2005 MITSUBISHI LANCER EVOLUTION IX engine

64G6 – TIGHTENING TORQUE
PartTightening 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 temperature sensor 14 ± 1
Boost sensor bolt 5.0 ± 1.0
Intake manifold stay bolt 31 ± 3
Intake manifold bolt (M8) 20 ± 2
Intake manifold bolt nut (M10) 36 ± 6
Exhaust manifold
Engine hanger bolt 22 ± 3
Turbocharger heat protector bolt 23 ± 3
Oxygen sensor 44 ± 5
Exhaust fitting bracket bolt 35 ± 6
Exhaust filling bolt nut 59 ± 5
Air outlet fitting bolt 19 ± 1
Oil return pipe bolt (flange) 14 ± 1
Oil return pipe bolt (washer) 9.0 ± 1.0
Turbocharger assembly and pipe assembly bolt, nut 64 ± 5
Oil pipe bolt (M10 eye bolt) 17 ± 2
Oil pipe bolt (M12 eye bolt) 31 ± 2
Oil pipe bolt (M12 flange) 11 ± 1
Water pipe bolt (flange) 10 ± 1
Water pipe bolt (eye bolt) 42 ± 7
Exhaust manifold nut (M8) 33 ± 6
Exhaust manifold nut (M10) 55 ± 10
Water pump / Water hose
Coolant temperature sensor 29 ± 10
Coolant temperature gauge unit 11 ± 1
Water outlet fitting bolt 10 ± 1
Thermostat housing bolt 23 ± 4
Water inlet pipe bolt (M6) 10 ± 1
Water inlet pipe bolt (M8) 13 ± 2
Water pump bolt 14 ± 1
Knock sensor 23 ± 2
Rocker arm / Camshaft
Cam position sensor bolt 11 ± 1
Cover bolt 10 ± 2
Cam position sensing cylinder bolt 22 ± 4
Cam position sensor support bolt 14 ± 1
Bearing cap bolt 20 ± 1
Oil delivery body bolt 11 ± 1

114G6 – TIMING BELT
9. Connector bracket
10. Rocker cover
11.Rocker cover gasket A
12. Rocker cover gasket B
13. Semi-circular packing
14. Plug cap
15. Timing belt
16. Tensioner pulley
17. Tensioner arm
18. Auto tensioner
19. Idler pulley
20. Crank angle sensor
21. Oil pump sprocket
22. Crankshaft bolt
23. Crankshaft sprocket
24. Crankshaft sensing blade
25. Tensioner B26. Timing belt B
27. Counterbalance shaft sprocket
28. Spacer
29. Crankshaft sprocket B
30. Crankshaft key
31. Engine support bracket
32. V.V.T. sprocket bolt
33. V.V.T. sprocket
34. Camshaft sprocket bolt
35. Camshaft sprocket
36. Timing belt rear right cover
37. Timing belt rear left upper cover
38. Timing belt rear left lower cover
Removal Service Point
Removal of plug cap
Hold hexagonal section of camshaft with wrench, and loosen plug cap.
Removal of V.V.T. sprocket bolt
Hold hexagonal section of camshaft with wrench, and loosen V.V.T.
sprocket bolt.
Installation Service Point
Installation of V.V.T. sprocket bolt / V.V.T.
sprocket
1. Apply the minimum suitable coating of engine oil to the following
points:
• Whole circumference of end of camshaft
• Inserted part of V.V.T. sprocket (full circumference; inner
& outer sides)
• Bolt seating of V.V.T. sprocket bolt
2. Install the V.V.T. sprocket.
V. V. T.
sprocket
boltV.V.T. sprocket
Camshaft

* A


* B 
B
*
A
*
A
*

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* * 1 
* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* A


* B


* A

154G6 – SECONDARY AIR SYSTEM / INLET MANIFOLD
Secondary Air System / Inlet Manifold
Removal and Installation
Removal Sequence
1. Exhaust manifold heat protector
2. Air pipe assembly
3. Air control valve gasket
4. Air control valve assembly
5. Engine hanger6. Intake air temperature sensor
7. Boost sensor
8. Inlet manifold stay
9. Inlet manifold
10. Inlet manifold gasket

