Mitsubishi Lancer Evolution VIII MR Technical Information

LANCER Evolution - IX • Chassis • Engine • Wiring Diagrams • Technical Information Workshop Manual - Supplement

ENGINE – CAMSHAFT, VALVE STEM SEAL11-5OORemoval procedure1. Oil feeder control valve connector2. Oil feeder control valve3. O-ring4. Breathe

CHASSIS ELECTRICAL – LICENCE PLATE LAMPSRS AIRBAG – GENERAL54A-152B-1SECTION 52BSRS AIRBAGCONTENTSGeneral...

CHASSIS ELECTRICAL – LICENCE PLATE LAMPSRS AIRBAG – GENERAL54A-152B-1SECTION 52BSRS AIRBAGCONTENTSGeneral...

Service ManualSupplementLancer Evolution IX

Service Manual4G6FOREWORDThis manual contains information about the 4G6DOHC engine. It only covers those points that aredifferent from the service man

2HOW TO USE THIS MANUALHow to Use this ManualRange of descriptionThis manual explains the service procedure for the engine after it has been removed f

3HOW TO USE THIS MANUALPage number Engine type Title

44G6 – GENERAL INFORMATION/ SERVICING SPECIFICATIONSGeneral InformationThe 4G63 MIVEC T/C engine fitted in the Lancer Evolution IX incorporates the fo

54G6 – TIGHTENING TORQUESTightening TorquesPartTightening Torque NmAlternator, ignition systemOil level gauge guide bolt13 ± 1Water pump pulley bolt8.

64G6 – TIGHTENING TORQUEPart Tightening TorqueAir pipe assembly bolt (eye bolt) 49 ± 5Air pipe assembly bolt (M6 flange) 11 ± 1Air pipe assembly bolt

74G6 - TIGHTENING TORQUESPartTightening TorqueOil control pump11 ± 1Check valve30 ± 3Eye bolt42 ± 2Oil pipe11 ± 1Oil pipe joint30 ± 3Oil pump / SumpDr

ENGINE – CAMSHAFT, VALVE STEM SEAL11-618. Camshaft position sensor support cover19. Camshaft position sensor support cover gasket20. Camshaft position

84G6 – ALTERNATOR / IGNITION SYSTEMAlternator / Ignition SystemRemoval and InstallationNote :The ignition coil boot must only be removed from the igni

94G6 – ALTERNATOR, IGNITION SYSTEMRemoval Service PointRemoval of ignition coil bootNote :• If the ignition coil boot is not installed according to th

104G6 – TIMING BELTTiming BeltRemoval and InstallationNote :NEVER disassemble the V.V.T. sprocket.Removal Sequence1. Timing belt front upper cover2.

114G6 – TIMING BELT9. Connector bracket10. Rocker cover11. Rocker cover gasket A12. Rocker cover gasket B13. Semi-circular packing14. Plug cap15. Timi

124G6 – TIMING BELT3. Push the V.V.T. sprocket firmly to the end and, holding thehexagonal part of the camshaft with a wrench, check that the V.V.T.s

134G6 – FUEL SYSTEMFuel SystemRemoval and InstallationRemoval Sequence1. Throttle body assembly2. Throttle body gasket3. Cover4. Gasket5. Fuel hose6

144G6 – FUEL SYSTEMInstallation Service PointInstallation of coverThe side of the cover marked “gasket side” should be assembledfacing the inlet manif

154G6 – SECONDARY AIR SYSTEM / INLET MANIFOLDSecondary Air System / Inlet ManifoldRemoval and InstallationRemoval Sequence1. Exhaust manifold heat pr

164G6 – EXHAUST MANIFOLDExhaust ManifoldRemoval and InstallationRemoval Sequence1. Engine hanger2. Turbocharger heat protector3. Oxygen sensor4. Exh

174G6 – WATER PUMP / WATER HOSE Water Pump / Water HoseRemoval and InstallationRemoval Sequence1. Water hose2. Water hose3. Water hose4. Water hose5.

