Mitsubishi MOTORS Lancer Evolution IX 2005 Instruction manual

LANCER
Evolution - IX
• Chassis
• Engine
• Wiring Diagrams

SERVICE MANUAL
Supplement

LANCER
EVOLUTION IX
FOREWORD
This manual contains details of the main changes to the
2005 model Lancer Evolution IX. Only differences to the
current Lancer Evolution VIII MR are included, so please use
this manual in conjunction with the related manuals as listed
on the following page.
Please read this manual carefully so that servicing can be
done correctly and quickly, and vehicle performance
maintained.
This manual is based on the current (March 2005) model.
Please bear in mind that vehicle specifications may change
and that future models may not be the same.
Please note that all the units shown in this manual follow the
internationally recognized SI unit system, and that the used
previously are not shown alongside the SI units.
(Nevertheless, please take care because units in reference
documents may be shown in the units which were previously
used).
March 2005
MITSUBISHI MOTOR CORPORATION
CONTENTS
General ........................................................
Engine .........................................................
Fuel ..............................................................
Engine Cooling ...........................................
Intake and Exhaust ....................................
Engine Electrical ........................................
Rear axle .....................................................
Wheels and tyres........................................
Front suspension ...............................................Body
Body.......................................................................
Exterior........................................................
Interior and SRS Airbag.............................N
Chassis Electrical.........................................
This manual is printed on recycled paper
00
11
13
14
15
16
27
31
33
42
51
52
54
Any opinions, requests or questions concerning this manual,
should be written on the ‘Servicing Comments Form’ at the
end of the manual, and sent to us by fax.

Related materials
Title No. Issue
date
Title 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 manual in a single volume.
WARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
Warning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fitted seatbelt component, or related parts,
could cause serious injury through the SRS air bag or pre-tensioner fitted 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-tensioner fitted
seatbelts and the clock spring, should be removed if there is a chance of 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 removed.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt 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 seatbelt components, or related parts, must
only be undertaken after this service manual (specifically Section 52B-SRS air bags) has been carefully studied.

CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL
54A-1
52B-1
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
Acaution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
bonnet
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.

<Notes>

CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL
54A-1
52B-1
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
Acaution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
bonnet
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.

<Notes>

EXTERIOR – GENERAL 51-1
SECTION 51
EXTERIOR
CONTENTS
General........................................................1
Front bumper..............................................2
Front bumper.......................................................2
Rear bumper...............................................4
Rear bumper ........................................................4
Markings .....................................................6
General
Servicing guidelines have been changed in conjunction with the changes or additions listed below.
Other servicing guidelines remain unchanged.
•Changes made to the shape and component of the front bumper.
•Changes made to the shape and component of the rear bumper.
•Changes made to the method for affixing the front 3-diamonds badge.
•Changes made to the position for affixing the LANCER badge and the EVOLUTION badge.

EXTERIOR – FRONT BUMPER
51-2
Front bumper
Front bumper
Removal and fitting
Removal procedure
1. Side valence
2. Centre valence
3. valence centre bracket
4. Front valence
5. Clip for attaching the splash shield
•Inter-cooler water spray hose connection
(Ref Section 15)
6. Front bumper ASSY
7. Front bumper stay
Cross section through A-A
clip
clip
Cross section through B-B
Cross section through C-C
cap
bumper

EXTERIOR – FRONT BUMPER 51-3
Dismantling and assembly
Dismantling procedure
1. Front 3-diamonds badge
2. Front bumper nut
3. Front number plate garnish
4. Front bumper cover A
5. Front bumper cover B
6. Air dam skirt panel
7. Front bumper centre net
8. Front bumper lower plate
9. Front bumper upper plate
10. Front bumper upper support
11.Air intake cover
12. Front bumper net
13. Bumper side net (LH)
14. Oil cooler duct
15. Bumper side net (RH)
•Inter-cooler water spray hose and nozzle
(Ref Section 15)
16. Front bumper side plate
17. Front bumper upper reinforcement
18. Front bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
Cross section through A-A
hook
Cross section through B-B
clip
!!A""""A!!

EXTERIOR – FRONT BUMPER, REAR BUMPER
51-4
Rear bumper
Rear bumper
Removal and fitting
Jobs to be completed before removal and after fitting
•Removal and refitting of the rear combination lamp
•Removal and refitting of the rear end trim
•Removal and refitting of the boot area side trim lid
Removal procedure
1. Screw for attaching the splash shield
2. Rear bumper bracket
3. Rear bumper ASSY
4. Rear number plate bracket
Cross section
through A-A
clip
splash
shield

EXTERIOR – REAR BUMPER 51-5
Dismantling and assembly
Dismantling procedure
1. Number plate lamp bracket
•Number plate lamp ASSY
2. Rear bumper reinforcement
3. Rear bumper side plate
4. Rear bumper facing support, side
reinforcement
5. Rear bumper valence
6. Rear bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
!!A""""A!!
!!A""""A!!

