2005 MITSUBISHI LANCER EVOLUTION IX engine oil

ENGINE COOLING – WATER HOSE AND PIPE14-4
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-ring into the groove at the end of the water inlet pipe, and
insert it after moistening with water the places where the O-ring and
the water inlet pipe will be in contact.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.



B 
Connecting the radiator lower hose and the radiator
upper hose
1. Insert the hose as far as the protrusion on the water inlet pipe
and the water outlet fitting.
2. Match up the indicator marks on the radiator hose and the hose
clamp, and fit the radiator hose.
indicator marks
water pump and
thermostat case
O-ring
water inlet pipe
protrusion
water inlet pipe and
water outlet pipe fittingindicator marks

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD15-5
Fitting guidelines



A 
Fitting the gasket
Fit the gasket so that the protruding part points in the direction
shown in the diagram.
Inlet manifold
Removal and fitting
Jobs to be completed before removal and
after fitting
•Take measures to prevent fuel leaking (only
before removal)
•Removal and refitting of the valence (Ref
Section 15: Front bumper)
•Draining and refilling the coolant
•Removal and refitting of the air duct•Removal and refitting of the strut tower bar
•Removal and refitting of the throttle body
•Removal and refitting of the secondary air
control valve (Ref P15-4)
•Removal and refitting of the cross member bar
•Removal and refitting of the front exhaust pipe
protruding
part
(engine oil)
(engine oil)

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 MANIFOLD15-10



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 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

Service Manual
4G6
FOREWORD
This manual contains information about the 4G6
DOHC engine. It only covers those points that are
different from the service manuals listed below.
Therefore, this manual should be used in conjunction
with the following manuals.
• 4G6 DOHC engine Service Manual (No. 1039G46)
• 4G6 DOHC engine Service Manual Supplement
(No.1039G63)
This manual is based on the engine specifications as of
March 2005. Please note that some engine details may
not match those given in this manual due to
subsequent changes in engine specifications. The units
shown in this manual are the standard international
SI units.
(However, conventional units are used for some figures
taken from existing documents)
If you have any opinions, requests or queries regarding
this manual, please write them down on the “Servicing
Comment Form” on the last page, and fax them to us.
March 2005
Mitsubishi Motor Corporation
This manual is printed on recycled paper.
CONTENTS
General Information . . . . . . . . . . . . . . . 4
Servicing Specification Values . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator / Ignition system . . . . . . . . . 8
Timing belt . . . . . . . . . . . . . . . . . . . . . 10
Fuel system . . . . . . . . . . . . . . . . . . . . . 13
Secondary air system /
inlet manifold . . . . . . . . . . . . . . . . . . . 15
Exhaust manifold . . . . . . . . . . . . . . . . 16
Water pump / Water hose . . . . . . . . . 17
Rocker arm / Cam shaft . . . . . . . . . . . 18
Oil pump / Sump . . . . . . . . . . . . . . . . . 21
Pistons / Connecting rods . . . . . . . . . 22
Crank shaft / Cylinder block . . . . . . . 25
Turbocharger. . . . . . . . . . . . . . . . . . . . 27
DOHC
ENGINE

2HOW 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 on
removing the engine from the vehicle, or "on-vehicle" servicing of the engine, please refer to the separate service manual for
the relevant vehicle model.
Understanding the description
Inspection
The manual only indicates inspection points where special tools or measuring devices are required. It does not mention general
visual checks, part cleaning requirements, and so on, but these must also be carried out as part of the actual service work.
Service sequence
(1) A component diagram is provided at the beginning of each section in order to give the reader a clear
understanding of where the various parts are installed.
(2) The numbers in the component diagram indicate the sequence of the service procedure. Tightening torques
are shown and non-reusable parts are indicated where appropriate
Removal sequence:The part numbers correspond to the numbers in the component diagram and indicate
the removal sequence.
Installation sequence:This is only shown if the parts cannot be installed in the reverse order to the removal
sequence.
Disassembly sequence: The numbers of the part names correspond to the symbols in the component
diagram and indicate the disassembly sequence.
Assembly sequence:This is only shown if the parts cannot be re-assembled in the reverse order to the
disassembly sequence.
Symbols for lubricants and sealants
Application points for lubricants and sealants are
indicated by special symbols (shown right) on the
component parts diagram or on the following page............... Grease
.............. Sealant or liquid gasket (FIPG)
.............. Brake fluid
.............. Engine oil
Types of service points
“Service point” notes are used to give a detailed
description of essential maintenance and service
points, standard values, procedures for using special
tools, and other important information at relevant
points in the service sequence. The different types
of “service point” are shown on the right-hand side.: Indicates that there is a removal or
disassembly service point
: Indicates that there is an installation or
assembly service point
: Indicates that the removal or disassembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the removal or disassembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.

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