ENGINE – CAMSHAFT, VALVE STEM SEAL11-746. Rocker arm47. Rush adjuster48. Oil delivery body49. Spark plug50. Valve spring retainer lock51. Valve spring

184G6 – ROCKER ARM / CAMSHAFTRocker Arm / CamshaftRemoval and InstallationRemoval Sequence1. Cam position sensor2. O ring3. Cover4. Gasket5. Cam pos

194G6 – ROCKER ARM / CAMSHAFTInstallation Service PointInstallation of OCV filterNote :Before fitting the filter, check that it is clean and is not da

204G6 – ROCKER ARM / CAMSHAFT2. Ensure that the cutaways in the intake side cover and the tabs on the gasket are aligned with the positions shown in

214G6 – OIL PUMP / SUMPOil Pump / Oil Pan Removal and InstallationRemoval Sequence1. Drain plug2. Drain plug gasket3. Oil filter4. Oil pan5. Oil scre

224G6 – PISTONS / CONNECTING RODSRemoval Sequence1. Connecting rod cap nut2. Connecting rod cap3. Connecting rod bearing4. Piston connecting rod5.

234G6 - PISTONS / CONNECTING RODSInstallation Service PointInstallation of bearings on connecting rod1. When replacing a bearing, connecting rod or

244G6 – PISTONS CONNECTING RODSInspectionPiston rings1. Check the clearance between the piston rings and the piston grooves.If it exceeds the clearan

254G6 – CRANKSHAFT / CYLINDER BLOCKCrankshaft / Cylinder BlockRemoval and InstallationRemoval Procedure1. Flywheel bolt2. Flywheel3. Rear plate4. Bel

264G6 – CRANKSHAFT / CYLINDER BLOCKInstallation Service PointInstallation of crankshaft bearings1. Using the table below, select a bearing of the cor

274G6 – TURBOCHARGERTurbochargerDisassembly and ReassemblyDisassembly Procedure1. Snap pin2. Waste gate actuator3. Cap ring4. Turbine housing5. Snap

ENGINE – CAMSHAFT, VALVE STEM SEAL11A-8Locations for the application of lubricant and seals<View from A>Semi-dry sealant:Three bond 1207D(around

ENGINE – CAMSHAFT, VALVE STEM SEAL11-9Removal guidelinesADetaching the radiator upper hoseAlign the indicator marks on the radiator upper hose and

ENGINE – CAMSHAFT, VALVE STEM SEAL11-10BFitting the valve springFit the valve spring so that the end of the valve spring which hasthe smaller radi

ENGINE – CAMSHAFT, VALVE STEM SEAL11-112. Because camshaft bearing caps Nos. 2~5 are the same shape,check the identification marks on them so that the

ENGINE – CAMSHAFT, VALVE STEM SEAL11-12HFitting the camshaft sprocket (inlet side)1. Apply engine oil to the edges of the camshaft, and to the par

ENGINE – CAMSHAFT, VALVE STEM SEAL11-13KFitting the camshaft position sensing cylinder (inletside)1. Set the inlet camshaft dowel pin in the posit

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14OFitting the O-ring/oil feeder control valveCaution1. Do not re-use O-rings.2. When f

SERVICE MANUALSupplement

ENGINE – CYLINDER HEAD GASKET11-15Removal procedure1. Ignition coil connector2. O2sensor connector3. Oil feeder control valve connector4. Crank angle

ENGINE – CYLINDER HEAD GASKET11-1622. Alternator bracket connection23. Inlet manifold stay24. Eye bolt25. Gasket26. Eye bolt 27. Gasket28. Oil feeder

ENGINE – CYLINDER HEAD GASKET11-17Removal guidelinesARemoving the cylinder head boltsUse the special wrench for cylinder head bolts (MB991654) to

ENGINE – CYLINDER HEAD GASKET11-183. Use the special wrench for cylinder head bolts (MB991654) to(loosely) tighten the bolts in the following order.(1

ENGINE – CYLINDER HEAD GASKET11-19DFitting the oil return pipe gasketReplace the gasket with a new one, and fit it to the protruded partshown in t

ENGINE – TIMING BELT, TIMING BELT B11-20TIMING BELT, TIMING BELT BRemoval and fittingCautionIf Brembo brake callipers are being used take care that th

ENGINE – TIMING BELT, TIMING BELT B11-2110. Power steering oil pressure switch connector11. Heat protector12. Power steering oil pump ASSY13. Power st

