check oil MITSUBISHI LANCER EVOLUTION IX 2005 Owner's Manual

INTAKE & EXHAUST – INLET MANIFOLD
15-7
Removal procedure
24. Knock sensor connector
25. Purge control solenoid valve ASSY
26. Vacuum hose
27. Fuel pressure solenoid valve ASSY
28. PCV hose
•Alternator (Ref Section 16: Alternator)
29. Secondary air control solenoid valve
connector
30. Vacuum tank, ACV solenoid valve,
vacuum hose & pipe ASSY31. Inlet manifold stay
32. Cover
33. Gasket
34. Harness connection
35. Crank angle sensor connector
36. Alternator bracket
37. Inlet manifold
38. Inlet manifold gasket
Removal guidelines
 
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Removal of the delivery pipe, the injector and the fuel
pressure regulator ASSY
Remove the deliver pipe, with the injector and the fuel pressure
regulator intact.
Caution
When removing the delivery pipe, be careful not to drop the
injector.
Fitting guidelines



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Connecting the O-ring and the fuel high pressure hose
1. Apply a small quantity of fresh engine oil to the O-ring, and
insert it into the delivery pipe without damaging the O-ring.
2. Check that the high pressure hose can be turned smoothly. If it
cannot be turned smoothly there is a possibility that it is biting
into the O-ring, so remove the high pressure hose and check for
any damage to the O-ring. If the O-ring is undamaged, reinsert it
into the delivery pipe and check once more whether the hose
can be turned smoothly.
3. Tighten the mounting bolt to the specified torque.
Tightening torque: 5.0 ± 1.0 N·m

FRONT SUSPENSION – STRUT ASSY33-2
pipe
2. Use the following tools to loosen the self-locking nut.
•Wrench (MB991681)
•Socket (MB991682)
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.
Assembly guidelines



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Fitting the self-locking nut
1. Check that the bearing has completely slotted in.
2. When the coil spring has been compressed using the special
tool, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench because there is a danger that
the special tool may be damaged.
3. Align the holes in the lower spring plate and the upper spring
plate of the strut ASSY.
Note
This operation can be easily performed by using a pipe to align
the holes.
4. Line up the two ends of the coil spring with the slots in the
spring plate, and loosen the special tool.
5. Use the following special tools to tighten the self-locking nut to
the specified tightening torque.
•Wrench (MB991681)
•Socket (MB991682)
Tightening torque: 60 ± 10 N·m
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.

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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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

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

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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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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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