2005 MITSUBISHI LANCER EVOLUTION IX key

ENGINE – ENGINE ASSY
11-31
Removal guidelines
 
A


Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, 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.
 
B


Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
 
C



Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
AholeB hole
L-shaped
hex-
agonal
Allen
wrench

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

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
*

* * 1


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* * 1

* * 1

* * 1

* * 1


* * 1 
* 1
* 
* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
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* 1
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* 1
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*

* A


* B


* A

LAYOUT DIAGRAMS - INSTRUMENT PANEL1-14
C-201 (6) Ignition switch
C-202 (7) Key reminder switch
C-203 (10) Column switch
C-204 (4-yellow) Clock spring
C-205 (6) Clock spring
C-206 (1) Horn switch
C-207 (2) Driver’s airbag module (squib)
C-208 (13) Instrument panel harness / J/B junctionC-209 (14) Instrument panel harness / J/B junction
C-210 (6) Instrument panel harness / J/B junction
C-211 (1-black) Instrument panel harness / J/B junction
C-212 (28) Instrument panel harness / J/B junction
C-213 (5) Demister relay
Instrument panel (cont’d)
Connector Symbol
Steering wheel
Clock spring
Instrument panel
harness

3-1
SECTION 3
CIRCUIT DIAGRAMS
CONTENTS
J/B ............................................................3-4
J/C ............................................................3-6
Central Junction....................................3-11
Power Supply ........................................3-18
Starting System ....................................3-23
Ignition ...................................................3-24
Charging ................................................3-26
Engine Control ......................................3-28
Cooling ..................................................3-36
Lighting
Headlights (excl. discharge type).....................3-38
Headlights (discharge type) .............................3-42
Tail lights, position lights, licence plate
lights, lighting monitor report buzzer................3-46
Cabin lights, boot compartment lights,
ignition key cylinder illumination light,
door ajar indicator light ....................................3-50
Fog lamps ........................................................3-54
Headlight levelling system ...............................3-58
Signals
Turn signal lights, hazard warning lights .........3-60
Reversing lights ...............................................3-64
Stop lights ........................................................3-65
Horn .................................................................3-66
Meters
Needle meters..................................................3-68
Remaining fuel warning light, oil pressure
warning light, brake warning light,
seatbelt warning light .......................................3-70
Door Opening / Closing Control
Power windows ................................................3-72
Central door locking
(vehicle without keyless entry) .........................3-78
Central door locking
(vehicle with keyless entry) ..............................3-80
Temperature Control
Heater ..............................................................3-86
Manual air-conditioning ....................................3-90
Fully automatic air-conditioning .......................3-96
Vision / Safety
Windscreen washer / wipers ..........................3-104
Rear washer / wiper .......................................3-108
Demister
(vehicle with heater or manual A/C) ...............3-110
Demister, door mirror heating elements
(vehicle with full auto A/C)..............................3-112
Electric stowable remote control
door mirrors ....................................................3-114
Accessories
Spare audio connectors .................................3-118
Clock ..............................................................3-120
Cigarette lighter, ashtray illumination lamp ....3-121
Cont. on next page

3-2
Equipment
ABS ................................................................3-122
ACD (vehicle without AYC) ............................3-130
ACD, AYC ......................................................3-138
SRS airbags, seatbelt pre-tensioners
(vehicle without front passenger airbag)........3-148
SRS airbags, seatbelt pre-tensioners
(vehicle with front passenger airbag).............3-152Sunroof ..........................................................3-154
Ignition key reminder buzzer..........................3-157
Intercooler water spray ..................................3-158
Engine immobilizer system ............................3-160
Security alarm ................................................3-162
Spare connector for fog lamp ........................3-167
Generic spare connectors..............................3-168

CIRCUIT DIAGRAMS - J/C3-7
• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer•Fog lamps
•Full auto A/C
•Headlights
•Headlight
levelling
system
•Manual A/C
•Cooling
• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer
• Fog lamps
• Headlights• Ignition key
reminder
buzzer
• Windscreen
washer / wiper
• Sunroof
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer• Power windows
• Fog lamps
• Headlight
• Rear washer /
wiper Generic spare
connector
Vehicle speed
sensor• Windscreen washer /
wiper
• Electric stowable
remote control door
mirrors
• Cabin lights, boot
compartment lights,
ignition key cylinder
illumination light, door
ajar indicator light
Diagnosis
connector• ABS
• ACD
(vehicle
w/out AYC)
• ACD, AYC Needle meters• Heater
• Full auto A/C
• Manual A/C
J/B
Sunroof
Power
windows• Windscreen
washer / wiper
• Turn signal
lights, hazard
lights
• Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer
• Fog lamps
• Headlights
• Rear washer /
wiperDiagnosis
connectorReversing
lights
Rear washer/
wiper• Reversing lights
• Rear washer /
wiper Generic
fuse
(
)

CIRCUIT DIAGRAMS - J/C3-8
J/C (cont’d)
•Ignition key
reminder
buzzer
•Windscreen
washer / wiper
•Sunroof
•Security alarm
•Central door
locking
•Turn signal
lights, hazard
lights•Tail lights,
position lights,
licence plate
lights, lighting
monitor
warning buzzer
•Electric
stowable
remote control
door mirrors
•Power
windows
•Heater
•Fog lamps•Full auto A/C
•Headlights
•Manual A/C
•Rear washer /
wiper
•Cabin lights,
boot
compartment
lights, ignition
key cylinder
illumination
light, door ajar
indicator light•Ignition key reminder buzzer
•Intercooler water spray
•Security alarm
•Central door locking (vehicle
with keyless entry)
•Cabin lights, boot
compartment lights, ignition
key cylinder illumination light,
door ajar indicator light
•Warning lights
•Starting system
Electric stowable
remote control
door mirror
Headlight
levelling
system
•ABS
•ACD
(vehicle
w/out AYC)
•ACD, AYC•Clock
•Turn signal
lights,
hazard lights
Fog lamps
Headlight
levelling systemFog lamps
Cigarette
lighter
illumination
light•Demister (vehicle
w/out full auto A/C)
•Demister, door
mirror heating
elements (vehicle
with full auto A/C)
•Heater
•Full auto A/C
•Manual A/C•ACD (vehicle
w/out AYC)
•ACD, AYC
Intercooler
water spray
Turn signal lights,
hazard lightsNeedle meters