Page 2 - SERVICE MANUAL; Supplement
Page 3 - LANCER; EVOLUTION IX; FOREWORD; CONTENTS; Body
LANCER EVOLUTION IX FOREWORD This manual contains details of the main changes to the2005 model Lancer Evolution IX. Only differences to thecurrent Lancer Evolution VIII MR are included, so please usethis manual in conjunction with the related manuals as listedon the following page.Please read this m...
Page 4 - Related materials
Related materials Title No. Issuedate Title No. Issuedate 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 10...
Page 5 - GENERAL; Inspection guidelines and troubleshooting; Note; Relevant vehicle numbers
GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP, RELEVANT VEHICLE NUMBERS 00-1 SECTION 00 GENERAL CONTENTS Inspection guidelines andtroubleshooting..........................................1 Model line-up ..............................................1 Relevant vehicle numbers .................
Page 6 - ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS; ENGINE
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 servicingguidelines remain unchanged. Servicing standards General .......................................
Page 7 - Tool
ENGINE – SPECIAL TOOLS 11-2 Special tools Tool Number Name Function MB991502 MUT-II SubASSY Checking and adjusting the tension in timing belt B NoteIf a MUT-III main harness A isconnected to a vehicle not fitted withCAN, there is a chance that a pulsesignal will be entered in the simulatedvehicle sp...
Page 8 - ENGINE – SPECIAL TOOLS
ENGINE – SPECIAL TOOLS 11-3 Tool Number Name Function MD998737 Valve stem sealinstaller Valve stem seal installation MD998713 Camshaft oil sealinstaller Camshaft oil seal installation MB991654 Cylinder head boltwrench Cylinder head bolt removal, installation MB991367 Special spanner Holding the cran...
Page 9 - ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL; Engine tuning; Checking revolutions when the engine is; Camshaft, valve stem seal
ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL 11-4 Engine tuning 1. Checking revolutions when the engine is idling The standard revolutions for when the engine is idling have beenchanged. Other servicing guidelines remain unchanged. Standard revolutions: 800 ± 50 r/min 2. Checking...
Page 10 - ENGINE – CAMSHAFT, VALVE STEM SEAL
ENGINE – CAMSHAFT, VALVE STEM SEAL 11-5 O O Removal procedure1. Oil feeder control valve connector2. Oil feeder control valve3. O-ring4. Breather hose• Secondary air control valve (refer to Section 15-2: Secondary Air Control System) 5. Centre cover• Ignition coil6. O2 sensor connector7. Crank angle...
Page 14 - Removal guidelines; Fitting guidelines
ENGINE – CAMSHAFT, VALVE STEM SEAL 11-9 Removal guidelines A Detaching the radiator upper hose Align the indicator marks on the radiator upper hose and the hoseclamp, and then detach the radiator upper hose. B Removing the camshaft sprockets Grip the hexagonal part of the camshaft with a wrench, loo...
Page 19 - ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET; Cylinder head gasket; Removal and fitting
ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET 11-14 O Fitting the O-ring/oil feeder control valve Caution1. 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 feedercontrol valve, in order to prevent damage to...
Page 20 - ENGINE – CYLINDER HEAD GASKET
ENGINE – CYLINDER HEAD GASKET 11-15 Removal procedure1. Ignition coil connector2. O2 sensor connector3. Oil feeder control valve connector4. Crank angle sensor connector5. Manifold absolute pressure sensor connector 6. Fuel pressure solenoid valve connector7. Knock sensor connector8. Purge control s...
Page 26 - ENGINE – TIMING BELT, TIMING BELT B
ENGINE – TIMING BELT, TIMING BELT B 11-21 10. Power steering oil pressure switch connector11. Heat protector12. Power steering oil pump ASSY13. Power steering oil pump bracket14. Idler pulley15. Crank angle sensor 16. Crankshaft sprocket17. Crankshaft sensing blade• Adjust the tension of the timing ...
