2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

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.

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234G6 - 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 the
external diameter of the crankshaft pin, in accordance with the
identification marks on the crankshaft pin and the connecting
rod bearing given in the table below.
2. The crankshaft identifier is engraved in the position shown in
the diagram.
3. The bearing identifier is engraved or printed at the position
shown in the diagram.
(Selecting a bearing : Example)
If the crankshaft identification mark is I, then choose a bearing
with the identification mark 0.
If it is difficult to make out the crankshaft identifier, measure the
external diameter of the pin and then choose the bearing that
corresponds to that diameter.
4. The selected bearing should be installed in the larger end of
the connecting rod and the cap.
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Crankshaft pin Connecting rod
bearing
Identification mark External diameter of
pin (mm)Identification mark
I44.995 – 45.005 0
II 44.985 – 44.995 1
III 44.980 – 44.985 2
Position of crankshaft pin diameter identification marks

244G6 – 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 both
the piston ring and the piston.
Standard values :
No. 1 0.03 – 0.07 mm
No. 2 0.02 – 0.06 mm
Limit value : 0.1 mm
2. Insert the piston ring and the side rail of the oil ring into the cylinder
bore, and press in using the top surface of the piston. After reaching
a right-angle position, measure the opening gaps in the rings using a
thickness gauge.
Remark :
Press the openings of the piston ring and the oil ring side rail with the
piston in the position shown in the diagram, and measure the opening
gaps in this position.
Standard value
No. 1 0.20 – 0.30 mm
No. 2 0.35 – 0.45 mm
Oil ring 0.10 – 0.40 mm
Standard value
No. 1 0.8 mm
No. 2 0.8 mm
Oil ring 1.0 mm
Press with piston
Opening gap
Piston ring

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)
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264G6 – 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, and the identifier on the
cylinder block bearing is 1, then a bearing with identification mark 1
should be chosen.
If the identifier on the crankshaft is difficult to make out, measure the
diameter of the journal and choose the bearing that corresponds to the
measured diameter.
Crankshaft journal diameter
Identification mark Journal
diameter (mm)Cylinder
block bearingCrankshaft
bearing
00
11
056.994~57.000
22
00
11
156.988~56.994
22
00
11
256.982~56.988
22
2. Install grooved bearing on cylinder block side.
3. Install bearing without oil groove on bearing cap side.
Position of crankshaft journal diameter identification marks
Timing belt
Cylinder block bearing hole diameter
identification mark
Cylinder
bore size
mark
Position of crankshaft bearing size
identification mark
Identification mark
Groove
Lower bearingUpper bearing
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274G6 – TURBOCHARGER
Turbocharger
Disassembly and Reassembly
Disassembly Procedure
1. Snap pin
2. Waste gate actuator
3. Cap ring
4. Turbine housing
5. Snap ring
6. Cartridge assembly
7. Compressor cover
8. O ring

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Service Manual
Electrical Wiring Diagrams