ENGINE – TIMING BELT, TIMING BELT B11-223. Twist the special tool for adjusting bolts (MD998738) by handuntil it touches the tensioner arm.CautionThe

ENGINE – TIMING BELT, TIMING BELT B11-23DRemoving timing belt BCautionIf planning to re-use a timing belt B, ensure that it will berefitted the sa

ENGINE – TIMING BELT, TIMING BELT B11-242. <Measuring the amount of give>(1) As shown in the diagram, apply a force of about 100N to themiddle o

LANCER EVOLUTION IXFOREWORDThis manual contains details of the main changes to the2005 model Lancer Evolution IX. Only differences to thecurrent Lanc

ENGINE – TIMING BELT, TIMING BELT B11-25CFitting the crankshaft sensing blade and the crankshaft sprocket1. Clean, and remove any grease from the

ENGINE – TIMING BELT, TIMING BELT B11-26FFitting the timing belt1. Check that all the timing marks for the camshaft sprocket, thecrankshaft sprock

ENGINE – TIMING BELT, TIMING BELT B11-27(3) Use a wrench to align the timing marks on the rocker cover andthe camshaft sprocket, and whilst doing so,

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-285. Using the special wrench for the tensioner pulley socket(MD998767) or a torque wrench, apply t

ENGINE – ENGINE ASSY11-29Removal procedure1. Ignition coil connector2. O2sensor connector3. Oil feeder control valve connector4. Crank angle sensor co

ENGINE – ENGINE ASSY11-30CautionParts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine isbeing

ENGINE – ENGINE ASSY11-31Removal guidelinesARemoving the drive beltThe following operations are necessary because the engine uses a serpentine dri

ENGINE – ENGINE ASSY11-32DRemoving the engine mount bracket & stopper ASSY1. Support the engine using a garage jack.2. Remove the special mech

ENGINE – ENGINE ASSY11-33BFitting the engine mount bracket & stopper ASSY1. Support the engine oil pan component with the garage jackthrough t

ENGINE – ENGINE ASSY11-34DFitting the O-ring and the fuel high pressure hose1. Apply a little fresh engine oil to the O-ring.CautionEnsure that no

Related materialsTitle No. IssuedateTitle No. IssuedateNew model manuals Body edition service manual• Lancer Sedia 1036K30 2000/5 • Lancer Sedia 1036K

MPI – GENERAL13A-1SECTION 13AMPI (Multi-point Fuel Injection)CONTENTSGeneral... 2Ser

MPI – GENERAL13A-2MPI system diagramEngine ECUH 1. O2 sensorH 2. Air flow sensorH 3. Intake air temp. sensorH 4. Throttle positionsensorH 5. Intake Ca

MPI – SERVICING STANDARDS, SPECIAL TOOLS13A-3Servicing standardsSpecial toolsItem Standard levelRevolutions when idling r/min 800 ± 50Air temperature

MPI- SPECIAL TOOLS13A-4Tool Number Name FunctionMB991348 Test harness Inspection using an oscilloscopeMB991709 Test harness • Troubleshooting voltag

MPI – TROUBLESHOOTING13A-5TROUBLESHOOTING1. Diagnosis Functions1-1 Engine warning light (Check engine lamp)Changes have been made to engine warning li

MPI- TROUBLESHOOTING13A-6Code No. Diagnosis item PageP0105 MAP sensor 13A-7P0340 Exhaust cam position sensor system 13A-9P1012 Intake cam position sen

13A-7MPI – TROUBLESHOOTING3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODEMUT-II/III service data• No.95 atmospheric pressuresensor(Ref: P13A-24)Go on

13A-8MPI – TROUBLESHOOTING Continued from the previous pageMeasurements taken at the B-135MAP sensor connector• Connect the test harness(MB991348) to

13A-9MPI – TROUBLESHOOTINGCheck connector B-115To next pageCheck connector B-19XMeasurements taken at engineECU connector C-50• Measurement of voltag

13A-10MPI – TROUBLESHOOTINGContinued from the previous pageReplace the engine ECUCheck connector B-19XInspect the harness between theexhaust cam posit

GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP, RELEVANT VEHICLE NUMBERS00-1SECTION 00GENERALCONTENTSInspection guidelines andtroubleshooting