EXTERIOR – MARKINGS
51-6
Markings
Removal and affixing
1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge
3. EVOLUTION badge
Guidelines for affixing markings
""A!!Affixing markings
1. Positioning
2. Guidelines for affixing
(1) Using white spirit, remove any grease from the place where the
badges will be affixed.
(2) Remove the protective paper from the back of the badges, and
affix them in the designated places.
Caution
1) Perform this job in an ambient temperature of 20~38ºC, and
in a dust free location.
2) If the job is being performed in an ambient temperature of
less than 20ºC, warm up the badges, and the area of the
body onto which they will be affixed, to a temperature of
20~38ºC.
3) Ensure that air bubbles are not trapped in the adhesive tape
when the badges are affixed.
""A!!
""A!!
2. LANCER badge 3. EVOLUTION badge
edge of boot lid

BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP 42-1
SECTION 42
BODY
CONTENTS
General........................................................1 Window glass channel, door-opening
weather strip <GT, GSR>...........................1
General
Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain
unchanged. <GT, GSR>
•Addition of front door opening inner lower weather strip
•Addition of front and rear door opening inner weather strip
Window glass channel, door-opening weather strip
<GT, GSR>
Removal and fitting
<front door> <rear door>
Note
: position of clips
Cross section A – A
front door trim
clip
Removal of the front door opening inner
lower weather strip
1. Front door opening inner lower weather
strip
Procedure for removing the front door
opening inner weather strip
•Front scuff plate
•Cowl side trim
•Lower centre pillar trim
2. Front door opening inner weather strip
Procedure for removing the rear door
opening inner weather strip
•Rear scuff plate
•Lower centre pillar trim
3. Rear door opening inner weather strip

<Notes>

FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY 33-1
SECTION 33
FRONT SUSPENSION
CONTENTS
General........................................................1
Special tools...............................................1
Strut ASSY..................................................1
General
The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the
shape of the Bilstein shock absorbers.
Special tools
Tool Number Name Function
A: MB991237
B: MB991238
A. Spring compressor body
B. Arm set
Dismantling and assembling
the strut ASSY
MB991680
A: MB991681
B: MB991682
Wrench set
A. Wrench
B. Socket
Strut ASSY
Dismantling guidelines
!!A""Removal of the self-locking nut
1. Use the following special tools to compress the coil spring.
• Spring compressor body (MB991237)
• Arm set (MB991238)
Caution
(1) In order to completely compress the coil spring, ensure that
the special tool is fixed when at its greatest possible
extension and that it is fixed evenly to the coil spring.
(2) Do not use an impact wrench, because there is a danger
that the special tool may be damaged.

FRONT SUSPENSION – STRUT ASSY
33-2
pipe
2. Use the following tools to loosen the self-locking nut.
•Wrench (MB991681)
•Socket (MB991682)
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.
Assembly guidelines
""A!!Fitting the self-locking nut
1. Check that the bearing has completely slotted in.
2. When the coil spring has been compressed using the special
tool, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench because there is a danger that
the special tool may be damaged.
3. Align the holes in the lower spring plate and the upper spring
plate of the strut ASSY.
Note
This operation can be easily performed by using a pipe to align
the holes.
4. Line up the two ends of the coil spring with the slots in the
spring plate, and loosen the special tool.
5. Use the following special tools to tighten the self-locking nut to
the specified tightening torque.
•Wrench (MB991681)
•Socket (MB991682)
Tightening torque: 60 ± 10 N·m
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.

TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING 31-1
SECTION 31
WHEELS AND TYRES
CONTENTS
General........................................................1
On-vehicle servicing..................................1
Removal of emergency puncture repairing agent....1
Disposal of emergency puncture repairing agent ....2
General
The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.
On-vehicle servicing
Removal of emergency puncture repairing
agent
When repairing or replacing a tyre which has been treated using the
puncture repair kit, remove the emergency puncture repairing agent
(henceforth, repairing agent) from the tyre, in accordance with the
guidelines below.
Note
When removing the repairing agent, a container (the empty bottle
which contained the repairing agent), and the insertion hose and the
extraction hose from the emergency puncture repair kit, are needed.
Caution
1. Carry out the operation in a well-ventilated, airy place.
2. Take appropriate measures in order to prevent repairing
agent; getting onto the skin, being inhaled, coming into
contact with clothing, or getting into the eyes.
3. After the job has been completed, wash hands and face
thoroughly.
1. Remove the wheel from the vehicle, and remove the air from the
tyre.
2. Cut away the rubber part of the valve using a cutter-knife.
3. Attach the injection hose to the empty repairing agent bottle, and
then attach the extraction hose onto the injection hose.
empty bottle of
repairing agent
injection
hose
extraction
hose
valve

TYRES AND WHEELS – ON-VEHICLE SERVICING
31-2
4. Put the tyre on a raised surface and tilt it to an angle. Insert the
extraction hose through the hole made by removing the valve,
so that the tip of the hose is submerged in the repairing agent.
5. Hold the bottle so that it is, as far as possible, below the tyre,
and suck the repairing agent out of the tyre by squeezing the
bottle by hand. Repeat this operation 2 or 3 times, so that as
much of the repairing agent as possible is removed.
6. After the repairing agent has been extracted, remove the tyre
from the wheel. Remove any repairing agent stuck onto the
tyre, and if the place from which air is escaping can be
identified, carry out a normal repair procedure. If the place from
which air is escaping cannot be identified, replace the tyre.
Disposal of emergency puncture repairing
agent
Dispose of the repairing agent extracted from the tyre, and any
unused agent which has exceeded its use-by date, in the same way
that used oil is discarded.
Note
The use-by date is printed on the bottle of repairing agent (about 3
years from the date of purchase)
Caution
The repairing agent includes propylene glycol which must be
handled as industrial waste.
extraction hose
raised surface
repairing
agent
extraction hose
injection hose
bottle