PDF Workshop Manual 2005 Mitsubishi Lancer Evolution IX - 8 MB
Get the complete factory workshop manual for the legendary 2005 Mitsubishi Lancer Evolution IX.
This comprehensive guide provides detailed information on all aspects of service and repair, from routine maintenance to full engine overhauls.
It's the same manual used by dealership technicians, covering everything from the 4G63 engine and transmission to suspension and bodywork.
This is a must-have for any Evo IX owner or enthusiast who works on their own car.
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--- Page 1 ---
GROUP INDEX
General . . . . . . . . . . . . . . . . . . . . . . . . 00
LANCER Engine . . . . . . . . . . . . . . . . . . . . . . . . 11
EVOLUTION IX Engine Lubrication . . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WORKSHOP MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust . . . . . . . . . . . . . . 15
Engine Electrical . . . . . . . . . . . . . . . . 16
Engine and Emission Control . . . . . 17
FOREWORD Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
This Workshop manual contains procedures for
service mechanics, including removal, disassembly, Manual Transmission . . . . . . . . . . . . 22
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
Propeller Shaft. . . . . . . . . . . . . . . . . . 25
manual as required. Front Axle. . . . . . . . . . . . . . . . . . . . . . 26
Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
Wheel and Tyre . . . . . . . . . . . . . . . . . 31
TECHNICAL INFORMATION MANUAL
IEVE04E1CD
Power Plant Mount . . . . . . . . . . . . . . 32
IEVE04E1CD Front Suspension . . . . . . . . . . . . . . . 33
IEVE04E1CD
Rear Suspension . . . . . . . . . . . . . . . . 34
WORKSHOP MANUAL
CHASSIS GROUP Service Brakes. . . . . . . . . . . . . . . . . . 35
BODY REPAIR MANUAL
CEVX04E1CD
Parking Brakes . . . . . . . . . . . . . . . . . 36
CEVX05E1CD Power Steering . . . . . . . . . . . . . . . . . 37
PARTS CATALOGUE B606K006A Body . . . . . . . . . . . . . . . . . . . . . . . . . . 42
All information, illustrations and product descriptions Exterior. . . . . . . . . . . . . . . . . . . . . . . . 51
contained in this manual are current as at the time of Interior and Supplemental
publication. We, however, reserve the right to make Restraint System (SRS) ............ 52
changes at any time without prior notice or obligation. Chassis Electrical . . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . 55
Component Locations . . . . . . . . . . . 70
Configuration Diagrams . . . . . . . . . . 80
Circuit Diagrams . . . . . . . . . . . . . . . . 90
©0LWVXELVKL0RWRUV(XURSH%9 2FW
--- Page 3 ---
GENERAL
SRS SERVICE PRECAUTIONS
00-23
SRS SERVICE PRECAUTIONS
M1001006000229
DANGER CAUTION
In order to avoid injury to yourself or others
from accidental deployment of the air bag
SRS-ECU connector
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-8.
AC300634 AB
CAUTION
Never Attempt to Repair the Following Compo- Do not attempt to repair the wiring harness con-
nents: nectors of the SRS. If a defective wiring harness
is found, repair or replace it by referring to the
1. SRS air bag control unit (SRS-ECU)
table below.
2. Clock spring
3. Driver's and passenger's (front) air bag mod-
ules
4. Front impact sensor
5. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE pro-
cedures in this manual, starting at page P.52B-105.
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (RH) → Front harness.
impact sensor (RH)
3, 4 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (LH) → Front harness.
impact sensor (LH)
7 Instrument panel wiring harness→ Correct or replace the instrument
Earth panel wiring harness.
8 Instrument panel wiring harness → Correct or replace the instrument
SRS warning lamp panel wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument
Passenger's (front) air bag module panel wiring harness.
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag wiring harness. Replace the clock
module spring.
13 Instrument panel wiring harness → Correct or replace the instrument
Junction block (fuse No.3) panel wiring harness.
16 Instrument panel wiring harness → Correct or replace the instrument
Junction block (fuse No.2) panel wiring harness.
--- Page 4 ---
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 4. If there are any problems in the procedure 1 or 3,
M1111003100612 replace the auto-tensioner.(Refer to P.11A-36).
CAUTION 5. Install the drive belt.(Refer to P.11A-15).
