Mitsubishi Lancer Evolution 2005 User Manual

Workshop Manual - Supplement

LANCER

Evolution - IX

• Chassis

• Engine

• Wiring Diagrams

SERVICE MANUAL

Supplement

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

This manual is printed on recycled paper

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.

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.........................................

Related materials

*Indicates where the new model manual was published with the service manual in a single volume.

WARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRETENSIONERS Warning

1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fitted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitted 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-tensioner fitted seatbelts and the clock spring, should be removed if there is a chance of 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 removed.

3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt 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 seatbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-SRS air bags) has been carefully studied.

Title 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)

• 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

1036K04 2001/10

Title No. Issue

date

SECTION 54A

CHASSIS ELECTRICAL

CONTENTS

Number plate lamp ....................................1

Number plate lamp

Due to changes made to the licence plate lamp, servicing guidelines have been changed to be the same as for the ’03 model Lancer. Other servicing guidelines remain unchanged.

<Notes>

CHASSIS ELECTRICAL – LICENCE PLATE LAMP

SRS AIRBAG – GENERAL

54A-1 52B-1

SECTION 52B

SRS AIRBAG

CONTENTS

General........................................................1

General

A caution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.

Warning/caution label

bonnet

<Notes>

EXTERIOR – GENERAL

51-1

SECTION 51

EXTERIOR

CONTENTS

General........................................................1

Front bumper..............................................2

Front bumper.......................................................2

Rear bumper...............................................4

Rear bumper ........................................................4

Markings .....................................................6

General

Servicing guidelines have been changed in conjunction with the changes or additions listed below. Other servicing guidelines remain unchanged.

• Changes made to the shape and component of the front bumper.

• Changes made to the shape and component of the rear bumper.

• Changes made to the method for affixing the front 3-diamonds badge.

• Changes made to the position for affixing the LANCER badge and the EVOLUTION badge.

EXTERIOR – FRONT BUMPER

51-2

Front bumper

Removal and fitting

Removal procedure

1. Side valence

2. Centre valence

3. valence centre bracket

4. Front valence

5. Clip for attaching the splash shield

• Inter-cooler water spray hose connection (Ref Section 15)

6. Front bumper ASSY

7. Front bumper stay

Cross section through A-A

clip

Cross section through B-B

Cross section through C-C

cap

bumper

EXTERIOR – FRONT BUMPER

51-3

Dismantling and assembly

Dismantling procedure

1. Front 3-diamonds badge

2. Front bumper nut

3. Front number plate garnish

4. Front bumper cover A

5. Front bumper cover B

6. Air dam skirt panel

7. Front bumper centre net

8. Front bumper lower plate

9. Front bumper upper plate

10. Front bumper upper support

11. Air intake cover

12. Front bumper net

13. Bumper side net (LH)

14. Oil cooler duct

15. Bumper side net (RH)

• Inter-cooler water spray hose and nozzle (Ref Section 15)

16. Front bumper side plate

17. Front bumper upper reinforcement

18. Front bumper facing

Note: The main points for dismantling and assembly remain unchanged.

Cross section through A-A

hook

Cross section through B-B

clip

!!A"" ""A!!

EXTERIOR – FRONT BUMPER, REAR BUMPER

51-4

Rear bumper

Rear bumper Removal and fitting

Jobs to be completed before removal and after fitting

• Removal and refitting of the rear combination lamp

• Removal and refitting of the rear end trim

• Removal and refitting of the boot area side trim lid

Removal procedure

1. Screw for attaching the splash shield

2. Rear bumper bracket

3. Rear bumper ASSY

4. Rear number plate bracket

Cross section through A-A

clip

splash shield

EXTERIOR – REAR BUMPER

51-5

Dismantling and assembly

Dismantling procedure

1. Number plate lamp bracket

• Number plate lamp ASSY

2. Rear bumper reinforcement

3. Rear bumper side plate

4. Rear bumper facing support, side reinforcement

5. Rear bumper valence

6. Rear bumper facing

Note: The main points for dismantling and assembly remain unchanged.