Page 34 - ENGINE – ENGINE ASSY
ENGINE – ENGINE ASSY 11-29 Removal procedure1. Ignition coil connector2. O2 sensor connector3. Oil feeder control valve connector4. Crank angle sensor connector5. Manifold absolute pressure sensor connector 6. Fuel pressure solenoid valve connector7. Knock sensor connector8. Purge control solenoid v...
Page 41 - MPI – GENERAL; MPI system diagram
MPI – GENERAL 13A-2 MPI system diagram Engine ECU H 1. O2 sensor H 2. Air flow sensor H 3. Intake air temp. sensor H 4. Throttle position sensor H 5. Intake Cam position sensor H 6. Exhaust Cam position sensor H 7. Crank angle sensor H 8. Atmospheric pressure sensor H 9. Water temp. sensor H 10. Kno...
Page 44 - Diagnosis Functions
MPI – TROUBLESHOOTING 13A-5 TROUBLESHOOTING 1. Diagnosis Functions 1-1 Engine warning light (Check engine lamp)Changes have been made to engine warning lights.Checklist for engine warning lights. 1-2 Checking of freeze frame dataAdditions have been made to the freeze frame data tables.Checklist for ...
Page 45 - Diagnosis code classification table
MPI- TROUBLESHOOTING 13A-6 Code No. Diagnosis item Page P0105 MAP sensor 13A-7 P0340 Exhaust cam position sensor system 13A-9 P1012 Intake cam position sensor system 13A-11 P1021 Oil feeder control valve system 13A-13 P2226 Atmospheric pressure system 13A-14 2. Diagnosis code classification table
Page 46 - MPI – TROUBLESHOOTING; INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE
13A-7 MPI – TROUBLESHOOTING 3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE MUT-II/III service data• No.95 atmospheric pressure sensor(Ref: P13A-24) Go on to the next page Measurements taken atC-50 engine ECU connector• Measure engine ECU terminal voltage • Ignition switch: ON• Voltage across earth...
Page 55 - Inspection procedure for each type of fault; Checklist of faults
13A-16 MPI – TROUBLESHOOTING Check the purge control solenoid valve (Refer to Section17: Checking the exhaust gas purification system) MUT-II/III Service data• No.11 O2 sensor (Ref: P13A-83)* Refer to the diagnosis code classification table (P13A-6) MUT-II/III diagnosis code• Is the diagnosis code d...
Page 63 - Service data table
13A-24 MPI – TROUBLESHOOTING 13A-23 6. Service data table 7. Engine ECU checks 7-1 Terminal voltage table
Page 64 - Checks using an oscilloscope
13A-25 MPI – TROUBLESHOOTING 13A-24 7-2 Table showing resistance and continuity across the terminals of harness side connectors 8. Checks using an oscilloscope Sensor output signals and actuator drive signals can bechecked visually by taking waveform measurements using anoscilloscope. crankanglesens...
Page 68 - MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING; Layout diagram for MPI system components
13A-29 MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING • Example 2 Waveform characteristics The waveform is displaced to the left or the right. Cause of the problem The timing belt is looseThere is an abnormality in the fuel pump camshaft On-vehicle servicing 1. Adjusting standard engine revolutionswhen...
Page 69 - MPI – ON-VEHICLE SERVICING; Inspection of the oil feeder control valve
MPI – ON-VEHICLE SERVICING 13A-30 (3) Remove the air temperature sensor (4) Use a hair dryer to increase the temperature and measure the resistance.Normal conditions: air temp. sensor Temperature (ºC) Resistance (kΩ) Temperature increases Resistance decreases (5) If the resistance deviates from the ...
Page 70 - ENGINE COOLING – GENERAL; ENGINE COOLING
ENGINE COOLING – GENERAL 14-1 SECTION 14 ENGINE COOLING CONTENTS General........................................................1 Water pump ................................................2 Water hose and pipe ..................................3 General The following servicing guidelines for the wa...