Check the drive belt tension after turning the
crankshaft clockwise one turn or more. FUNCTION CHECK
You can verify if the auto-tensioner is defective or not
by checking the drive belt tension.
When using the M.U.T.-II
1. Check the drive belt tension. (Refer to P.11A-7).
A 2. Measure the drive belt tension vibration frequency
by the following procedures:
CAUTION
Indicator mark
AC211616AB
1. Make sure that the indicator mark is within the
area marked with A in the illustration.
16-pin
2. If the mark is out of the area, replace the drive
belt. (Refer to P.11A-15).
NOTE: The drive belt tension check is not neces-
sary as auto-tensioner is adopted.
AUTO-TENSIONER CHECK
M1111003000284
OPERATION CHECK M.U.T.-II
1. Turn OFF the engine from the idle state then
check to see that the drive belt is not protruding
from the pulley width of the auto-tensioner.
2. Remove the drive belt.(Refer to P.11A-15).
Y1848AU
MB991668
AC211432 AB
To prevent damage to the M.U.T.-II, always turn
the ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting the M.U.T.-II.
(1) Connect special tool belt tension meter set
(MB991668) to the M.U.T.-II.
AC211619 (2) Connect the M.U.T.-II to the diagnosis
connector.
3. Securely insert the spindle handle or ratchet
(3) Turn the ignition switch to "ON" position, and
handle with a 12.7 mm insertion angle into the jig
select "BELT TENSION" on the menu screen.
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
--- Page 5 ---
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-33
26 25 27 28
5.0 ± 1.0 N·m
20 ± 2 N·m
<Cold engine> 9 29 N
78 ± 2 N·m to 0 N·m to
20 ± 2 N·m to +90˚ to +90˚ (Engine oil)
30
31
(Engine oil)
11
10 24
31 ± 3 N·m
42 ± 2 N·m 11 ± 1 N·m
12 16 15 N
14 N 32
35 ± 6 N·m
N 13 30 ± 3 N·m
17 22 N
30 ± 3 N·m 18
N 19
21
9.0 ± 1.0 N·m
N 23 14 ± 1 N·m
N 20
AC407431AC
Removal steps Removal steps (Continued)
9. Alternator brace bolt 24. Turbocharger bracket
10. Battery wiring harness connection • Water outlet fitting and thermostat
11. Inlet manifold stay case assembly (Refer to GROUP
>>E<< 12. Eye bolt 14, Water Hose and Water Pipe
13. Gasket P.14-22).
14. Eye bolt • Rocker cover (Refer to P.11A-17).
15. Gasket 25. Water return hose connection
16. Oil feeder control valve pipe 26. Heater hose connection
17. Filter 27. Fuel return line hose connection
18. Oil pipe joint >>C<< 28. Fuel high-pressure hose
19. Gasket connection
20. Gasket >>C<< 29. O-ring
21. Oil return tube <<A>> >>B<< 30. Cylinder head bolts
22. Oil return tube gasket 31. Cylinder head assembly
>>D<< 23. Oil return tube gasket >>A<< 32. Cylinder head gasket
--- Page 6 ---
ENGINE OVERHAUL
TORQUE SPECIFICATIONS
11B-7
Item N⋅m
WATER PUMP AND WATER HOSE
Engine coolant temperature sensor 29 ± 10
Engine coolant temperature gauge unit 11 ± 1
Water outlet fitting bolts 10 ± 1
Thermostat housing bolts 23 ± 4
Water inlet pipe bolt (M6) 10 ± 1
Water inlet pipe bolt (M8) 13 ± 2
Water pump bolts 14 ± 1
Detonation sensor 23 ± 2
ROCKER ARMS AND CAMSHAFT
Camshaft position sensor bolt 11 ± 1
Cover bolts 10 ± 2
Camshaft position sensing cylinder bolt 22 ± 4
Camshaft position sensor support bolts 14 ± 1
Bearing cap bolts 20 ± 1
Oil delivery body bolts 11 ± 1
Oil feeder control valve bolt 11 ± 1
Check valve 30 ± 3
Eye bolt 42 ± 2
Oil pipe bolt 11 ± 1
Oil pipe joint 30 ± 3
CYLINDER HEAD AND VALVES
Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → +90° → +90°
OIL PAN AND OIL PUMP
Drain plug 39 ± 5
Oil level sensor bolts 9.0 ± 1.0
Oil filter 14 ± 2
Oil pan bolts 9.0 ± 3.0
Oil screen bolts 19 ± 3
Baffle plate bolts 22 ± 4
Oil pressure switch 19 ± 3
Oil cooler by-pass valve 54 ± 5
Relief plug 44 ± 5
Oil filter bracket bolts 19 ± 3
Plug cap 23 ± 3
Flange bolt 36 ± 3
Oil pump case bolts 23 ± 3
Oil pump cover bolts 17 ± 1
Oil pump cover screw 10 ± 2
--- Page 7 ---
ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-33
INSTALLATION SERVICE POINT >>B<< OIL RETURN PIPE GASKET
>>A<< EXHAUST MANIFOLD INSTALLA- INSTALLATION
TION
Tab
1. Hand tighten all the exhaust manifold mounting
nuts.
