2005 MITSUBISHI LANCER EVOLUTION IX transmission

Related materials

Title No. IssuedateTitle No. Issue
date
New model manuals Body edition service manual
• Lancer Sedia 1036K30 2000/5 • Lancer Sedia 1036K50 2000/5
• Lancer Sedia 1036K31 2000/7 • Lancer Sedia (supplement) 1036K51 2000/7
• Lancer Evolution VII 1036K32 2001/1 • Lancer Evolution VII 1036K52 2001/5
• Lancer Sedia 1036K33 2001/5 (supplement)
• Lancer Sedia 1036K34 2001/5 • Lancer Sedia (supplement) 1036K53 2001/10
• Lancer Evolution VII 1036K35 2002/1 • Lancer Evolution VII _MR 1036K54 2004/2
• Lancer Sedia 1036K36 2002/5 (supplement)
• Lancer Evolution VII 1036K37 2003/1
• Lancer 1036K38 2003/2
• Lancer 1036K39 2003/12 Electrical wiring service manual
• Lancer Evolution VII _MR 1036K40 2004/2 • Lancer Evolution IX 1036K82 2005/3
• Lancer* 1036K41 2004/3
• Lancer 1036K42 2005/1
• Lancer Evolution IX 1036K43 2005/3
Service manuals Engine service manual
• Lancer Sedia 1036K00 2000/5 • 4G6 engine 1039G46 2001/1
• Lancer Sedia
(supplement) 1036K01 2000/7 • 4G6 engine (supplement) 1039G63 2003/1
• Lancer Evolution VII 1036K02 2001/1 • 4G6 engine (supplement) 1039G71 2003/3
(supplement)
• Lancer Sedia
(supplement) 1036K03 2001/5
• Lancer Sedia
(supplement) 1036K04 2001/10
• Lancer Evolution VII 1036K05 2002/1 Transmission service manuals
(supplement) • W5M51 manual transmission 1039M17 2001/1
• Lancer Sedia
(supplement) 1036K06 2002/5 • W5M51 manual transmission 1039M22 2003/1
• Lancer Evolution VII 1036K07 2003/1 (supplement)
(supplement) • WGMAA manual transmission 1039M23 2003/1
• Lancer Sedia
(supplement) 1036K08 2003/2
• Lancer Sedia
(supplement) 1036K09 2003/12
• Lancer Evolution VII MR 1036K10 2004/2
• Lancer* 1036K41 2004/3
• Lancer 1036K11 2005/1
*Indicates where the new model manual was published with the service man\
ual in a single volume.
W
ARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
W arning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fi\
tted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitt\
ed seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensio\
ner fitted seatbelts and the clock spring, should be removed if there is a chance o\
f them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be rem\
oved.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-\
SRS air bags) has been carefully studied.

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 – CYLINDER HEAD GASKET
11-15
Removal procedure
1. Ignition coil connector
2. O
2sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position sensor connector
10. Injector connector
11.Exhaust camshaft position sensor
connector12. Inlet camshaft position sensor
connector
13. Water temperature gauge unit
connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Secondary air control solenoid valve
connector
17. Vacuum tank, solenoid valve, vacuum
pipe and hose assembly
18. Brake booster vacuum hose connection
19. Oil level gauge and guide assembly
20. O-ring
21. Purge hose connection
(engine oil)

ENGINE – ENGINE ASSY
11-29
Removal procedure
1. Ignition coil connector
2. O
2sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position connector
10. Injector connector11.Exhaust cam position sensor connector
12. Inlet cam position sensor connector
13. Water temperature gauge unit connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Alternator connector and terminal
17. Secondary air control solenoid valve
connector
18. Engine oil pressure switch connector
19. Drive belt
 
A

ENGINE – ENGINE ASSY11-30
Caution
Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is
being supported by the chassis.
20. Vacuum tank, solenoid valve, vacuum
pipe and hose ASSY
21. Brake booster vacuum hose connection
22. Purge hose connection
23. Power steering oil pressure switch
connector
24. Heat protector
25. Power steering oil pump
26. A/C compressor connector

27. A/C compressor A/C>28. Heater hose connection
29. Fuel return hose connection
30. Fuel high pressure hose connection
31. O-ring
•Transfer ASSY, transmission ASSY
32. Engine mount bracket & stopper ASSY
33. Engine ASSY
 
B


 
B






D 



D 
 
C






C 
 
D






B 
 
E






A 
(engine oil)

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 – ENGINE ASSY
11-33



B 
Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
(1) (MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2)
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)



C 
Fitting the transfer ASSY and the transmission ASSY
1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).engine sideengine side
engine mount stopper
rear of chassis> front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)

GENERAL INFORMATION - HOW TO READ THE WIRING DIAGRAMS0-3
Reading Layout Diagrams
The wiring layout diagrams give a clear and simple illustration of the connector positions and the routing of the wiring
harnesses at different points in the actual vehicle.
Indicates connector number.
The same connector number is used in the circuit diagrams, so that connector positions can be located easily.
The initial letter indicates the installation position of the connector, and the number that follows is the unique number for that
connector. In principle, the connectors are numbered in clockwise order in each layout diagrams, starting from the top left-hand side.
Example : A – 19Unique connector number (serial number)
Connector location code
A: Engine compartment D: Floor / Roof
B: Engine / Transmission E: Door
C: Instrument panel F: Tail gate
Indicates earth point.
The same earth numbers are used in the circuit
diagrams, so earth points can be located easily.
For details of earth points, refer to Section 2,
"Individual Part Installation Positions – Earth".
Indicates name of harness
Shows section covered with
corrugated tube.
The * symbol shows a standard
harness mounting point.
Indicates the external colour of the harness.
(Black, unless specified otherwise.)
R : Red
Y: Yellow
The number of connector pins and the connector colour (except
cream colour)* are indicated, so that they can be located easily.
Example : 2 – Black
*^: Typical connector colours:
Black, grey, red, blue, yellow, green, brown, etc.
Colour of connector pins(Cream colour, unless specified
otherwise)
Number of connector pinsA-15 (2) Fog lamp (RH)
A-16 (2-Black) Windshield washer motor
A-17 (2-Black) Headlamp (RH)
A-18 (2-Brown) Horn (LO)
A-19 (2-Green) Dual pressure switch
Indicates the device to which the
connector is connected.
Front
harness