diagram MITSUBISHI LANCER EVOLUTION IX 2005 Owner's Manual

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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1
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A

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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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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)
A
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B

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C


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D


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E


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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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A


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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.
A
*
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

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

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

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.