Page 73 - ENGINE COOLING – WATER HOSE AND PIPE
ENGINE COOLING – WATER HOSE AND PIPE 14-4 Removal guidelines A Removing the radiator upper hose and the radiator lower hose Mark the radiator hose and the hose clamp with indicator marks and then remove the radiator hose. Fitting guidelines A Fitting the O-ring and the water inlet pipe Fit the O-rin...
Page 74 - Turbocharger supercharging pressure check; Servicing standards
INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS, ON-VEHICLE SERVICING 15-1 SECTION 15 INTAKE & EXHAUST CONTENTS General................................................................................1Servicing standards ............................................................
Page 76 - INTAKE & EXHAUST INTER-COOLER WATER SPRAY
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...
Page 78 - INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD; Inlet manifold
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD 15-5 Fitting guidelines A Fitting the gasket Fit the gasket so that the protruding part points in the directionshown in the diagram. Inlet manifold Removal and fitting Jobs to be completed before removal andafter fitting• Take measu...
Page 79 - INTAKE & EXHAUST – INLET MANIFOLD
INTAKE & EXHAUST – INLET MANIFOLD 15-6 Removal procedure1. Centre cover2. Ignition coil connector3. O2 sensor connector4. Oil feeder control valve connector5. Crank angle sensor connector6. Injector connector7. Air temperature sensor connector8. Manifold absolute pressure sensor connector 9. Pur...
Page 81 - EXHAUST MANIFOLD & TURBOCHARGER; Exhaust manifold and turbocharger
INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER 15-8 Exhaust manifold and turbocharger Removal and fitting Jobs to be completed before removal and after fitting • Removal and refitting of the valence• Removal and refitting of the radiator• Removal and refitting of the air intake hose and ...
Page 83 - INTAKE & EXHAUST – EXHAUST MANIFOLD
INTAKE & EXHAUST – EXHAUST MANIFOLD 15-10 B Fitting the air outlet fitting gasket Fit the gasket so that the protruding part is in the position located inthe diagram. C Fitting the oil return pipe gasket (oil pan side) Fit so that the printed side of the gasket is on the oil pan side. D Fitting ...
Page 84 - ENGINE ELECTRICAL – CHARGING SYSTEM; ENGINE ELECTRICAL; General
ENGINE ELECTRICAL – CHARGING SYSTEM 16-1 SECTION 16 ENGINE ELECTRICAL CONTENTS Charging system ........................................1 General .................................................................1Alternator...............................................................1 Ignition syste...
Page 87 - Cam position sensor
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 C...
Page 88 - REAR AXLE; Differential carrier
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 tig...
Page 89 - TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING; WHEELS AND TYRES
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 repai...
Page 90 - TYRES AND WHEELS – ON-VEHICLE SERVICING
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, belo...
Page 91 - FRONT SUSPENSION; Strut ASSY; Dismantling guidelines
FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY 33-1 SECTION 33 FRONT SUSPENSION CONTENTS General........................................................1 Special tools ...............................................1 Strut ASSY ..................................................1 General The g...
Page 92 - FRONT SUSPENSION – STRUT ASSY
FRONT SUSPENSION – STRUT ASSY 33-2 pipe 2. Use the following tools to loosen the self-locking nut.• Wrench (MB991681) • Socket (MB991682)CautionDo not use an impact wrench when loosening the self-locking nut, because there is a danger that the lock nut onthe piston rod inside the strut, may work loo...
Page 93 - BODY
BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP 42-1 SECTION 42 BODY CONTENTS General........................................................1 Window glass channel, door-openingweather strip <GT, GSR> ...........................1 General Servicing guidelines have been amended ...
Page 94 - EXTERIOR – GENERAL; EXTERIOR
EXTERIOR – GENERAL 51-1 SECTION 51 EXTERIOR CONTENTS General........................................................1Front bumper..............................................2 Front bumper .......................................................2 Rear bumper ............................................