2. Tighten the M8 nuts to 29 ± 3 N⋅m in the indicated
sequence.
3. Tighten the M10 nuts to 49 ± 5 N⋅m in the
indicated sequence.
4. Tighten the M8 nuts again to 29 ± 3 N⋅m in the
indicated sequence. AK304540AB
Install the oil return pipe gasket with its tab located
as shown in the drawing.
NOTE: The gasket on the turbocharger end of the
3 4 5 6
pipe does not require special alignment for installa-
tion.
1 7 9 8 2
>>C<< OUTLET FITTING GASKET
INSTALLATION
AK202866 AB
5. Finally tighten the M10 nuts and the M8 nuts to Tab
the specified torque, both in the indicated
sequence.
Tightening torque:
33 ± 6 N⋅m <M8>
55 ± 10 N⋅m <M10>
A
A AK202868 AB
Install the air outlet fitting gasket with its tab located
as shown in the drawing.
--- Page 8 ---
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
NOTE: Keep the disassembled pistons, piston
pins and connecting rods cylinder by cylinder.
Push rod
INSTALLATION SERVICE POINTS P
>>A<< PISTON PIN INSTALLATION
Front mark
Timing belt side Crankshaft
bore size mark Front mark
P
No.4
No.3 Guide A
No.2
No.1
Base
AK202923 AB
Guide B
1. When replacing a piston, check the cylinder bore
size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Cylinder bore size mark Piston size mark AK501783AB
I A 7. Install the piston and connecting rod assembly
II No mark with the tools onto the special tool Piston Setting
Base, ensuring that the piston front mark faces
III C
upwards.
NOTE: The piston size mark is located on the pis- 8. Using a press, press fit the piston pin. If the force
ton top surface. required to press fit the piston pin is less than the
2. Insert the special tool Push Rod into the piston standard value, replace the piston pin (piston
pin, and install Guide A. assembly) or the connecting rod, or both.
3. Assemble the piston and the connecting rod Standard value: 7,350 − 17,100 N
together, ensuring that their front marks are
aligned with each other.
>>B<< OIL RING INSTALLATION
4. Apply engine oil onto the periphery of the piston
pin. Coil expander
5. Insert the piston pin assembled in Step 1 above end gap
into the piston pin boss. Guide A end of the piston
pin should be inserted first into the front mark end
of the boss.
L
Oil ring
end gap
AK502373 AB
1. Fit the oil ring coil expander and oil ring into the
piston ring groove.
NOTE: Locate the oil ring and coil expander end
Guide B Guide A gaps as shown in the drawing.
AK304522AC
NOTE: New coil expander and oil ring are an
6. Insert Guide B into Guide A with having 1.25 mm identified by colour marks as follows:
of the clearance "L" between Guide A and B.
--- Page 9 ---
MULTIPORT FUEL INJECTION (MPI)
TROUBLESHOOTING
13A-9
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150001572
Refer to P.00-5, GROUP 00 − How to Use Trouble- DIAGNOSIS FUNCTION
shooting/Inspection Service Points. M1131155501527
NOTE: If the engine-ECU is replaced, the steering ENGINE WARNING LAMP (CHECK
lock cylinder and ignition key should be replaced ENGINE LAMP)
together with it.
