MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

244G6 – PISTONS CONNECTING RODS
Inspection
Piston rings
1. Check the clearance between the piston rings and the piston grooves.
If it exceeds the clearance limit value, replace the piston ring, or both
the piston ring and the piston.
Standard values :
No. 1 0.03 – 0.07 mm
No. 2 0.02 – 0.06 mm
Limit value : 0.1 mm
2. Insert the piston ring and the side rail of the oil ring into the cylinder
bore, and press in using the top surface of the piston. After reaching
a right-angle position, measure the opening gaps in the rings using a
thickness gauge.
Remark :
Press the openings of the piston ring and the oil ring side rail with the
piston in the position shown in the diagram, and measure the opening
gaps in this position.
Standard value
No. 1 0.20 – 0.30 mm
No. 2 0.35 – 0.45 mm
Oil ring 0.10 – 0.40 mm
Standard value
No. 1 0.8 mm
No. 2 0.8 mm
Oil ring 1.0 mm
Press with piston
Opening gap
Piston ring

254G6 – CRANKSHAFT / CYLINDER BLOCK
Crankshaft / Cylinder Block
Removal and Installation
Removal Procedure
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
5. Rear oil seal case
6. Rear oil seal
7. Bearing cap bolt
8. Beam being cap9. Crankshaft bearing lower
10. Crankshaft
11.Crankshaft bearing upper
12. Thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block
Apply engine oil to all
sliding parts before
installing. Bolt with washer : 9.0 ± 1.0 N-m
Flange bolt : 10 ± 2 N-m (supplementary part)
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264G6 – CRANKSHAFT / CYLINDER BLOCK
Installation Service Point
Installation of crankshaft bearings
1. Using the table below, select a bearing of the correct size
corresponding to the diameter of the crankshaft journal.
(Selecting a bearing : Example)
If the identifier on the crankshaft journal is 0, and the identifier on the
cylinder block bearing is 1, then a bearing with identification mark 1
should be chosen.
If the identifier on the crankshaft is difficult to make out, measure the
diameter of the journal and choose the bearing that corresponds to the
measured diameter.
Crankshaft journal diameter
Identification mark Journal
diameter (mm)Cylinder
block bearingCrankshaft
bearing
00
11
056.994~57.000
22
00
11
156.988~56.994
22
00
11
256.982~56.988
22
2. Install grooved bearing on cylinder block side.
3. Install bearing without oil groove on bearing cap side.
Position of crankshaft journal diameter identification marks
Timing belt
Cylinder block bearing hole diameter
identification mark
Cylinder
bore size
mark
Position of crankshaft bearing size
identification mark
Identification mark
Groove
Lower bearingUpper bearing
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274G6 – TURBOCHARGER
Turbocharger
Disassembly and Reassembly
Disassembly Procedure
1. Snap pin
2. Waste gate actuator
3. Cap ring
4. Turbine housing
5. Snap ring
6. Cartridge assembly
7. Compressor cover
8. O ring

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Service Manual
Electrical Wiring Diagrams

LANCER
Evolution IX
Foreword
This manual is designed to facilitate inspection and
repair work relating to the electrical wiring system in the
’05 Lancer Evolution IX, and contains layout diagrams
which give a three-dimensional representation of the
electrical wires and connectors of the various parts of
the vehicle, as well as circuit diagrams indicating the
wiring design for different systems, and diagrams
showing the points at which each individual component
is installed.
When inspecting or repairing electrical parts, this
manual should be used in conjunction with the related
documents listed on the following pages, if necessary.
This manual contains various different types of wiring
diagrams and circuit diagrams, but it should be
remembered that these may not always coincide with
the exact specifications of each individual vehicle.
This manual is based on the vehicle specifications as
of March 2005.
Please note that future vehicles may not match the
contents of this manual completely, due to changes
in specifications, or the like.
The units shown in this manual are the standard
international SI units. Conventional units are not
included.
March 2005
Mitsubishi Motor CorporationGeneral ..........................................
Layout Diagrams ..........................
Individual part Installation
Positions .......................................
Circuit Diagrams...........................
Index ..............................................
1
2
3
4
0
This manual is printed on recycled paper.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.
CONTENTS

Related Documentation
Cautionary Note regarding servicing of vehicles fitted with SRS airbags and/or seatbelts
with pre-tensioner systems.
Warnings:
1. Incorrect inspection or servicing of a component part of the SRS airbag system or seatbelt pre-tensioner system,
or a part relating to these systems, may cause accidental operation (deployment) of the SRS airbag or seatbelt
pre-tensioners, or may cause these systems to be disabled, leading in either case the risk of serious injury.
2. If parts may be affected by heat during painting operations, then those parts must be removed in advance. This
applies to the SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors, and pre-tensioner seatbelts.
• 93ºC or above : SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front
impact sensors, side impact sensors
•90ºC or above : Pre-tensioner seatbelts
3. The component parts of the SRS airbag system or seatbelt pre-tensioner system, and parts relating to these
systems, must always be inspected and serviced by a Mitsubishi dealer.
4. Service personnel must read the relevant service manuals (particularly, Section 52B – SRS Airbags) carefully and
thoroughly, before inspecting or servicing the component parts of the SRS airbag system or seatbelt pre-
tensioner system, and parts relating to these systems.

0-1
SECTION 0
General Information
CONTENTS
Vehicle Identification ..............................0-2
Implementation Code .............................0-2How to Read the Wiring Diagrams........0-2
Composition and Contents of Wiring Diagrams..........0-2
How to Read Layout Diagrams...................................0-3
How to Read Circuit Diagrams ...................................0-4
Connector and Earth Markings ...................................0-6
Wire Colour Codes .....................................................0-9
Abbreviation Symbols .................................................0-9

GENERAL INFORMATION - VEHICLE IDENTIFICATION 0-2
VEHICLE IDENTIFICATION
Note : The [
] symbol indicates a new model; the [] symbol indicates an existing model; and the [x] symbol
indicates a discontinued model.
Implementation Code
GH-CT9A ; CT9A-0400001
How to Read the Wiring Diagrams
Composition and Contents of Wiring Diagrams
1. This manual contains wiring layout diagrams, individual part installation positions, circuit diagrams and an index.
2. All specifications, including those relating to optional equipment, are given in each section. Accordingly, some of the
specifications may not apply to a particular vehicle.