Page 95 - Front bumper
EXTERIOR – FRONT BUMPER 51-2 Front bumper Front bumper Removal and fitting Removal procedure1. Side valence2. Centre valence3. valence centre bracket4. Front valence5. Clip for attaching the splash shield • Inter-cooler water spray hose connection(Ref Section 15) 6. Front bumper ASSY 7. Front bumper...
Page 96 - EXTERIOR – FRONT BUMPER; Dismantling and assembly
EXTERIOR – FRONT BUMPER 51-3 Dismantling and assembly Dismantling procedure1. Front 3-diamonds badge2. Front bumper nut3. Front number plate garnish4. Front bumper cover A5. Front bumper cover B6. Air dam skirt panel7. Front bumper centre net8. Front bumper lower plate9. Front bumper upper plate10. ...
Page 98 - EXTERIOR – REAR BUMPER
EXTERIOR – REAR BUMPER 51-5 Dismantling and assembly Dismantling procedure1. Number plate lamp bracket• Number plate lamp ASSY 2. Rear bumper reinforcement3. Rear bumper side plate 4. Rear bumper facing support, side reinforcement 5. Rear bumper valence6. Rear bumper facing Note:The main points for ...
Page 99 - Removal and affixing
EXTERIOR – MARKINGS 51-6 Markings Removal and affixing 1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge3. 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 wil...
Page 100 - SRS AIRBAG; Warning/caution label; CHASSIS ELECTRICAL; Number plate lamp
CHASSIS ELECTRICAL – LICENCE PLATE LAMP SRS AIRBAG – GENERAL 54A-152B-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. War...
Page 102 - Lancer Evolution IX
Page 103 - Service Manual; DOHC
Service Manual 4G6 FOREWORD This manual contains information about the 4G6DOHC engine. It only covers those points that aredifferent from the service manuals listed below.Therefore, this manual should be used in conjunctionwith the following manuals. • 4G6 DOHC engine Service Manual (No. 1039G46)• 4...
Page 104 - Range of description; Service sequence; Symbols for lubricants and sealants
2 HOW TO USE THIS MANUAL How to Use this Manual Range of description This manual explains the service procedure for the engine after it has been removed from the vehicle. For information onremoving the engine from the vehicle, or "on-vehicle" servicing of the engine, please refer to the sepa...
Page 105 - HOW TO USE THIS MANUAL; Page number Engine type Title
3 HOW TO USE THIS MANUAL Page number Engine type Title
Page 108 - G6 – TIGHTENING TORQUE
6 4G6 – TIGHTENING TORQUE Part Tightening Torque Air pipe assembly bolt (eye bolt) 49 ± 5 Air pipe assembly bolt (M6 flange) 11 ± 1 Air pipe assembly bolt (M8 flange) 24 ± 3 Air pipe assembly bolt (M8 washer) 14 ± 1 Air control valve assembly bolt 22 ± 4 Engine hanger bolt 19 ± 3 Intake air temperat...
Page 110 - Removal and Installation
8 4G6 – ALTERNATOR / IGNITION SYSTEM Alternator / Ignition System Removal and Installation Note :The ignition coil boot must only be removed from the ignition coil when it is to be replaced.If removed, always replace with a new part. Removal sequence 1. Oil level gauge2. O-ring 3. Oil level gauge gu...
Page 111 - Removal of ignition coil boot
9 4G6 – ALTERNATOR, IGNITION SYSTEM Removal Service Point Removal of ignition coil boot Note : • If the ignition coil boot is not installed according to the specifications, then this can lead to various problems, suchas malfunction of the ignition coil, damage to the ignition coil,leaking of high vo...
Page 113 - Removal of plug cap; Installation Service Point
11 4G6 – TIMING BELT 9. Connector bracket10. Rocker cover11. Rocker cover gasket A12. Rocker cover gasket B13. Semi-circular packing14. Plug cap15. Timing belt16. Tensioner pulley17. Tensioner arm18. Auto tensioner19. Idler pulley20. Crank angle sensor21. Oil pump sprocket22. Crankshaft bolt23. Cran...