<L.H.drive vehicles>
Engine warning lamp
(check engine lamp)
<R.H.drive vehicles>
Engine warning lamp
(check engine lamp)
AK501993AB
If an abnormality occurs in any of the following items
related to the Multipoint Fuel Injection (MPI) system,
the engine warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illumi-
nates while the engine is running, check the diagno-
sis code output.
--- Page 10 ---
MULTIPORT FUEL INJECTION (MPI)
TROUBLESHOOTING
13A-35
Code No. P105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-105
(MU802552)
Barometric pressure sensor
1 2 3 4 5 6 7 (Incorporated in air flow sensor)
1 2 5
GR Y-L B
42 51 34 C-121
C-119
(MU803782) (MU803783)
41 42 43 44 45 46 47 1 2 3 4 5 6 7 8
48 49 50 51 52 53 54 55 56 57 58 59 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
60 61 62 63 64 65 66 67 68 24 25 26 27 28 29 30 3132 33 34 35
5V
Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V: Violet PU: Purple
AK501801 AB
OPERATION TROUBLE JUDGMENT
• A power voltage of 5 V is applied to the baromet- Check Condition
ric pressure sensor power terminal (terminal No. • 2 seconds after the ignition switch has been
1) of the air flow sensor connector from the placed in the "ON" position or the engine has
engine-ECU (terminal No. 42) and earthed to the started up.
engine-ECU (terminal No. 34) from the air flow
sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The sensor output voltage of 4.5 V or more (Baro-
metric pressure above 114 kPa or equivalent) for
(terminal No. 51) from the barometric pressure 2 seconds.
sensor output terminal (terminal No. 2) of the air or
flow sensor connector. • The sensor output voltage 0.2 V or less (Baro-
metric pressure below 53 kPa or equivalent) for 2
FUNCTION seconds.
• The barometric pressure sensor converts the bar- PROBABLE CAUSES
ometric pressure into a voltage signal and inputs • Failed barometric pressure sensor
the signal to the engine-ECU. • Open/short circuit in barometric pressure sensor
• In response to the signal, the engine-ECU cor- circuit or loose connector contact
rects the fuel injection amount, etc. • Failed engine-ECU
--- Page 11 ---
MULTIPORT FUEL INJECTION (MPI)
TROUBLESHOOTING
13A-61
PROBABLE CAUSES STEP 3. Check throttle position sensor itself.
• Failed throttle position sensor • Check throttle position sensor itself (Refer to
• Open/short circuit in throttle position sensor cir- P.13A-404).
cuit or loose connector contact
• Failed engine-ECU Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace the throttle position sensor.
DIAGNOSIS PROCEDURE
STEP 4. Perform voltage measurement at B-03
STEP 1. M.U.T.-II/III data list throttle position sensor connector.
• Refer to Data List Reference Table P.13A-372.
a. Item No. 14: Throttle position sensor Connector : B-03
Q: Is the check result normal? B-03(B)
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
Troubleshooting/Inspection Service Points
P.00-5).
NO : Go to Step 2 . 4 3 2 1
Harness side
STEP 2. Connector check: B-03 throttle position connector AK305010 AB
sensor connector • Disconnect connector, and measure at harness
Connector : B-03 side.
• Ignition switch: "ON"
B-03(B) • Voltage between terminal No. 1 and earth.
OK: 4.9 − 5.1 V
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 5 .
4 3 2 1
Harness side
connector AK305010 AB
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector.
--- Page 12 ---
MULTIPORT FUEL INJECTION (MPI)
TROUBLESHOOTING
13A-87
STEP 9. Check harness between B-113 (terminal STEP 10. Check harness between B-113 (terminal
No. 1) oxygen sensor (front) connector and No. 3) oxygen sensor (front) connector and C-121
B-12X (terminal No. 4) engine control relay (terminal No. 3) engine-ECU connector.
connector. Connector : B-113
Connector : B-113
Oxygen sensor(front)
Oxygen sensor(front)
2 1
2 1 B-113(B)
4 3
B-113(B) Harness side
4 3
Harness side connector
AK305011AB
connector
AK305011AB
Connector: C-121
Connector : B-12X Relay box’s
triangle marks <L. H. drive vehicles>
2 1
B-12X
4 3
Harness side
connector
AK305003 AB
C-121 (GR)
• Check power supply line for damage.
<R. H. drive vehicles>
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Repair the damaged harness wire.
C-121 (GR)
8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9