* 1
* 
* 1
*

* 1
*

164G6 – EXHAUST MANIFOLD
Exhaust Manifold
Removal and Installation
Removal Sequence
1. Engine hanger
2. Turbocharger heat protector
3. Oxygen sensor
4. Exhaust fitting bracket
5. Exhaust fitting
6. Exhaust fitting gasket
7. Air outlet fitting
8. Air outlet fitting gasket
9. Oil return pipe10. Oil return pipe gasket
11.Oil return pipe gasket
12. Turbocharger assembly & pipe assembly
13. Turbocharger gasket
14. Oil pump
15. Water pipe B
16. Water pipe A
17. Turbocharger assembly
18. Exhaust manifold
19. Exhaust manifold gasket

* 1
*

* 1

*

* 1
*

184G6 – ROCKER ARM / CAMSHAFT
Rocker Arm / Camshaft
Removal and Installation
Removal Sequence
1. Cam position sensor
2. O ring
3. Cover
4. Gasket
5. Cam position sensing cylinder
6. Cam position sensor support
7. Cam position sensor
8. O ring
9. Cover
10. Gasket
11.Cam position sensing cylinder
12. Cam position sensor support
13. Camshaft oil seal
14. Bearing cap : rear right
15. Bearing cap : rear left
16. Bearing cap : front17. Bearing cap No. 5
18. Bearing cap No. 2
19. Bearing cap No. 3
20. Bearing cap No. 4
21. Camshaft
22. Rocker arm
23. Lash adjuster
24. Oil delivery body
25. Oil control valve (OCV)
26. O ring
27. Check valve
28. Eye bolt
29. Oil pump
30. OCV filter
31. Oil pump joint
32. Gasket
Apply engine oil to all
sliding parts before
installing.
E

*
E


*
D


*
D


*
C


*
C


*
E


*
E


*

* 1
*

*1
* 
* 1
*

* 1
*

*1
*

* 1
*

* 1
* 
* 1
*

* 1
*

* 1
*
* * 1

B
*
A

*

214G6 – OIL PUMP / SUMP
Oil Pump / Oil Pan
Removal and Installation
Removal Sequence
1. Drain plug
2. Drain plug gasket
3. Oil filter
4. Oil pan
5. Oil screen
6. Oil screen gasket
7. Baffle plate
8. Oil pressure switch
9. Oil cooler bypass valve
10. Relief plug
11.Gasket
12. Relief spring
13. Relief plunger
14. Oil filter bracket
15. Oil filter bracket gasket
16. Plug cap
17. O ring18. Flange bolt
19. Oil pump case
20. Oil pump case gasket
21. Oil pump cover
22. Oil pump driven gear
23. Oil pump drive gear
24. Crankshaft front oil seal
25. Counterbalance shaft oil seal
26. Oil pump oil seal
27. Counterbalance shaft, right
28. Counterbalance shaft, left
29. Counterbalance shaft front bearing
30. Counterbalance shaft rear bearing, right
31. Counterbalance shaft rear bearing, left
Apply engine oil to all
sliding parts before
installing.

* 1
*

* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* 1
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* * 1

224G6 – PISTONS / CONNECTING RODS
Removal Sequence
1. Connecting rod cap nut
2. Connecting rod cap
3. Connecting rod bearing
4. Piston connecting rod
5. Connecting rod bearing
6. Piston ring No. 17. Piston ring No. 2
8. Oil ring
9. Piston pin
10. Piston
11.Connecting rod
12. Bolt
Piston / Connecting Rod
Removal and Installation
Apply engine oil to all
sliding parts before
installing.

* 1
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* 1
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* 1
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* 1
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* 1
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* 2
*

* 1
*

* * 1


* * 1 A
*
A
*

254G6 – CRANKSHAFT / CYLINDER BLOCK
Crankshaft / Cylinder Block
Removal and Installation
Removal Procedure
1. Flywheel bolt
2. Flywheel
3. Rear plate
4. Bell housing cover
5. Rear oil seal case
6. Rear oil seal
7. Bearing cap bolt
8. Beam being cap9. Crankshaft bearing lower
10. Crankshaft
11.Crankshaft bearing upper
12. Thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block
Apply engine oil to all
sliding parts before
installing. Bolt with washer : 9.0 ± 1.0 N-m
Flange bolt : 10 ± 2 N-m (supplementary part)
A
*
A
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*1
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