13A-11MPI – TROUBLESHOOTINGCheck connector B-33To next pageCheck connectors B-19X & C-23Inspect the harness between theintake cam position sensor

13A-12MPI – TROUBLESHOOTINGContinued from the previous pageCheck connectors B-19X & C-23Check the intake cam positionsensing cylinderCheck that th

13A-13MPI – TROUBLESHOOTINGReplace the engine ECUCheck connectors B-19X & C-23Check connector B-134Check connectors B-19 & C-23Check connector

13A-14MPI – TROUBLESHOOTINGMUT-II/III Service data• No.25: atmospheric sensor(Ref: P13A-83) *Temporary malfunction (RefSection 00: Dealing withtempora

13A-15MPI – TROUBLESHOOTINGContinued from previous pageMeasurements taken at B-08 AFSconnector• Only connect the test harness(MB991709) to terminalsNo

13A-16MPI – TROUBLESHOOTINGCheck the purge control solenoid valve (Refer to Section17: Checking the exhaust gas purification system)MUT-II/III Service

13A-17MPI – TROUBLESHOOTING*: Refer to the 01-1 Service Manual for the Lancer Evolution VIII (No.1036K02)*: Refer to the 03-1 Service Manual for the L

13A-18MPI – TROUBLESHOOTINGMeasure the output wave fromthe crank angle sensor and thecam position sensor (using anoscilloscope).• Engine: idling<Cr

13A-19MPI – TROUBLESHOOTINGCheck the operation of the inter-cooler water spray• Ignition switch: ON• Inter-cooler water sprayswitch (manual): ONOK: In

13A-20MPI – TROUBLESHOOTINGMeasure at the inter-cooler waterspray relay connector C-220• Undo the connector, andmeasure on the harness side•Voltage ac

ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS 11-1SECTION 11ENGINECONTENTSGeneralThe following servicing guidelines have been prepared for vehicles

13A-21MPI – TROUBLESHOOTINGCheck connector: B-32Replace the No 2. waste gate solenoidvalveCheck connector: B-19XMeasure at the waste gatesolenoid valv

13A-22MPI – TROUBLESHOOTINGInspect the air temperaturesensor on its own (Ref: P13A-29)Check connector B-34Measure at the air temperaturesensor connect

13A-23MPI – TROUBLESHOOTINGContinued from the previous pageMeasure at the air temperaturesensor connector B-34• Connect the test harness(MB991658), to

13A-24MPI – TROUBLESHOOTING13A-236. Service dat

13A-25MPI – TROUBLESHOOTING13A-247-2 Table showing resistance and continuity across the terminals of harness side connectors 8. Checks using

13A-26MPI – TROUBLESHOOTING<Standard waveforms>Observation conditionsExhaust cam position sensor Crank angle sensorProbe switch X1 x1AC-GND-DC D

13A-27MPI – TROUBLESHOOTING<Examples of abnormal waveforms>• Example 1Waveform characteristicsA rectangular waveform is produced even though the

13A-28MPI – TROUBLESHOOTINGStandard waveform2 engine revolutions (1 camshaft revolution)crank anglesensor outputwaveformexhaust camposition sensoroutp

13A-29MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING• Example 2Waveform characteristicsThe waveform is displaced to the left or the right.Cause of the pr

MPI – ON-VEHICLE SERVICING13A-30(3) Remove the air temperature sensor(4) Use a hair dryer to increase the temperature and measure theresistance.Normal

ENGINE – SPECIAL TOOLS11-2Special toolsTool Number Name FunctionMB991502 MUT-II SubASSYChecking and adjusting the tension in timing belt BNoteIf a MU

ENGINE COOLING – GENERAL14-1SECTION 14ENGINE COOLINGCONTENTSGeneral...1Water pump ...

ENGINE COOLING – WATER PUMP14-2Water pumpRemoval and fittingJobs to be completed before removal and after fitting• Draining and refilling of the coola

ENGINE COOLING – WATER HOSE AND PIPE14-3Water hose and pipeRemoval and fittingJobs to be completed before removal and after fitting• Removal and refit

ENGINE COOLING – WATER HOSE AND PIPE14-4Removal guidelinesARemoving the radiator upper hose and the radiator lower hoseMark the radiator hose and

INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS, ON-VEHICLE SERVICING15-1SECTION 15INTAKE & EXHAUSTCONTENTSGeneral...

