oil MITSUBISHI LANCER EVOLUTION IX 2005 Repair Manual

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
*
B

*
C


*
D


*
E


*

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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* 1
*

* 1
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* 1
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* 1
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* 1
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* * 1

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* * 1

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.

* 1
*

* 1
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* 1
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* 1
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* 1
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* 2
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* 1
*

* * 1


* * 1 A
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A
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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)
A
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A
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*1
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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
A
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LAYOUT DIAGRAMS - ENGINE / TRANSMISSION1-6
B-01 (1-black) Engine oil pressure switch
B-02 Alternator
B-03 (4-grey) Alternator
B-04 Starter
B-05 (1-black) Starter
B-06 (4-black) Throttle position sensorB-07 (2-black) Purge control solenoid valve
B-08 (7-black) Airflow sensor
B-12 (5-grey) Windscreen wiper motor
B-13X Engine speed detection connector
B-14X Starter relay
B-17X Ignition coil relay
ENGINE / TRANSMISSION
Connector Symbol
Control harnessGround cable
Battery
harness

LAYOUT DIAGRAMS - ENGINE / TRANSMISSION1-8
B-106 (2-grey) Knock sensor
B-108 (2-black) Coolant temperature sensor
B-109 (34-black) ABS-ECU
B-114 (1-black) Water temperature gauge unit
B-115 (3-black) Exhaust cam position sensorB-119 (3-grey) Ignition coil 2
B-122 (3-black) Crank angle sensor
B-123 (3-grey) Ignition coil 1
B-124 (2-black) Fuel pressure solenoid valve
Engine / Transmission (continued)
Connector Symbol
Control harness
Battery harness

LAYOUT DIAGRAMS - ENGINE / TRANSMISSION1-9
B-126 (6-black) Idle speed control servo
B-127 (4) Electric pump relay
B-128 (4) Fuel pump relay 3
B-129 (6-black) Register (for injector)
B-130 (2-black) Fuel pump register
B-131 (3-black) Vehicle speed sensorB-132 (2-black) Back-up lamp switch
B-133 (2-black) Secondary air control solenoid valve
B-134 (2-black) Oil feeder control valve
B-135 (3-black) Manifold absolute pressure sensor
Ground cable
Transmission harness

PART INSTALLATION POSITIONS - RELAY2-9
RELAYS
Fuel pump relay 3
Electric pump relay
Hydraulic unit
A/C compressor relay
Engine control relay
Ignition coil relay
Starter relayCompressor fan relay (HI)
Compressor fan relay (LO)
Horn relay
Fog lamp relay
Radiator fan control relay
M3020000400514