MITSUBISHI LANCER EVOLUTION IX 2005 Manual PDF

ENGINE COOLING – GENERAL
14-1
SECTION 14
ENGINE COOLING
CONTENTS
General........................................................1
Water pump ................................................2Water hose and pipe ..................................3
General
The following servicing guidelines for the water pump and the water hose and pipe have been prepared for vehicles which use
the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.

ENGINE COOLING – WATER PUMP14-2
Water pump
Removal and fitting
Jobs to be completed before removal and after fitting
•Draining and refilling of the coolant
•Removal and refitting of the timing belt (Ref Section 11)
Removal procedure
1. Alternator bracket
2. Water pump
3. Water pump gasket
4. O-ring
Fitting guidelines



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Fitting the O-ring
Fit the O-ring into the O-ring groove at the end of the water inlet
pipe, and insert it into the water pump after moistening with water
the places where the O-ring will make contact with the water pump.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.
Positions for fitting different sized bolts
Nominal diameter and nominal length (mm)



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water pump
O-ring
water inlet pipe

ENGINE COOLING – WATER HOSE AND PIPE
14-3
Water hose and pipe
Removal and fitting
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence
•Draining and refilling of the water coolant
•Removal and refitting of the air cleaner ASSY
•Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C
•Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system)
Removal procedure
1. Connection to the radiator upper hose
2. Connection to the radiator lower hose
3. Water temperature gauge unit connector
4. Water temperature sensor connector
5. Water hose
6. Bracket
7. Water outlet fitting and thermostat case
ASSY
8. Thermostat case gasket
9. Connection to the knock sensor harness
clamp
10. O-ring
11. Water hose12. Water hose
13. Connection to the heater hose
14. Water hose
15. Water inlet pipe
16. O-ring
17. Turbocharger water feed pipe
18. Gasket
•Turbocharger ASSY
19. Turbocharger water return pipe
20. Gasket
 
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ENGINE COOLING – WATER HOSE AND PIPE14-4
Removal guidelines
 
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Removing the radiator upper hose and the radiator
lower hose
Mark the radiator hose and the hose clamp with indicator marks
and then remove the radiator hose.
Fitting guidelines



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Fitting the O-ring and the water inlet pipe
Fit the O-ring into the groove at the end of the water inlet pipe, and
insert it after moistening with water the places where the O-ring and
the water inlet pipe will be in contact.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.



B 
Connecting the radiator lower hose and the radiator
upper hose
1. Insert the hose as far as the protrusion on the water inlet pipe
and the water outlet fitting.
2. Match up the indicator marks on the radiator hose and the hose
clamp, and fit the radiator hose.
indicator marks
water pump and
thermostat case
O-ring
water inlet pipe
protrusion
water inlet pipe and
water outlet pipe fittingindicator marks

INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS,
ON-VEHICLE SERVICING15-1
SECTION 15
INTAKE & EXHAUST
CONTENTS
General................................................................................1
Servicing standards ..........................................................1
Special tools.......................................................................1
On-vehicle servicing..........................................................1
Turbocharger super charging pressure check ...............1Inter-cooler water spray ....................................................2
Secondary air control system ..........................................4
Inlet manifold .....................................................................5
Exhaust manifold and turbocharger ................................8
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
• Changes to the turbocharger supercharging pressure
• Changes to the inter-cooler water spray hose
• Changes to the secondary air control valve
• Changes to the inlet manifold
• Changes to the exhaust manifold and the turbocharger
Special tools
On-vehicle servicing
Turbocharger supercharging pressure check
The standard value for the turbocharger charging pressure has
been changed. Other servicing guidelines remain unchanged.
Standard value: 97 ~ 157 kPa
ItemStandard value
Turbocharger charging pressure kPa97~157
Servicing standards
ToolNumberNameFunction
MD998770O
2sensor wrenchRemoval and fitting of the O
2
sensor

INTAKE & EXHAUST INTER-COOLER WATER SPRAY15-2
Inter-cooler water spray
Removal and fitting

Procedure for removing the water spray nozzle
and the hose
1. Water spray hose connection
• Front bumper ASSY (Ref: Section 51)
• Tape (for fitting the water spray hose ASSY)
2. Water spray nozzle ASSY
3. Water spray hose ASSY
4. Clamp
5. Water spray nozzle (top)
6. Water spray nozzle bracket
7. Water spray nozzle (bottom)
8. Water spray hose
9. Three-way joint10. Washer valve
•Tape (for attaching clip)
11. Clip
12. Pad
Procedure for removing the washer tank
1. Water spray hose connection
13. Water spray motor connector
14. Washer tank
15. Water spray hose
16. Washer valve
17. Water spray motor
18. Packing
19. Bracket



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INTAKE & EXHAUST INTER-COOLER WATER SPRAY
15-3
Fitting guidelines



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Fitting the water spray hose ASSY and fixing tape (for securing the water spray hose ASSY)
1. After fitting the water spray hose, the three-way joint and the washer valve, affix pads, clips and tape at the positions
shown in the water spray hose diagram.
2. Fit the water spray hose ASSY to the front bumper using the water spray hose ASSY clip.
3. Affix tape as shown in the diagram, so that the water spray hose ASSY does not slip.
View of the inside of the front bumper
tape
three-way joint
pads
tape
washer
valve
clip
tapeclip
three-way joint
padclip
washer valve
tape
clip
tape
clipclip
water spray hose ASSY
water spray
nozzle brackets
tape

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM15-4
Secondary air control system
Removal and fitting
Jobs to be completed before removal and after fitting
• Removal and refitting of the air duct
• Removal and refitting of the strut tower bar
Removal procedure
1. Control harness connection
2. Heat protector
3. Vacuum hose connection
• Air pipe C
4. Vacuum pipe
5. Harness bracket6. Air hose
7. Air pipe ASSY
8. Gasket
9. Gasket
10. Secondary air control valve
11.Harness bracket
air pipe C




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INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD15-5
Fitting guidelines



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Fitting the gasket
Fit the gasket so that the protruding part points in the direction
shown in the diagram.
Inlet manifold
Removal and fitting
Jobs to be completed before removal and
after fitting
•Take measures to prevent fuel leaking (only
before removal)
•Removal and refitting of the valence (Ref
Section 15: Front bumper)
•Draining and refilling the coolant
•Removal and refitting of the air duct•Removal and refitting of the strut tower bar
•Removal and refitting of the throttle body
•Removal and refitting of the secondary air
control valve (Ref P15-4)
•Removal and refitting of the cross member bar
•Removal and refitting of the front exhaust pipe
protruding
part
(engine oil)
(engine oil)

INTAKE & EXHAUST – INLET MANIFOLD15-6
Removal procedure
1. Centre cover
2. Ignition coil connector
3. O
2sensor connector
4. Oil feeder control valve connector
5. Crank angle sensor connector
6. Injector connector
7. Air temperature sensor connector
8. Manifold absolute pressure sensor
connector
9. Purge control solenoid valve connector
10. Knock sensor connector
11.Fuel pressure solenoid valve connector12. Vacuum hose connection
13. Vacuum hose connection
14. Fuel return hose connection
15. Fuel high pressure hose connection
16. O-ring
17. Delivery pipe, injector and fuel pressure
regulator ASSY
18. Insulator
19. Insulator
20. Oil level gauge & guide ASSY
21. O-ring
22. Brake booster vacuum hose connection
23. Purge hose connection



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