND OIL PUMP

ENGINE OVERHAUL

11B-56

INSPECTION

M1113008200308

COUNTERBALANCE SHAFTS

1. Check that the oil holes are not blocked.

Clean if necessary.

2. Check the journals for seizure, damage and 

defective contact with bearings. 
If any of these faults is found, replace the 
counterbalance shaft, bearings and/or oil pump 
case assembly.

OIL PUMP

1. Install the drive and driven gears in the oil pump 

case.

2. Measure the gear side clearance using a straight 

edge and thickness gauge.

Standard values:

Drive gear 0.08 

− 0.14 mm

Driven gear 0.06 

− 0.12 mm

OIL COOLER BY-PASS VALVE

1. Make sure that valve moves smoothly.
2. Ensure that the dimension L measures the 

standard value under normal temperature and 
humidity.

Standard value: 34.5 mm

3. The dimension must be the standard value when 

measured after the valve has been dipped in 97 to 
103

°C oil.

Standard value: 40.0 mm

OIL LEVEL SENSOR

Put the oil level sensor in oil, then move the float 
up and down with the oil at a temperature either 
lower than 40

°C or higher than 80°C, and check 

for continuity.

40

°C

80

°C

AK202835AB

AK202831

Float position

Switch ON/OFF

Condition when down

ON (continuity)

Condition when up

ON (continuity)

Float position

Switch ON/OFF

Condition when down

OFF (no continuity)

Condition when up

ON (continuity)

AK000032

L

Valve

AC

AK304606AB

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-57

PISTON AND CONNECTING ROD

REMOVAL AND INSTALLATION

M1113008401338

AK501781AB

4

1

2

3

11

9

6

7
8

10

12

5

20 ± 2 N·m  

+90˚ to 94˚

Apply engine oil to
all moving parts
before installation.

Removal steps 

>>

G

<< 1. Connecting rod cap nut

<<

A

>> >>

F

<< 2. Connecting rod cap

>>

E

<< 3. Connecting rod bearing

<<

B

>> >>

D

<< 4. Piston and connecting rod assembly

5. Connecting rod bearing

>>

C

<< 6. Piston ring No. 1

>>

C

<< 7. Piston ring No. 2

>>

B

<< 8. Oil ring

<<

C

>> >>

A

<< 9. Piston pin

10. Piston
11. Connecting rod
12. Bolt

Removal steps (Continued)

PISTON AND CONNECTING ROD

ENGINE OVERHAUL

11B-58

REMOVAL SERVICE POINTS
<<A>> CONNECTING ROD CAP 
REMOVAL

Mark the cylinder number on the side of the connect-
ing rod big end as a guide for reassembly.

<<B>> PISTON AND CONNECTING ROD 
ASSEMBLY REMOVAL

1. Not to damage the crank pin, attach a special tool 

Bolt guide (MB992010), to the connecting rod 
bolt.

2. Remove the piston and connecting rod assembly 

from the cylinder block.

<<C>> PISTON PIN REMOVAL

The special tool Piston pin setting tool (MD998780), 
consists of the elements shown in the drawing.

1. Insert the tool element, Push rod, into the piston 

from the front mark side, then attach the element, 
Guide C, to the push rod.

2. Place the piston and connecting rod assembly on 

the element, Base, with the front mark facing up.

3. Use a press to remove the piston pin.

AK202812

Cylinder 
number

AB

AK402310 AC

MB992010

Crank pin

AK301431

Push rod

Guide B

Guide C

Guide A: 17.9 mm

Guide A: 18.9 mm

Guide A: 20.9 mm

Guide A: 21.9 mm

Base

AD

AK501782

P

P

Push rod

Front mark

Base

Front mark

Guide C

AB