MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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

64G6 – TIGHTENING TORQUE
PartTightening Torque
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
Engine hanger bolt 19 ± 3
Intake air temperature sensor 14 ± 1
Boost sensor bolt 5.0 ± 1.0
Intake manifold stay bolt 31 ± 3
Intake manifold bolt (M8) 20 ± 2
Intake manifold bolt nut (M10) 36 ± 6
Exhaust manifold
Engine hanger bolt 22 ± 3
Turbocharger heat protector bolt 23 ± 3
Oxygen sensor 44 ± 5
Exhaust fitting bracket bolt 35 ± 6
Exhaust filling bolt nut 59 ± 5
Air outlet fitting bolt 19 ± 1
Oil return pipe bolt (flange) 14 ± 1
Oil return pipe bolt (washer) 9.0 ± 1.0
Turbocharger assembly and pipe assembly bolt, nut 64 ± 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
Coolant temperature sensor 29 ± 10
Coolant temperature gauge unit 11 ± 1
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 11 ± 1
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

74G6 - TIGHTENING TORQUES
Par tTightening Torque
Oil control pump11 ± 1
Check valve30 ± 3
Eye bolt42 ± 2
Oil pipe11 ± 1
Oil pipe joint30 ± 3
Oil pump / Sump
Drain plug39 ± 5
Sump bolt9.0 ± 3.0
Oil screen bolt19 ± 3
Baffle plate bolt22 ± 4
Oil pressure switch10 ± 2
Oil cooler bypass valve54 ± 5
Relief plug44 ± 5
Oil filter bracket bolt19 ± 3
Plug cap23 ± 3
Flange bolt36 ± 3
Front case bolt23 ± 3
Oil pump cover bolt17 ± 2
Oil pump cover screw10 ± 2
Piston / Connecting rod
Connecting rod cap nut20 ± 2 _ +90° ~94°
Crankshaft / Cylinder block
Flywheel bolt132 ± 5
Rear plate bolt11 ± 1
Bell housing cover bolt (flange)10 ± 2
Bell housing cover bolt (washer)9.0 ± 1.0
Rear oil seal case bolt11 ± 1
Beam bearing cap bolt25 ± 2 _ +90° ~ 100°
Check valve32 ± 2
Turbocharger
Waste gate actuator bolt12 ± 1
Sealants
Par tSpecified Sealant
Cam position sensor support *MZ100191 or equivalent
Note : * indicates point where liquid gasket (FIPG) used

84G6 – ALTERNATOR / IGNITION SYSTEM
Alternator / Ignition System
Removal and Installation
Note :
The ignition coil boot must only be removed from the ignition coil when it is to be replaced.
If removed, always replace with a new part.
Removal sequence
1. Oil level gauge
2. O-ring
3. Oil level gauge guide
4. O-ring
5. Water pump pulley
6. Auto tensioner assembly
7. Alternator bracket8. Alternator
9. Crankshaft pulley
10. Centre cover
11. Spark plug cable
12. Ignition coil
13. Ignition coil boot
14. Spark plug
A
*

94G6 – ALTERNATOR, IGNITION SYSTEM
Removal Service Point
Removal of ignition coil boot
Note :
• If the ignition coil boot is not installed according to the
specifications, then this can lead to various problems, such
as malfunction of the ignition coil, damage to the ignition coil,
leaking of high voltage to external parts, infiltration of water
into the hole, etc.
• The spark plug coupling section of the ignition coil boot is
coated with a white powder. This coating helps to prevent the
boot from welding to the spark plug, and must not be touched
or wiped away.
1. Please check that a spring is fitted inside the new ignition coil
boot.
2. Press the new ignition coil boot firmly onto the ignition coil,
and turn the coupling section 2 or 3 times to seat it correctly
in position, ensuring that there are no gaps.
3. After installation, turn the boot until the air blow hole is
positioned as shown in the diagram.
Coupling
section
Air blow hole
White powder coating on
interior part. Do not touchAir blow hole
Upper faceA

*

104G6 – TIMING BELT
Timing Belt
Removal and Installation
Note :
NEVER disassemble the V.V.T. sprocket.
Removal Sequence
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering pump bracket4. Breather hose
5. PCV hose
6. PCV valve
7. PCV valve gasket
8. Oil filler cap

114G6 – TIMING BELT
9. Connector bracket
10. Rocker cover
11.Rocker cover gasket A
12. Rocker cover gasket B
13. Semi-circular packing
14. Plug cap
15. Timing belt
16. Tensioner pulley
17. Tensioner arm
18. Auto tensioner
19. Idler pulley
20. Crank angle sensor
21. Oil pump sprocket
22. Crankshaft bolt
23. Crankshaft sprocket
24. Crankshaft sensing blade
25. Tensioner B26. Timing belt B
27. Counterbalance shaft sprocket
28. Spacer
29. Crankshaft sprocket B
30. Crankshaft key
31. Engine support bracket
32. V.V.T. sprocket bolt
33. V.V.T. sprocket
34. Camshaft sprocket bolt
35. Camshaft sprocket
36. Timing belt rear right cover
37. Timing belt rear left upper cover
38. Timing belt rear left lower cover
Removal Service Point
Removal of plug cap
Hold hexagonal section of camshaft with wrench, and loosen plug cap.
Removal of V.V.T. sprocket bolt
Hold hexagonal section of camshaft with wrench, and loosen V.V.T.
sprocket bolt.
Installation Service Point
Installation of V.V.T. sprocket bolt / V.V.T.
sprocket
1. Apply the minimum suitable coating of engine oil to the following
points:
• Whole circumference of end of camshaft
• Inserted part of V.V.T. sprocket (full circumference; inner
& outer sides)
• Bolt seating of V.V.T. sprocket bolt
2. Install the V.V.T. sprocket.
V. V. T.
sprocket
boltV.V.T. sprocket
Camshaft

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* B 
B
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* A

124G6 – TIMING BELT
3. Push the V.V.T. sprocket firmly to the end and, holding the
hexagonal part of the camshaft with a wrench, check that the V.V.T.
sprocket does not rotate.
4. Hold the hexagonal section of the camshaft with a wrench and
tighten the V.V.T. sprocket bolt to the specified torque of 65 ±5 N-m.
5. Hold the hexagonal section of the camshaft with a wrench and
check that the V.V.T. sprocket does not rotate.
Note :
This check shows that the V.V.T. sprocket is locked at the maximum
delay angle by the interior pin.
Installation of plug cap
Note :
The washer must not be reused.
1. Install the washer on the plug cap.
2. Hold the hexagonal section of the camshaft with a wrench and
tighten the plug cap to the specified torque of 32±2 N-m.
B
*

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
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A
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