ESP MITSUBISHI LANCER EVOLUTION IX 2005 Workshop 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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44G6 – GENERAL INFORMATION/ SERVICING SPECIFICATIONS
General Information
The 4G63 MIVEC T/C engine fitted in the Lancer Evolution IX incorporates the following changes with respect to the previous
4G63 T/C engine.
• Adoption of variable valve timing control system
• Modification to clearance gap in piston No.2 ring coupling
• Addition of air intake temperature sensor
• Addition of boost sensor
Vehicle Model List
Specifications
Servicing Specification Values
Name Vehicle model Engine type Exhaust capacity cc Specifications
Lancer Evolution IX CT9A 4G63-7 1,997 DOHC 16-valve
MIVEC – T/C
Item Specification
Bore x stroke 85 x 88
Total displacement cc 1,997
Combustion chamber shape Pentroof type
No. of cylinders 4
Valve mechanism Type DOHC
Intake valves 8
Exhaust valves 8
Lash adjuster Hydraulic
Rocker arm Roller follower type
Compression ratio 8.8
Fuel injection device Electronically controlled MPI
Ignition device Electronically controlled two-coil type
Alternator AC type (with IC regulator)
Starter motor Deceleration drive
g
Item Standard value Limit value
Cylinder head, valves
Valve spring : free height mm 50.4 49.4
Valve spring : perpendicularity 2º or less 4º
Pistons, connecting rods
No.1 0.03~0.07 0.1Piston rings : Clearance between ring and ring
groove mm
No.2 0.02~0.06 0.1
No.1 0.20~0.30 0.8Piston rings : Closed gap mm
No.2 0.30~0.45 0.8
Oil ring 0.10~0.40 1.0

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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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
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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

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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GENERAL INFORMATION - HOW TO READ THE WIRING DIAGRAMS0-5
Indicates input / output to
and from control unit
(direction of current flow).
Input Output Input/Output
Indicates a wiring connector inside a device,
which is not shown in the layout diagrams.
Example :
Indicates a connector
located inside a
device, numbered in
order starting from 1.
Indicates the number of the connector
shown in the layout diagram.
Indicates that these are the same
intermediate connector.
Indicates that the diagram
continues from section [A] in
block [1].
Indicates the terminal No.
If two or more connectors are
connected to the same device, a
broken line between parts indicates
that the same connector is used.
The two-way arrow shows that
current can flow downwards or
upwards, under the control of
the ECU.
Indicates a harness junction point
where the wire changes colour or
diameter.
Indicates an intersection
where the wires are not
connected.
Indicates an intersection
where the wires are
connected
Indicates the representative earth
point on the vehicle body for that
circuit. (This number matches that of
the earth point in the layout diagrams
and the diagrams of individual part
installation positions.)
Indicates a spare connector, if the
corresponding device is not
installed, due to the vehicle
specifications.Indicates the connector part number given in
the harness repair manual. A number in
( ) indicates the part number of the connector
that corresponds to a connector symbol.
Ignition
switch (IG1)
Solenoid
valve 1
Solenoid
valve
2
Solenoid
valve
ASSY
Sensor
MotorRegister

CIRCUIT DIAGRAMS - J/B3-4
J/B
Power
window
relay
Water
spray
relay
Dummy
connectorDummy connector
J/B side connector Note :
The connector numbers correspond to the layout diagrams,
and to the instrument panel and respective circuit diagrams. Demister
relayBlower
relayFuel
pump
relay 2
Fuel
pump
relay 1 Generic fuse

CIRCUIT DIAGRAMS - J/C3-6
J/C
Note :
In the actual vehicle, any of the terminals connected inside the J/C
may be used. Therefore the terminal numbers indicated on the circuit
diagrams may not correspond to the terminal sequence in the vehicle.
• Windscreen
washer/wiper
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning
buzzer•Fog lamps
•Headlights
•Headlight
levelling
system
•Rear washer /
wiper
Full auto A/C
Generic spare
connector
Generic spare
connectorFog lamps
Spare audio
connector
• Demister (vehicle w/out
full auto A/C)
• Demister, door mirror
heating elements (vehicle
with full auto A/C)
• Heater
• Full auto A/C
• Manual A/CCigarette
lighter, ashtray,
illumination
light
Clock• ACD (vehicle
w/out AYC)
• ACD, AYC
Head-light
levelling systemTurn signal
lights, hazard
lights
Inter-cooler
water spray• ACD (vehicle w/out AYC)
• ACD, AYC
• Intercooler water spray
• Clock
• Cigarette lighter, ashtray
illumination lights
• Needle meters
• Turn signal lights, hazard
lights
• Demister (vehicle w/out full
auto A/C)
• Demister, door mirror heating
elements (vehicle with full
auto A/C)
• Tail lights, position lights,
licence plate lights, lighting
monitor warning buzzer
• Generic spare connector
• Fog lamps
• Full auto A/C Clock
Spare audio
connector• ACD (vehicle
w/out AYC)
• ACD, AYC
• Engine control
• Warning lights
• Needle metersGeneric
fuse
J/B
(
)
Generic
fuse