fuel MITSUBISHI LANCER EVOLUTION IX 2005 Owner's Manual

ENGINE ELECTRICAL – CHARGING SYSTEM
16-3
Removal guidelines
 
A



Removing the delivery pipe, the injector, and the fuel
pressure regulator ASSY
Loosen the bolts holding it in place, slightly dislodge all of the
components and make space for the alternator to be removed.
 
B


Removing the drive belt
The following procedures are necessary because a serpentine drive
system with auto-tensioner has been installed.
1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and
turn the auto-tensioner in an anti-clockwise direction until it
reaches the stopper.
2. Align the A hole and the B hole, hold them in place by inserting
an L-shaped hexagonal Allen Key, and remove the drive belt.
Caution
If planning to re-use the drive belt, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
 
C


Removing the alternator
Push the whole engine up using a garage jack, and remove the
alternator from above.
AholeB hole
L-shaped
hexagonal
Allen
wrench

REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM> 27B-1
SECTION 27B
REAR AXLE
CONTENTS
General........................................................1 Differential carrier <vehicles with an
AYC system> ..............................................1
General
The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been
changed. Other servicing guidelines remain unchanged.
Differential carrier <vehicles with an AYC system>
Removal and fitting
Note
*1: When the screw is dry.
*2: When the screw is lubricated.
NEWOLDfuel pressure unit hose ASSY
differential carrier ASSY

Service Manual
4G6
FOREWORD
This manual contains information about the 4G6
DOHC engine. It only covers those points that are
different from the service manuals listed below.
Therefore, this manual should be used in conjunction
with the following manuals.
• 4G6 DOHC engine Service Manual (No. 1039G46)
• 4G6 DOHC engine Service Manual Supplement
(No.1039G63)
This manual is based on the engine specifications as of
March 2005. Please note that some engine details may
not match those given in this manual due to
subsequent changes in engine specifications. The units
shown in this manual are the standard international
SI units.
(However, conventional units are used for some figures
taken from existing documents)
If you have any opinions, requests or queries regarding
this manual, please write them down on the “Servicing
Comment Form” on the last page, and fax them to us.
March 2005
Mitsubishi Motor Corporation
This manual is printed on recycled paper.
CONTENTS
General Information . . . . . . . . . . . . . . . 4
Servicing Specification Values . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator / Ignition system . . . . . . . . . 8
Timing belt . . . . . . . . . . . . . . . . . . . . . 10
Fuel system . . . . . . . . . . . . . . . . . . . . . 13
Secondary air system /
inlet manifold . . . . . . . . . . . . . . . . . . . 15
Exhaust manifold . . . . . . . . . . . . . . . . 16
Water pump / Water hose . . . . . . . . . 17
Rocker arm / Cam shaft . . . . . . . . . . . 18
Oil pump / Sump . . . . . . . . . . . . . . . . . 21
Pistons / Connecting rods . . . . . . . . . 22
Crank shaft / Cylinder block . . . . . . . 25
Turbocharger. . . . . . . . . . . . . . . . . . . . 27
DOHC
ENGINE

44G6 – GENERAL INFORMATION/ SERVICING SPECIFICATIONS
General Information
The 4G63 MIVEC T/C engine fitted in the Lancer Evolution IX incorporates the following changes with respect to the previous
4G63 T/C engine.
• Adoption of variable valve timing control system
• Modification to clearance gap in piston No.2 ring coupling
• Addition of air intake temperature sensor
• Addition of boost sensor
Vehicle Model List
Specifications
Servicing Specification Values
Name Vehicle model Engine type Exhaust capacity cc Specifications
Lancer Evolution IX CT9A 4G63-7 1,997 DOHC 16-valve
MIVEC – T/C
Item Specification
Bore x stroke 85 x 88
Total displacement cc 1,997
Combustion chamber shape Pentroof type
No. of cylinders 4
Valve mechanism Type DOHC
Intake valves 8
Exhaust valves 8
Lash adjuster Hydraulic
Rocker arm Roller follower type
Compression ratio 8.8
Fuel injection device Electronically controlled MPI
Ignition device Electronically controlled two-coil type
Alternator AC type (with IC regulator)
Starter motor Deceleration drive
g
Item Standard value Limit value
Cylinder head, valves
Valve spring : free height mm 50.4 49.4
Valve spring : perpendicularity 2º or less 4º
Pistons, connecting rods
No.1 0.03~0.07 0.1Piston rings : Clearance between ring and ring
groove mm
No.2 0.02~0.06 0.1
No.1 0.20~0.30 0.8Piston rings : Closed gap mm
No.2 0.30~0.45 0.8
Oil ring 0.10~0.40 1.0

