engine MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

LANCER

• Chassis

• Engine

• Wiring Diagrams

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.

Related materials

Title No. IssuedateTitle No. Issue
date
New model manuals Body edition service manual
• Lancer Sedia 1036K30 2000/5 • Lancer Sedia 1036K50 2000/5
• Lancer Sedia 1036K31 2000/7 • Lancer Sedia (supplement) 1036K51 2000/7
• Lancer Evolution VII 1036K32 2001/1 • Lancer Evolution VII 1036K52 2001/5
• Lancer Sedia 1036K33 2001/5 (supplement)
• Lancer Sedia 1036K34 2001/5 • Lancer Sedia (supplement) 1036K53 2001/10
• Lancer Evolution VII 1036K35 2002/1 • Lancer Evolution VII _MR 1036K54 2004/2
• Lancer Sedia 1036K36 2002/5 (supplement)
• Lancer Evolution VII 1036K37 2003/1
• Lancer 1036K38 2003/2
• Lancer 1036K39 2003/12 Electrical wiring service manual
• Lancer Evolution VII _MR 1036K40 2004/2 • Lancer Evolution IX 1036K82 2005/3
• Lancer* 1036K41 2004/3
• Lancer 1036K42 2005/1
• Lancer Evolution IX 1036K43 2005/3
Service manuals Engine service manual
• Lancer Sedia 1036K00 2000/5 • 4G6 engine 1039G46 2001/1
• Lancer Sedia
(supplement) 1036K01 2000/7 • 4G6 engine (supplement) 1039G63 2003/1
• Lancer Evolution VII 1036K02 2001/1 • 4G6 engine (supplement) 1039G71 2003/3
(supplement)
• Lancer Sedia
(supplement) 1036K03 2001/5
• Lancer Sedia
(supplement) 1036K04 2001/10
• Lancer Evolution VII 1036K05 2002/1 Transmission service manuals
(supplement) • W5M51 manual transmission 1039M17 2001/1
• Lancer Sedia
(supplement) 1036K06 2002/5 • W5M51 manual transmission 1039M22 2003/1
• Lancer Evolution VII 1036K07 2003/1 (supplement)
(supplement) • WGMAA manual transmission 1039M23 2003/1
• Lancer Sedia
(supplement) 1036K08 2003/2
• Lancer Sedia
(supplement) 1036K09 2003/12
• Lancer Evolution VII MR 1036K10 2004/2
• Lancer* 1036K41 2004/3
• Lancer 1036K11 2005/1
*Indicates where the new model manual was published with the service man\
ual in a single volume.
W
ARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
W arning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fi\
tted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitt\
ed seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensio\
ner fitted seatbelts and the clock spring, should be removed if there is a chance o\
f them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be rem\
oved.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-\
SRS air bags) has been carefully studied.

ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS
11 - 1
SECTION 11
ENGINE
CONTENTS
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
Servicing standards
General .......................................................1
Servicing standards .................................1
Sealants .....................................................1
Special tools ..............................................2
Engine tuning .............................................4
1. Checking of revolutions when idling ................4
2. Checking compression pressure.......................4
Camshaft, valve stem seals .....................4
Cylinder head gaskets.............................14
Timing belt, timing belt B ........................20
Engine ASSY ............................................28





Sealants

Note
The code inside the brackets ( ) is the actual product number.

ENGINE – SPECIAL TOOLS11 - 2
Special tools
ToolNumber NameFunction
MB991502MUT-II Sub
ASSYChecking and adjusting the tension in
timing belt B
Note
If a MUT-III main harness A is
connected to a vehicle not fitted with
CAN, there is a chance that a pulse
signal will be entered in the simulated
vehicle speed line, when the MUT-III is
activated. Therefore, use a MUT-III main
harness B with vehicles not fitted with
CAN.
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826MUT-III Sub ASSY
A: Vehicle
Communication
Interface (VCI)
B: USB cable
C: MUT-III Main
harness A
(For vehicles
fitted with CAN)
D: MUT-III Main
harness B
(For vehicles
not fitted with
CAN)
E: Adaptor
F: Trigger harness
MB991668
A: MB991969
B: MB991670Belt tension meter
set
A: Tension meter
cartridge
B: Mic ASSY• Checking the tension in the drive belt.
(Use in conjunction with VCI)
• Checking the tension in the balancer
timing belt.
Adjusting (Use in conjunction with VCI)
MD998772Valve spring
compressorCompression of the valve spring.
DO NOT USE

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL11 - 4
Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting
Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools
because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it
should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
ToolNumberNameFunction
MB991454Engine hanger
balancerHolding the engine assembly while the
transmission assembly is removed/installed
Recommended
tools MZ203830
panzai or
MZ203831 safe
vehicle handlingMechanical engine
hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934Engine hanger
A: joint (50) x2
B: joint (90) x2
C: joint (140) x2
D: Foot (standard) x4
E: Foot (short) x4
F: Chain and hook
ASSYSlide bracket (HI)

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 5



O 



O 
Removal procedure
1. Oil feeder control valve connector
2. Oil feeder control valve
3. O-ring
4. Breather hose
• Secondary air control valve
(refer to Section 15-2: Secondary Air
Control System)
5. Centre cover
• Ignition coil
6. O
2sensor connector
7. Crank angle sensor connector8. Connection of the control harness
9. Vacuum hose
10. PCV hose
11.Connection of the radiator upper hose
12. Camshaft position sensor connector
(exhaust side)
13. Camshaft position sensor connector
(inlet side)
14. Connection of the earth cable
15. Rocker cover ASSY
16. Spark plug hole gasket
17. Rocker cover gasket
 
A






N 



M 

ENGINE – CAMSHAFT, VALVE STEM SEAL11 - 6
18. Camshaft position sensor support cover
19. Camshaft position sensor support cover
gasket
20. Camshaft position sensing cylinder
(exhaust side)
21. Camshaft position sensor support
22. Camshaft position sensor support cover
23. Camshaft position sensor support cover
gasket
24. Camshaft position sensing cylinder (inlet
side)
25. Camshaft position sensor support
26. Camshaft sprocket (exhaust side)
27. Camshaft oil seal
28. Camshaft bearing cap front
29. Camshaft bearing cap rear left30. Camshaft bearing cap No. 2
31. Camshaft bearing cap No. 5
32. Camshaft bearing cap No. 3
33. Camshaft bearing cap No. 4
34. Exhaust camshaft
35. Camshaft sprocket cap
36. Washer
37. Camshaft sprocket (inlet side)
38. Camshaft oil seal
39. Camshaft bearing cap front
40. Camshaft bearing cap rear right
41. Camshaft bearing cap No. 2
42. Camshaft bearing cap No. 5
43. Camshaft bearing cap No. 3
44. Camshaft bearing cap No. 4
45. Inlet camshaft
During assembly, apply
engine oil to all sliding
parts.



F 



F 



F 



F 



E 
 
B






H 



G 



F 



F 



F 



F 



F 



F 



E 




L 



J 



K 



J 
 
B






I 



G 



F 



F 

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 7
46. Rocker arm
47. Rush adjuster
48. Oil delivery body
49. Spark plug
50. Valve spring retainer lock51. Valve spring retainer
52. Valve spring
53. Inlet valve stem seal
54. Exhaust valve stem seal



D 
 
C






C 



B 



A 



A