cooling MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

LANCER
EVOLUTION IX
FOREWORD
This manual contains details of the main changes to the
2005 model Lancer Evolution IX. Only differences to the
current Lancer Evolution VIII MR are included, so please use
this manual in conjunction with the related manuals as listed
on the following page.
Please read this manual carefully so that servicing can be
done correctly and quickly, and vehicle performance
maintained.
This manual is based on the current (March 2005) model.
Please bear in mind that vehicle specifications may change
and that future models may not be the same.
Please note that all the units shown in this manual follow the
internationally recognized SI unit system, and that the used
previously are not shown alongside the SI units.
(Nevertheless, please take care because units in reference
documents may be shown in the units which were previously
used). March 2005
MITSUBISHI MOTOR CORPORATION

CONTENTS
General ........................................................
Engine .........................................................
Fuel ..............................................................
Engine Cooling ...........................................
Intake and Exhaust ....................................
Engine Electrical ........................................
Rear axle .....................................................
Wheels and tyres ........................................
Front suspension ...............................................Body
Body.......................................................................
Exterior ........................................................
Interior and SRS Airbag .............................N
Chassis Electrical.........................................
This manual is printed on recycled paper
00
11
13
14
15
16
27
31
33
42
51
52
54
Any opinions, requests or questions concerning this manual,
should be written on the ‘Servicing Comments Form’ at the
end of the manual, and sent to us by fax.

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



A 
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)



A 
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
 
A






B 
 
A






B 



A 




A 



A 

ENGINE COOLING – WATER HOSE AND PIPE14-4
Removal guidelines
 
A


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



A 
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

3-1
SECTION 3
CIRCUIT DIAGRAMS
CONTENTS
J/B ............................................................3-4
J/C ............................................................3-6
Central Junction....................................3-11
Power Supply ........................................3-18
Starting System ....................................3-23
Ignition ...................................................3-24
Charging ................................................3-26
Engine Control ......................................3-28
Cooling ..................................................3-36
Lighting
Headlights (excl. discharge type).....................3-38
Headlights (discharge type) .............................3-42
Tail lights, position lights, licence plate
lights, lighting monitor report buzzer................3-46
Cabin lights, boot compartment lights,
ignition key cylinder illumination light,
door ajar indicator light ....................................3-50
Fog lamps ........................................................3-54
Headlight levelling system ...............................3-58
Signals
Turn signal lights, hazard warning lights .........3-60
Reversing lights ...............................................3-64
Stop lights ........................................................3-65
Horn .................................................................3-66
Meters
Needle meters..................................................3-68
Remaining fuel warning light, oil pressure
warning light, brake warning light,
seatbelt warning light .......................................3-70
Door Opening / Closing Control
Power windows ................................................3-72
Central door locking
(vehicle without keyless entry) .........................3-78
Central door locking
(vehicle with keyless entry) ..............................3-80
Temperature Control
Heater ..............................................................3-86
Manual air-conditioning ....................................3-90
Fully automatic air-conditioning .......................3-96
Vision / Safety
Windscreen washer / wipers ..........................3-104
Rear washer / wiper .......................................3-108
Demister
(vehicle with heater or manual A/C) ...............3-110
Demister, door mirror heating elements
(vehicle with full auto A/C)..............................3-112
Electric stowable remote control
door mirrors ....................................................3-114
Accessories
Spare audio connectors .................................3-118
Clock ..............................................................3-120
Cigarette lighter, ashtray illumination lamp ....3-121
Cont. on next page

CIRCUIT DIAGRAMS - J/C3-7
• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer•Fog lamps
•Full auto A/C
•Headlights
•Headlight
levelling
system
•Manual A/C
•Cooling
• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer
• Fog lamps
• Headlights• Ignition key
reminder
buzzer
• Windscreen
washer / wiper
• Sunroof
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer• Power windows
• Fog lamps
• Headlight
• Rear washer /
wiper Generic spare
connector
Vehicle speed
sensor• Windscreen washer /
wiper
• Electric stowable
remote control door
mirrors
• Cabin lights, boot
compartment lights,
ignition key cylinder
illumination light, door
ajar indicator light
Diagnosis
connector• ABS
• ACD
(vehicle
w/out AYC)
• ACD, AYC Needle meters• Heater
• Full auto A/C
• Manual A/C
J/B
Sunroof
Power
windows• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer
• Fog lamps
• Headlights
• Rear washer /
wiperDiagnosis
connectorReversing
lights
Rear washer/
wiper• Reversing lights
• Rear washer /
wiper Generic
fuse
(
)

CIRCUIT DIAGRAMS - J/C3-10
J/C (cont’d)
Diagnosis
connector
Full auto
A/C
•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC•ACD (vehicle
w/out AYC)
•ACD, AYC
•Engine
control
•IgnitionNeedle meter•Engine control
•Needle meter
•Ignition
•Engine control
•Full auto A/C
•Manual A/C
•Cooling
Engine immobiliser system •Engine
immobiliser
system
•Engine control Engine
control
•Engine immobiliser system
•Engine control
•Full auto A/C
•Manual A/C
•Cooling •ACD (vehicle
w/out AYC)
•ACD, AYC
•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC •ACD (vehicle w/out
AYC)
•ACD, AYC
•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC •ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC•Security alarm
•Horn Security alarm
Horn
•Ignition key
reminder
buzzer
•Windscreen
washer /
wiper
•Sunroof
•Security alarm
•Central door
locking•Turn signal
lights, hazard
lights
•Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning
buzzer •Electric
stowable
remote control
door mirrors
•Power
windows
•Fog lamps
•Rear washer /
wiper •Cabin lights,
boot
compartment
lights, ignition
key cylinder
illumination
light, door ajar
indicator light

3-18CIRCUIT DIAGRAMS - POWER DISTRIBUTION
Battery
Fusible
links
Charging
Charging •ACD (vehicle
w/out AYC)
•ACD, AYC•Full auto A/C
•Manual A/C
•Cooling
Dedicated
fuses
•Full auto A/C
•Manual A/C
•CoolingEngine control
•Security alarm
•Central door
locking (keyless
entry)
•Turn signal
lights, hazard
lights•Full auto
A/C
•Manual
A/C
•Cooling•ABS
•ACD
(vehicle
w/out AYC)
•ACD, AYC
•Stop lights•Heater
•Full auto
A/C
•Manual
A/C
POWER DISTRIBUTION

CIRCUIT DIAGRAMS - POWER DISTRIBUTION3-21
•ABS
•ACD (vehicle w/out
AYC)
•ACD, AYC
•Intercooler water spray
•Windscreen washer /
wiper
•Turn signal lights,
hazard lights
•Tail lights, position
lights, licence plate
lights, lighting monitor
warning buzzer
•Heater
•Fog lamps
•Full auto A/C
•Headlights
•Headlight levelling
system
•Manual A/C
•Cooling•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC
•SunroofWindscreen
washer / wiper Cigarette light,
ashtray
illumination lightsElectric stowable
remote control
door mirrors•Rear washer /
wiper
•Cabin lights,
boot
compartment
lights, ignition
key cylinder
illumination
light, door ajar
indicator light •Spare audio
connector
•Clock
•Generic
spare
connector
•Cabin lights,
boot
compartment
lights, ignition
key cylinder
illumination
light, door
ajar indicator
light