Page 114 - G6 – TIMING BELT; Installation of plug cap
12 4G6 – TIMING BELT 3. Push the V.V.T. sprocket firmly to the end and, holding the hexagonal part of the camshaft with a wrench, check that the V.V.T.sprocket does not rotate. 4. Hold the hexagonal section of the camshaft with a wrench and tighten the V.V.T. sprocket bolt to the specified torque of...
Page 116 - Installation of cover
14 4G6 – FUEL SYSTEM Installation Service Point Installation of cover The side of the cover marked “gasket side” should be assembledfacing the inlet manifold. A Gasket side Cover Gasket Inlet manifold
Page 121 - Installation of OCV filter; Installation of cover / gasket
19 4G6 – ROCKER ARM / CAMSHAFT Installation Service Point Installation of OCV filter Note :Before fitting the filter, check that it is clean and is not damagedor deformed in any way. Installation of eye bolt Note : The oil pump may be damaged if the oil pipe joint turns with theeye bolt when it is f...
Page 122 - G6 – ROCKER ARM / CAMSHAFT
20 4G6 – ROCKER ARM / CAMSHAFT 2. Ensure that the cutaways in the intake side cover and the tabs on the gasket are aligned with the positions shown in the diagram, andtighten at the specified torque of 14 ±1 N-m. The exhaust side coverand gasket do not have a specified installation direction. Commen...
Page 123 - G6 – OIL PUMP / SUMP
21 4G6 – OIL PUMP / SUMP Oil Pump / Oil Pan Removal and Installation Removal Sequence 1. Drain plug2. Drain plug gasket3. Oil filter4. Oil pan5. Oil screen6. Oil screen gasket7. Baffle plate8. Oil pressure switch9. Oil cooler bypass valve10. Relief plug11. Gasket12. Relief spring13. Relief plunger14...
Page 124 - G6 – PISTONS / CONNECTING RODS; Removal Sequence; Piston / Connecting Rod
22 4G6 – PISTONS / CONNECTING RODS Removal Sequence 1. Connecting rod cap nut2. Connecting rod cap3. Connecting rod bearing4. Piston connecting rod5. Connecting rod bearing6. Piston ring No. 1 7. Piston ring No. 28. Oil ring9. Piston pin10. Piston11. Connecting rod12. Bolt Piston / Connecting Rod Re...
Page 125 - Installation of bearings on connecting rod
23 4G6 - PISTONS / CONNECTING RODS Installation Service Point Installation of bearings on connecting rod 1. When replacing a bearing, connecting rod or crankshaft, choose a bearing of the correct size which corresponds to theexternal diameter of the crankshaft pin, in accordance with theidentificati...
Page 126 - Piston rings
24 4G6 – PISTONS CONNECTING RODS Inspection Piston rings 1. Check the clearance between the piston rings and the piston grooves. If it exceeds the clearance limit value, replace the piston ring, or boththe piston ring and the piston. Standard values : No. 1 0.03 – 0.07 mm No. 2 0.02 – 0.06 mm Limit ...
Page 128 - Installation of crankshaft bearings
26 4G6 – CRANKSHAFT / CYLINDER BLOCK Installation Service Point Installation of crankshaft bearings 1. Using the table below, select a bearing of the correct size corresponding to the diameter of the crankshaft journal. (Selecting a bearing : Example)If the identifier on the crankshaft journal is 0,...
Page 129 - Disassembly and Reassembly
27 4G6 – TURBOCHARGER Turbocharger Disassembly and Reassembly Disassembly Procedure 1. Snap pin2. Waste gate actuator3. Cap ring4. Turbine housing5. Snap ring6. Cartridge assembly7. Compressor cover8. O ring * 1 * * 1 * * 1 * * 1 * * 1 * * * 1 * * 1