!!A"" ""A!!

EXTERIOR – MARKINGS

51-6

Markings

Removal and affixing

1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge

3. EVOLUTION badge

Guidelines for affixing markings

""A!!

Affixing markings

1. Positioning

2. Guidelines for affixing

(1) Using white spirit, remove any grease from the place where the

badges will be affixed.

(2) Remove the protective paper from the back of the badges, and

affix them in the designated places.

Caution

1) Perform this job in an ambient temperature of 20~38ºC, and in a dust free location.

2) If the job is being performed in an ambient temperature of less than 20ºC, warm up the badges, and the area of the body onto which they will be affixed, to a temperature of 20~38ºC.

3) Ensure that air bubbles are not trapped in the adhesive tape when the badges are affixed.

""A!! ""A!!

2. LANCER badge 3. EVOLUTION badge

edge of boot lid

BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP

42-1

SECTION 42

BODY

CONTENTS

General........................................................1 Window glass channel, door-opening

weather strip <GT, GSR>...........................1

General

Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain unchanged. <GT, GSR>

• Addition of front door opening inner lower weather strip

• Addition of front and rear door opening inner weather strip

Window glass channel, door-opening weather strip <GT, GSR>

Removal and fitting

Note

: position of clips

Cross section A – A

front door trim

clip

Removal of the front door opening inner lower weather strip

1. Front door opening inner lower weather strip

Procedure for removing the front door opening inner weather strip

• Front scuff plate

• Cowl side trim

• Lower centre pillar trim

2. Front door opening inner weather strip

Procedure for removing the rear door opening inner weather strip

• Rear scuff plate

• Lower centre pillar trim

3. Rear door opening inner weather strip

<Notes>

FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY

33-1

SECTION 33

FRONT SUSPENSION

CONTENTS

General........................................................1

Special tools...............................................1

Strut ASSY..................................................1

General

The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the shape of the Bilstein shock absorbers.

Special tools

Tool Number Name Function

A: MB991237 B: MB991238

A. Spring compressor body B. Arm set

Dismantling and assembling the strut ASSY

MB991680

A: MB991681 B: MB991682

Wrench set A. Wrench B. Socket

Strut ASSY

Dismantling guidelines

!!A""

Removal of the self-locking nut

1. Use the following special tools to compress the coil spring.

• Spring compressor body (MB991237)

• Arm set (MB991238)

Caution (1) In order to completely compress the coil spring, ensure that

the special tool is fixed when at its greatest possible extension and that it is fixed evenly to the coil spring.

(2) Do not use an impact wrench, because there is a danger

that the special tool may be damaged.

FRONT SUSPENSION – STRUT ASSY

33-2

pipe

2. Use the following tools to loosen the self-locking nut.

•Wrench (MB991681)

• Socket (MB991682)

Caution Do not use an impact wrench when loosening the selflocking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose.

Assembly guidelines

""A!!

Fitting the self-locking nut

1. Check that the bearing has completely slotted in.

2. When the coil spring has been compressed using the special tool, provisionally tighten the self-locking nut.

Caution Do not use an impact wrench because there is a danger that the special tool may be damaged.

3. Align the holes in the lower spring plate and the upper spring plate of the strut ASSY. Note This operation can be easily performed by using a pipe to align the holes.

4. Line up the two ends of the coil spring with the slots in the spring plate, and loosen the special tool.

5. Use the following special tools to tighten the self-locking nut to the specified tightening torque.

•Wrench (MB991681)

• Socket (MB991682)

Tightening torque: 60 ± 10 N·m

Caution Do not use an impact wrench when loosening the selflocking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose.

TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING

31-1

SECTION 31

WHEELS AND TYRES

CONTENTS

General........................................................1

On-vehicle servicing..................................1

Removal of emergency puncture repairing agent....1

Disposal of emergency puncture repairing agent ....2

General

The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.