54G6 – TIGHTENING TORQUES
Tightening Torques
Par tTightening Torque Nm
Alternator, ignition system
Oil level gauge guide bolt13 ± 1
Water pump pulley bolt8.8 ± 1.0
Auto tension bolt (washer)44 ± 10
Auto tension bolt (flange)24 ± 4
Alternator bracket bolt (flange)24 ± 4
Alternator bracket bolt (washer M8 x 22)22 ± 4
Alternator bracket bolt (washer M8 x 32)20 ± 2
Alternator nut44 ± 10
Crankshaft pulley bolt25 ± 4
Centre cover holt3.0 ± 0.5
Ignition coil bolt10 ± 2
Spark plug25 ± 5
Timing belt
Timing belt cover bolt (flange)11 ± 1
Timing belt cover bolt (washer)9.0 ± 1.0
Power steering pump bracket bolt49 ± 9
Connector bracket bolt11 ± 1
Locker cover bolt3.5 ± 0.5
Plug cap32 ± 2
Tensioner pulley bolt48 ± 5
Tensioner arm bolt21 ± 4
Auto tensioner bolt23 ± 3
Idler pulley bolt35 ± 6
Crank angle sensor bolt8.8 ± 1.0
Oil pump sprocket nut54 ± 5
Crankshaft holt167
Tensioner B bolt19 ± 3
Counterbalance shaft sprocket bolt45 ± 3
Engine support bracket bolt49 ± 5
V.V.T. sprocket bolt65 ± 5
Camshaft sprocket bolt88 ± 10
Fuel system
Throttle body bolt19 ± 3
Cover bolt12 ± 1
Fuel pressure regulator bolt8.8 ± 2.0
Delivery pipe and injector bolt11 ± 1
Vacuum hose and pipe bolt11 ± 1
Solenoid valve assembly bolt9.0 ± 1.0
Vacuum tank bracket bolt9.0 ± 1.0
Secondary air system / Intake manifold
Exhaust manifold heat protector bolt20 ± 3
Air pipe assembly

134G6 – FUEL SYSTEM
Fuel System
Removal and Installation
Removal Sequence
1. Throttle body assembly
2. Throttle body gasket
3. Cover
4. Gasket
5. Fuel hose
6. Fuel pressure regulator
7. O ring
8. Delivery pipe and injector
9. Insulator
10. Fuel return pipe
11.Insulator
12. Injector
13. O ring14. Grommet
15. Delivery pipe
16. Vacuum hose
17. Vacuum hose
18. Vacuum hose
19. Solenoid valve assembly
20. Solenoid valve assembly
21. Vacuum hose and pipe
22. Solenoid valve assembly
23. Vacuum tank bracket
24. Vacuum tank
25. Vacuum hose assembly
26. Vacuum hose and pipe

* 1
*

* 1
*

* 1
*
A
*

144G6 – FUEL SYSTEM
Installation Service Point
Installation of cover
The side of the cover marked “gasket side” should be assembled
facing the inlet manifold.
 A
Gasket
sideCover
Gasket
Inlet manifold

LAYOUT DIAGRAMS - GENERAL LAYOUT DIAGRAM1-3
Front
harness (RH)Control panelInstrument
panel harnessRoof harness
Floor harness (RH)
Battery
harness
Front harness (LH)
Front door
harness *Floor
harness (LH)Fuel harnessRear door harness *
Note :
1. This diagram shows the main wiring harnesses only.
2. The * symbol indicates that the harness is also fitted on the right-hand side.
General Layout Diagram

LAYOUT DIAGRAMS - ENGINE / TRANSMISSION1-8
B-106 (2-grey) Knock sensor
B-108 (2-black) Coolant temperature sensor
B-109 (34-black) ABS-ECU
B-114 (1-black) Water temperature gauge unit
B-115 (3-black) Exhaust cam position sensorB-119 (3-grey) Ignition coil 2
B-122 (3-black) Crank angle sensor
B-123 (3-grey) Ignition coil 1
B-124 (2-black) Fuel pressure solenoid valve
Engine / Transmission (continued)
Connector Symbol
Control harness
Battery harness

LAYOUT DIAGRAMS - ENGINE / TRANSMISSION1-9
B-126 (6-black) Idle speed control servo
B-127 (4) Electric pump relay
B-128 (4) Fuel pump relay 3
B-129 (6-black) Register (for injector)
B-130 (2-black) Fuel pump register
B-131 (3-black) Vehicle speed sensorB-132 (2-black) Back-up lamp switch
B-133 (2-black) Secondary air control solenoid valve
B-134 (2-black) Oil feeder control valve
B-135 (3-black) Manifold absolute pressure sensor
Ground cable
Transmission harness