MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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

154G6 – SECONDARY AIR SYSTEM / INLET MANIFOLD
Secondary Air System / Inlet Manifold
Removal and Installation
Removal Sequence
1. Exhaust manifold heat protector
2. Air pipe assembly
3. Air control valve gasket
4. Air control valve assembly
5. Engine hanger6. Intake air temperature sensor
7. Boost sensor
8. Inlet manifold stay
9. Inlet manifold
10. Inlet manifold gasket

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164G6 – EXHAUST MANIFOLD
Exhaust Manifold
Removal and Installation
Removal Sequence
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting bracket
5. Exhaust fitting
6. Exhaust fitting gasket
7. Air outlet fitting
8. Air outlet fitting gasket
9. Oil return pipe10. Oil return pipe gasket
11.Oil return pipe gasket
12. Turbocharger assembly & pipe assembly
13. Turbocharger gasket
14. Oil pump
15. Water pipe B
16. Water pipe A
17. Turbocharger assembly
18. Exhaust manifold
19. Exhaust manifold gasket

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174G6 – WATER PUMP / WATER HOSE
Water Pump / Water Hose
Removal and Installation
Removal Sequence
1. Water hose
2. Water hose
3. Water hose
4. Water hose
5. Coolant temperature sensor
6. Coolant temperature gauge unit
7. Water outlet fitting
8. Thermostat9. Thermostat housing
10. Gasket
11.Water inlet pipe
12. O-ring
13. O-ring
14. Water pump
15. Water pump gasket
16. Knock sensor

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184G6 – ROCKER ARM / CAMSHAFT
Rocker Arm / Camshaft
Removal and Installation
Removal Sequence
1. Cam position sensor
2. O ring
3. Cover
4. Gasket
5. Cam position sensing cylinder
6. Cam position sensor support
7. Cam position sensor
8. O ring
9. Cover
10. Gasket
11.Cam position sensing cylinder
12. Cam position sensor support
13. Camshaft oil seal
14. Bearing cap : rear right
15. Bearing cap : rear left
16. Bearing cap : front17. Bearing cap No. 5
18. Bearing cap No. 2
19. Bearing cap No. 3
20. Bearing cap No. 4
21. Camshaft
22. Rocker arm
23. Lash adjuster
24. Oil delivery body
25. Oil control valve (OCV)
26. O ring
27. Check valve
28. Eye bolt
29. Oil pump
30. OCV filter
31. Oil pump joint
32. Gasket
Apply engine oil to all
sliding parts before
installing.
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194G6 – ROCKER ARM / CAMSHAFT
Installation Service Point
Installation of OCV filter
Note :
Before fitting the filter, check that it is clean and is not damaged
or deformed in any way.
Installation of eye bolt
Note :
The oil pump may be damaged if the oil pipe joint turns with the
eye bolt when it is fitted.
Hold the oil pipe joint in place with a spanner, etc., and then tighten
the eye bolt to the specified torque 42 ±2 N-m.
Installation of cam position sensor
support
1. Wipe away all traces of the old liquid gasket left on the cam
position sensor support and the cylinder head.
2. Apply a 3 mm-thick coat of the liquid gasket to the parts of the
cam position sensor support indicated on the diagram.
Liquid Gasket
Product name : MZ100191 or equivalent
Installation of cam position sensing
cylinder
1. Set the camshaft to the top dead centre for No.1.
2. Install the various vanes of the cam position sensing cylinder at
the positions indicated on the diagram.
Installation of cover / gasket
1. Before installing the cover and gasket, put the camshaft to the
No.1 top dead centre position, and check that the vanes of the
respective sensing cylinders are located in the positions shown in
the diagram.
Eye bolt
Hold with
spanner, etc.
Oil pipe joint
Exhaust sideIntake side
Exhaust side
Exhaust sideIntake side
Intake sideVane
Vane
Vane
Vane VaneVane
Vane Vane
Vane
(large) Vane
(large) Vane
(small)
Vane
(small)
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204G6 – ROCKER ARM / CAMSHAFT
2. Ensure that the cutaways in the intake side cover and the tabs on the
gasket are aligned with the positions shown in the diagram, and
tighten at the specified torque of 14 ±1 N-m. The exhaust side cover
and gasket do not have a specified installation direction.
Comment :
The cover and gasket do not have distinct front and rear sides.
No cutawayNo installation direction Exhaust side
Intake side
Ta b Ta b
Cutaway
Cutaway

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214G6 – OIL PUMP / SUMP
Oil Pump / Oil Pan
Removal and Installation
Removal Sequence
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Oil pan
5. Oil screen
6. Oil screen gasket
7. Baffle plate
8. Oil pressure switch
9. Oil cooler bypass valve
10. Relief plug
11.Gasket
12. Relief spring
13. Relief plunger
14. Oil filter bracket
15. Oil filter bracket gasket
16. Plug cap
17. O ring18. Flange bolt
19. Oil pump case
20. Oil pump case gasket
21. Oil pump cover
22. Oil pump driven gear
23. Oil pump drive gear
24. Crankshaft front oil seal
25. Counterbalance shaft oil seal
26. Oil pump oil seal
27. Counterbalance shaft, right
28. Counterbalance shaft, left
29. Counterbalance shaft front bearing
30. Counterbalance shaft rear bearing, right
31. Counterbalance shaft rear bearing, left
Apply engine oil to all
sliding parts before
installing.

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224G6 – PISTONS / CONNECTING RODS
Removal Sequence
1. Connecting rod cap nut
2. Connecting rod cap
3. Connecting rod bearing
4. Piston connecting rod
5. Connecting rod bearing
6. Piston ring No. 17. Piston ring No. 2
8. Oil ring
9. Piston pin
10. Piston
11.Connecting rod
12. Bolt
Piston / Connecting Rod
Removal and Installation
Apply engine oil to all
sliding parts before
installing.

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234G6 - PISTONS / CONNECTING RODS
Installation Service Point
Installation of bearings on connecting rod
1. When replacing a bearing, connecting rod or crankshaft,
choose a bearing of the correct size which corresponds to the
external diameter of the crankshaft pin, in accordance with the
identification marks on the crankshaft pin and the connecting
rod bearing given in the table below.
2. The crankshaft identifier is engraved in the position shown in
the diagram.
3. The bearing identifier is engraved or printed at the position
shown in the diagram.
(Selecting a bearing : Example)
If the crankshaft identification mark is I, then choose a bearing
with the identification mark 0.
If it is difficult to make out the crankshaft identifier, measure the
external diameter of the pin and then choose the bearing that
corresponds to that diameter.
4. The selected bearing should be installed in the larger end of
the connecting rod and the cap.
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Crankshaft pin Connecting rod
bearing
Identification mark External diameter of
pin (mm)Identification mark
I44.995 – 45.005 0
II 44.985 – 44.995 1
III 44.980 – 44.985 2
Position of crankshaft pin diameter identification marks