2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

INTAKE & EXHAUST – INLET MANIFOLD
15-7
Removal procedure
24. Knock sensor connector
25. Purge control solenoid valve ASSY
26. Vacuum hose
27. Fuel pressure solenoid valve ASSY
28. PCV hose
•Alternator (Ref Section 16: Alternator)
29. Secondary air control solenoid valve
connector
30. Vacuum tank, ACV solenoid valve,
vacuum hose & pipe ASSY31. Inlet manifold stay
32. Cover
33. Gasket
34. Harness connection
35. Crank angle sensor connector
36. Alternator bracket
37. Inlet manifold
38. Inlet manifold gasket
Removal guidelines
 
A


Removal of the delivery pipe, the injector and the fuel
pressure regulator ASSY
Remove the deliver pipe, with the injector and the fuel pressure
regulator intact.
Caution
When removing the delivery pipe, be careful not to drop the
injector.
Fitting guidelines



A 

Connecting the O-ring and the fuel high pressure hose
1. Apply a small quantity of fresh engine oil to the O-ring, and
insert it into the delivery pipe without damaging the O-ring.
2. Check that the high pressure hose can be turned smoothly. If it
cannot be turned smoothly there is a possibility that it is biting
into the O-ring, so remove the high pressure hose and check for
any damage to the O-ring. If the O-ring is undamaged, reinsert it
into the delivery pipe and check once more whether the hose
can be turned smoothly.
3. Tighten the mounting bolt to the specified torque.
Tightening torque: 5.0 ± 1.0 N·m

INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER15-8
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
air hose A• Removal and refitting of the cross member bar
• Removal and refitting of the front exhaust pipe
• Draining and refilling of the engine oil

INTAKE & EXHAUST – EXHAUST MANIFOLD15-9
Removal procedure
1. Exhaust manifold heat protector
2. Air pipe ASSY connection
3. O
2sensor
4. Turbocharger heat protector
5. Turbocharger water feed pipe connection
6. Gasket
7. Water hose connection
8. Oil feed pipe
9. Gasket
10. Starter
11.Oil return pipe
12. Oil return pipe gasket (turbocharger side)
13. Oil return pipe gasket (oil pan side)14. Vacuum hose connection
15. Air outlet fitting
16. Air outlet fitting gasket
17. Exhaust fitting bracket
18. Turbocharger and exhaust fitting ASSY
19. Turbocharger ASSY
20. Exhaust fitting gasket
21. Exhaust fitting
22. Turbocharger gasket
23. Turbocharger water return pipe
24. Gasket
25. Exhaust manifold
26. Exhaust manifold gasket
Removal guidelines
 
A


Removing the O
2sensor
After removing the O
2sensor connector and the clamp, use the
special O
2 sensor wrench (MD998770) to remove the O
2sensor.
 
B


Removing the oil feed pipe
Caution
After removing the oil feed pipe, ensure that there is no foreign
matter in the oil access hole on the turbocharger.
Fitting guidelines



A 
Fitting the turbocharger ASSY
1. Clean away any grease clogging the connection between the oil
pipe and the water pipe, and any grease clogging the eyebolts
and the inside of the pipes.
2. If there is any carbon in the oil access on the turbocharger
ASSY, clean it or blow it away.
Caution
Ensure that no foreign matter gets inside the turbocharger
ASSY.
 
A


 
B






D 



C 




B 



A 
O
2sensor

INTAKE & EXHAUST – EXHAUST MANIFOLD15-10



B 
Fitting the air outlet fitting gasket
Fit the gasket so that the protruding part is in the position located in
the 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 the oil return pipe gasket (turbocharger side)
Fit so that the printed side of the gasket is on the turbocharger side.turbocharger
protruding part
view “A”
view “A”
print
print
gasket
gasket
3. Apply some fresh engine oil via the fitting hole for the oil feed
pipe in the turbocharger ASSY.

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

ENGINE ELECTRICAL – CHARGING SYSTEM16-2
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 connector10. 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. O
2sensor 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.
AholeB hole
L-shaped
hexagonal
Allen
wrench

ENGINE ELECTRICAL – IGNITION SYSTEM16-4
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
1. Cam position sensor connector
2. Cam position sensor
3. O-ringRemoval procedure
4. Cam position sensor connector
5. Cam position sensor
6. O-ring
ItemStandard ValueUpper Limit
Spark plug cap mm0.5~0.60.75
ManufacturerModelStandard Value mmUpper Limit mm
NGKILFR7H0.5~0.60.75