INTAKE & EXHAUST INTER-COOLER WATER SPRAY15-2Inter-cooler water sprayRemoval and fitting<Water spray nozzle, hose and washer tank>Procedure

INTAKE & EXHAUST INTER-COOLER WATER SPRAY15-3Fitting guidelinesA Fitting the water spray hose ASSY and fixing tape (for securing the water s

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM15-4Secondary air control systemRemoval and fittingJobs to be completed before removal and after fi

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD15-5Fitting guidelinesAFitting the gasketFit the gasket so that the protruding

INTAKE & EXHAUST – INLET MANIFOLD15-6Removal procedure1. Centre cover2. Ignition coil connector3. O2sensor connector4. Oil feeder control valve

ENGINE – SPECIAL TOOLS11-3Tool Number Name FunctionMD998737 Valve stem sealinstallerValve stem seal installationMD998713 Camshaft oil sealinstallerCam

INTAKE & EXHAUST – INLET MANIFOLD15-7Removal procedure24. Knock sensor connector25. Purge control solenoid valve ASSY26. Vacuum hose27. Fuel press

INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER15-8Exhaust manifold and turbochargerRemoval and fittingJobs to be completed before removal

INTAKE & EXHAUST – EXHAUST MANIFOLD15-9Removal procedure1. Exhaust manifold heat protector2. Air pipe ASSY connection3. O2sensor4. Turbocharger he

INTAKE & EXHAUST – EXHAUST MANIFOLD15-10BFitting the air outlet fitting gasketFit the gasket so that the protruding part is in the position lo

ENGINE ELECTRICAL – CHARGING SYSTEM16-1SECTION 16ENGINE ELECTRICALCONTENTSCharging system...1General ...

ENGINE ELECTRICAL – CHARGING SYSTEM16-2Removal procedure1. Injector connector2. Accelerator cable connection3. Delivery pipe, injector, and fuel pre

ENGINE ELECTRICAL – CHARGING SYSTEM16-3Removal guidelinesA Removing the delivery pipe, the injector, and the fuel pressure regulator ASSYLoosen

ENGINE ELECTRICAL – IGNITION SYSTEM16-4Ignition systemGeneralThe following servicing guidelines for spark plugs and the cam position sensor have been

REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM> 27B-1SECTION 27BREAR AXLECONTENTSGeneral...

TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING31-1SECTION 31WHEELS AND TYRESCONTENTSGeneral...1

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL11-4Engine tuning1. Checking revolutions when the engine is idlingThe standard revolut

TYRES AND WHEELS – ON-VEHICLE SERVICING31-24. Put the tyre on a raised surface and tilt it to an angle. Insert theextraction hose through the hole m

FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY33-1SECTION 33FRONT SUSPENSIONCONTENTSGeneral...

FRONT SUSPENSION – STRUT ASSY33-2pipe2. Use the following tools to loosen the self-locking nut.•Wrench (MB991681)• Socket (MB991682)CautionDo not use

BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP42-1SECTION 42BODYCONTENTSGeneral...

EXTERIOR – GENERAL51-1SECTION 51EXTERIORCONTENTSGeneral...1Front bumper...

EXTERIOR – FRONT BUMPER51-2Front bumperFront bumperRemoval and fittingRemoval procedure1. Side valence2. Centre valence3. valence centre bracket4. Fr

EXTERIOR – FRONT BUMPER51-3Dismantling and assemblyDismantling procedure1. Front 3-diamonds badge2. Front bumper nut3. Front number plate garnish4.

EXTERIOR – FRONT BUMPER, REAR BUMPER51-4Rear bumperRear bumperRemoval and fittingJobs to be completed before removal and after fitting• Removal and re

EXTERIOR – REAR BUMPER51-5Dismantling and assemblyDismantling procedure1. Number plate lamp bracket• Number plate lamp ASSY2. Rear bumper reinforcem

EXTERIOR – MARKINGS 51-6MarkingsRemoval and affixing1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge3. EVOLUTION badgeGuidelines for affixing