2005 MITSUBISHI LANCER EVOLUTION IX engine coolant

ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL11 - 4
Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting
Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools
because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it
should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
ToolNumberNameFunction
MB991454Engine hanger
balancerHolding the engine assembly while the
transmission assembly is removed/installed
Recommended
tools MZ203830
panzai or
MZ203831 safe
vehicle handlingMechanical engine
hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934Engine hanger
A: joint (50) x2
B: joint (90) x2
C: joint (140) x2
D: Foot (standard) x4
E: Foot (short) x4
F: Chain and hook
ASSYSlide bracket (HI)

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14



O 
Fitting the O-ring/oil feeder control valve
Caution
1. 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 feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Check the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape

ENGINE – CYLINDER HEAD GASKET
11-17
Removal guidelines



A 
Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn
the bolts 2~3 times in order to loosen them, before removing them
in the numerical order as shown in the diagram.
Fitting guidelines



A 
Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of
the gasket.
Caution
Do not allow any foreign matter to get into the channels for
coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the
holes in the cylinder head gasket match up with the holes in the
cylinder head.



B 
Fitting the cylinder head bolts
1. Check that the length of the body of cylinder head bolts is less
than the maximum permitted. If the length is in excess of the
maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the
bolt, and to the washer.
Front of engine
(engine oil)

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11.Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking.
•Check for fuel dripping.
•Removal and refitting of the bonnet.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Checking the tension of the drive belt.
•Adjustment of the axle letter cable.
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.

ENGINE COOLING – WATER PUMP14-2
Water pump
Removal and fitting
Jobs to be completed before removal and after fitting
•Draining and refilling of the coolant
•Removal and refitting of the timing belt (Ref Section 11)
Removal procedure
1. Alternator bracket
2. Water pump
3. Water pump gasket
4. O-ring
Fitting guidelines



A 
Fitting the O-ring
Fit the O-ring into the O-ring groove at the end of the water inlet
pipe, and insert it into the water pump after moistening with water
the places where the O-ring will make contact with the water pump.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.
Positions for fitting different sized bolts
Nominal diameter and nominal length (mm)



A 
water pump
O-ring
water inlet pipe

ENGINE COOLING – WATER HOSE AND PIPE
14-3
Water hose and pipe
Removal and fitting
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence
•Draining and refilling of the water coolant
•Removal and refitting of the air cleaner ASSY
•Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C
•Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system)
Removal procedure
1. Connection to the radiator upper hose
2. Connection to the radiator lower hose
3. Water temperature gauge unit connector
4. Water temperature sensor connector
5. Water hose
6. Bracket
7. Water outlet fitting and thermostat case
ASSY
8. Thermostat case gasket
9. Connection to the knock sensor harness
clamp
10. O-ring
11. Water hose12. Water hose
13. Connection to the heater hose
14. Water hose
15. Water inlet pipe
16. O-ring
17. Turbocharger water feed pipe
18. Gasket
•Turbocharger ASSY
19. Turbocharger water return pipe
20. Gasket
 
A






B 
 
A






B 



A 




A 



A 

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)

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