On-vehicle servicing

Removal of emergency puncture repairing agent

When repairing or replacing a tyre which has been treated using the puncture repair kit, remove the emergency puncture repairing agent (henceforth, repairing agent) from the tyre, in accordance with the guidelines below.

Note When removing the repairing agent, a container (the empty bottle which contained the repairing agent), and the insertion hose and the extraction hose from the emergency puncture repair kit, are needed.

Caution

1. Carry out the operation in a well-ventilated, airy place.

2. Take appropriate measures in order to prevent repairing agent; getting onto the skin, being inhaled, coming into contact with clothing, or getting into the eyes.

3. After the job has been completed, wash hands and face thoroughly.

1. Remove the wheel from the vehicle, and remove the air from the tyre.

2. Cut away the rubber part of the valve using a cutter-knife.

3. Attach the injection hose to the empty repairing agent bottle, and then attach the extraction hose onto the injection hose.

empty bottle of repairing agent

injection

hose

extraction

hose

valve

TYRES AND WHEELS – ON-VEHICLE SERVICING

31-2

4. Put the tyre on a raised surface and tilt it to an angle. Insert the extraction hose through the hole made by removing the valve, so that the tip of the hose is submerged in the repairing agent.

5. Hold the bottle so that it is, as far as possible, below the tyre, and suck the repairing agent out of the tyre by squeezing the bottle by hand. Repeat this operation 2 or 3 times, so that as much of the repairing agent as possible is removed.

6. After the repairing agent has been extracted, remove the tyre from the wheel. Remove any repairing agent stuck onto the tyre, and if the place from which air is escaping can be identified, carry out a normal repair procedure. If the place from which air is escaping cannot be identified, replace the tyre.

Disposal of emergency puncture repairing agent

Dispose of the repairing agent extracted from the tyre, and any unused agent which has exceeded its use-by date, in the same way that used oil is discarded. Note The use-by date is printed on the bottle of repairing agent (about 3 years from the date of purchase)

Caution The repairing agent includes propylene glycol which must be handled as industrial waste.

extraction hose

raised surface

repairing agent

extraction hose

injection hose

bottle

REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM>

27B-1

SECTION 27B

REAR AXLE

CONTENTS

General........................................................1 Differential carrier <vehicles with an

AYC system> ..............................................1

General

The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been changed. Other servicing guidelines remain unchanged.

Differential carrier <vehicles with an AYC system>

Removal and fitting

Note *1: When the screw is dry. *2: When the screw is lubricated.

NEW

OLD

fuel pressure unit hose ASSY

differential carrier ASSY

<Notes>

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 <only after fitting>

• Removal and refitting of the strut tower bar

• Removal and refitting of the front exhaust pipe ASSY

• Adjustment of the accelerator cable <only after fitting>

ENGINE ELECTRICAL – CHARGING SYSTEM

16-2

Removal procedure

1. Injector connector

2. Accelerator cable connection

3. Delivery pipe, injector, and fuel pressure regulator ASSY

4. Insulator

5. Insulator

6. Fuel pressure solenoid valve connector

7. Fuel pressure solenoid valve ASSY

8. Knock sensor connector

9. Purge control solenoid valve connector

10. Purge control solenoid valve ASSY

11. Oil level gauge and guide ASSY

12. O-ring

13. Drive belt

14. Alternator connector and terminal

• Engine mount

15. Alternator

16. Water pump pulley

17. O2sensor connector

18. Alternator bracket

(engine oil)

!!A""

!!B""

!!C""

ENGINE ELECTRICAL – CHARGING SYSTEM

16-3

Removal guidelines

!!A""

Removing the delivery pipe, the injector, and the fuel

pressure regulator ASSY

Loosen the bolts holding it in place, slightly dislodge all of the components and make space for the alternator to be removed.

!!B""

Removing the drive belt

The following procedures are necessary because a serpentine drive system with auto-tensioner has been installed.

1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and turn the auto-tensioner in an anti-clockwise direction until it reaches the stopper.

2. Align the A hole and the B hole, hold them in place by inserting an L-shaped hexagonal Allen Key, and remove the drive belt.

