tow MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14



O 
Fitting the O-ring/oil feeder control valve
Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Check the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape

ENGINE – TIMING BELT, TIMING BELT B
11-23
 
D


Removing timing belt B
Caution
If planning to re-use a timing belt B, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
Fitting guidelines



A 
Fitting timing belt B and the timing belt B tensioner
1. Check that the timing marks for the crankshaft sprocket and the
balancer shaft sprocket are aligned.
2. Fit timing belt B onto the crankshaft sprocket and the balancer
shaft sprocket. Ensure that the side of the belt under tension is
not slack.
3. As a temporary step, fit the timing belt B tensioner pulley so that
its centre is to the upper left of the centre of the mounting bolt,
and so that the flange of the pulley is facing towards the front of
the engine.
4. Adjust the tension of timing belt B.



B 
Adjusting the tension of timing belt B
1. Hold the timing belt B tensioner between fingertips and in the
direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to
timing belt B until the side of the belt under tension becomes
taught. In this condition, tighten the mounting bolt to the
specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m
Caution
When tightening the mounting bolt, ensure that the
tensioner does not turn round with it. If the tensioner turns
with the mounting bolt, it could cause the tension in the belt
to become too high.
timing marks
balancer shaft
sprocket
crankshaft sprocket
side of belt
under tension
timing
marks
centre of the
pulley
centre of the
mounting bolt

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11.Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the bonnet.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Checking the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.

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




A 

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



A 
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)

ENGINE ELECTRICAL – CHARGING SYSTEM
16-1
SECTION 16
ENGINE ELECTRICAL
CONTENTS
Charging system ........................................1
General .................................................................1
Alternator...............................................................1
Ignition system...........................................4
General .................................................................4
Servicing standards...................................4
On-vehicle servicing ..................................4
Checking, cleaning and replacing spark plugs .....4
Cam position sensor .................................4
Charging system
General
The following alternator servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other
servicing guidelines remain unchanged.
Alternator
Removal and fitting
Jobs to be done before removal and after fitting
• Removal and refitting of the valence
• Checking the tension of the drive belt
• Removal and refitting of the strut tower bar
• Removal and refitting of the front exhaust pipe ASSY
• Adjustment of the accelerator cable

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/C3-8
J/C (cont’d)
•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
•Heater
•Fog lamps•Full auto A/C
•Headlights
•Manual A/C
•Rear washer /
wiper
•Cabin lights,
boot
compartment
lights, ignition
key cylinder
illumination
light, door ajar
indicator light•Ignition key reminder buzzer
•Intercooler water spray
•Security alarm
•Central door locking (vehicle
with keyless entry)
•Cabin lights, boot
compartment lights, ignition
key cylinder illumination light,
door ajar indicator light
•Warning lights
•Starting system
Electric stowable
remote control
door mirror
Headlight
levelling
system
•ABS
•ACD
(vehicle
w/out AYC)
•ACD, AYC•Clock
•Turn signal
lights,
hazard lights
Fog lamps
Headlight
levelling systemFog lamps
Cigarette
lighter
illumination
light•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/C•ACD (vehicle
w/out AYC)
•ACD, AYC
Intercooler
water spray
Turn signal lights,
hazard lightsNeedle meters

CIRCUIT DIAGRAMS - J/C3-9
SRS
airbags,
seatbelt
pre-
tensioners•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC
•Engine
immobiliser
system
•Engine controlDiagnosis
connector
Cabin lights,
boot compartment lights,
ignition key cylinder
illumination light, door
ajar indicator light•Central door locks
(vehicle with keyless
entry)
•Cabin lights, boot
compartment lights,
ignition key cylinder
illumination light, door
ajar indicator light•Warning lights
•Needle meters•Fog lamps
•Spare
connector for
fog lamps Fog lamps
• Spare
connector for
fog lamps
Clock Spare audio
connector
Generic spare
connector Electric stowable
remote control
door mirrors
Generic
fuseGeneric
fuse
J/BJ/B
((
))