MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

EXTERIOR – REAR BUMPER
51-5
Dismantling and assembly
Dismantling procedure
1. Number plate lamp bracket
•Number plate lamp ASSY
2. Rear bumper reinforcement
3. Rear bumper side plate4. Rear bumper facing support, side
reinforcement
5. Rear bumper valence
6. Rear bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
 
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EXTERIOR – MARKINGS 51-6
Markings
Removal and affixing
1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge
3. EVOLUTION badge
Guidelines for affixing markings



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Affixing markings
1. Positioning
2. Guidelines for affixing
(1) Using white spirit, remove any grease from the place where the
badges will be affixed.
(2) Remove the protective paper from the back of the badges, and
affix them in the designated places.
Caution
1) Perform this job in an ambient temperature of 20~38ºC, and
in a dust free location.
2) If the job is being performed in an ambient temperature of
less than 20ºC, warm up the badges, and the area of the
body onto which they will be affixed, to a temperature of
20~38ºC.
3) Ensure that air bubbles are not trapped in the adhesive tape
when the badges are affixed.



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2. LANCER badge 3. EVOLUTION badge
edge of boot lid

CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL54A-1
52B-1
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
Acaution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
bonnet
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.

CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL54A-1
52B-1
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
Acaution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
bonnet
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.

Service Manual
Supplement
Lancer Evolution IX

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

2HOW TO USE THIS MANUAL
How to Use this Manual
Range of description
This manual explains the service procedure for the engine after it has been removed from the vehicle. For information on
removing the engine from the vehicle, or "on-vehicle" servicing of the engine, please refer to the separate service manual for
the relevant vehicle model.
Understanding the description
Inspection
The manual only indicates inspection points where special tools or measuring devices are required. It does not mention general
visual checks, part cleaning requirements, and so on, but these must also be carried out as part of the actual service work.
Service sequence
(1) A component diagram is provided at the beginning of each section in order to give the reader a clear
understanding of where the various parts are installed.
(2) The numbers in the component diagram indicate the sequence of the service procedure. Tightening torques
are shown and non-reusable parts are indicated where appropriate
Removal sequence:The part numbers correspond to the numbers in the component diagram and indicate
the removal sequence.
Installation sequence:This is only shown if the parts cannot be installed in the reverse order to the removal
sequence.
Disassembly sequence: The numbers of the part names correspond to the symbols in the component
diagram and indicate the disassembly sequence.
Assembly sequence:This is only shown if the parts cannot be re-assembled in the reverse order to the
disassembly sequence.
Symbols for lubricants and sealants
Application points for lubricants and sealants are
indicated by special symbols (shown right) on the
component parts diagram or on the following page............... Grease
.............. Sealant or liquid gasket (FIPG)
.............. Brake fluid
.............. Engine oil
Types of service points
“Service point” notes are used to give a detailed
description of essential maintenance and service
points, standard values, procedures for using special
tools, and other important information at relevant
points in the service sequence. The different types
of “service point” are shown on the right-hand side.: Indicates that there is a removal or
disassembly service point
: Indicates that there is an installation or
assembly service point
: Indicates that the removal or disassembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the removal or disassembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.

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3HOW TO USE THIS MANUAL
Page number Engine type Title