Caution If planning to re-use the drive belt, 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.

!!C""

Removing the alternator

Push the whole engine up using a garage jack, and remove the alternator from above.

A hole

B hole

L-shaped hexagonal Allen wrench

ENGINE ELECTRICAL – IGNITION SYSTEM

16-4

Ignition system

General

The following servicing guidelines for spark plugs and the cam position sensor have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.

Servicing standards

On-vehicle servicing

Checking cleaning and replacing spark plugs

The standard value and the upper limit for plug caps, has been changed in conjunction with the changes made to the spark plugs. Other servicing guidelines remain unchanged.

Standard values and upper limits

Cam position sensor

Removal and fitting

Removal procedure <Exhaust side>

1. Cam position sensor connector

2. Cam position sensor

3. O-ring

Removal procedure <Inlet side>

4. Cam position sensor connector

5. Cam position sensor

6. O-ring

Item Standard Value Upper Limit Spark plug cap mm 0.5~0.6 0.75

Manufacturer Model Standard Value mm Upper Limit mm

NGK ILFR7H 0.5~0.6 0.75

INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS,

ON-VEHICLE SERVICING

15-1

SECTION 15

INTAKE & EXHAUST

CONTENTS

General................................................................................1

Servicing standards ..........................................................1

Special tools.......................................................................1

On-vehicle servicing..........................................................1

Turbocharger super charging pressure check ...............1

Inter-cooler water spray ....................................................2

Secondary air control system ..........................................4

Inlet manifold .....................................................................5

Exhaust manifold and turbocharger................................8

General

The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.

• Changes to the turbocharger supercharging pressure

• Changes to the inter-cooler water spray hose

• Changes to the secondary air control valve

• Changes to the inlet manifold

• Changes to the exhaust manifold and the turbocharger

Special tools

On-vehicle servicing

Turbocharger supercharging pressure check

The standard value for the turbocharger charging pressure has been changed. Other servicing guidelines remain unchanged.

Standard value: 97 ~ 157 kPa

Item Standard value

Turbocharger charging pressure kPa 97~157

Servicing standards

Tool Number Name Function

MD998770 O2sensor wrench Removal and fitting of the O

sensor

INTAKE & EXHAUST INTER-COOLER WATER SPRAY

15-2

Inter-cooler water spray

Removal and fitting

Procedure for removing the water spray nozzle and the hose

1. Water spray hose connection

• Front bumper ASSY (Ref: Section 51)

• Tape (for fitting the water spray hose ASSY)

2. Water spray nozzle ASSY

3. Water spray hose ASSY

4. Clamp

5. Water spray nozzle (top)

6. Water spray nozzle bracket

7. Water spray nozzle (bottom)

8. Water spray hose

9. Three-way joint

10. Washer valve

•Tape (for attaching clip)

11. Clip

12. Pad

Procedure for removing the washer tank

1. Water spray hose connection

13. Water spray motor connector

14. Washer tank

15. Water spray hose

16. Washer valve

17. Water spray motor

18. Packing

19. Bracket

!!A""

INTAKE & EXHAUST INTER-COOLER WATER SPRAY

15-3

Fitting guidelines

!!A""

Fitting the water spray hose ASSY and fixing tape (for securing the water spray hose ASSY)

1. After fitting the water spray hose, the three-way joint and the washer valve, affix pads, clips and tape at the positions shown in the water spray hose diagram.

2. Fit the water spray hose ASSY to the front bumper using the water spray hose ASSY clip.

3. Affix tape as shown in the diagram, so that the water spray hose ASSY does not slip.

View of the inside of the front bumper

tape

three-way joint

pads

tape

washer valve

clip

tape

clip

three-way joint

pad

clip

washer valve

tape

clip

tape

clip

water spray hose ASSY

water spray nozzle brackets

tape

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM

15-4

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 bracket

6. Air hose

7. Air pipe ASSY

8. Gasket

9. Gasket

10. Secondary air control valve

11. Harness bracket

air pipe C

!!A""

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