2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (Evo VII-IX) Generation: Eighth Generation (Evo VII-IX) Model Years Covered: 2003, 2004, 2005 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS Key Features Powertrain: Advanced All-Wheel Drive (AWD) system (S-AYC), turbocharged engine Performance: Renowned for rally racing heritage and exceptional handling Tuning Potential: High potential for aftermarket modification and performance tuning 📋 Manual Details Coverage Areas Engine Mechanical: Yes Engine Performance: Yes Fuel System: Yes Emission Control: Yes Transmission Manual: Yes Transmission Automatic: Yes (if applicable to specific models covered) Transfer Case: Yes Drivetrain AWD: Yes Suspension Front: Yes Suspension Rear: Yes Steering: Yes Brakes Hydraulic: Yes Brakes Parking: Yes Wheels Tires: Yes Body Exterior: Yes Body Interior: Yes HVAC Climate Control: Yes Electrical System Lighting: Yes Electrical System Instruments: Yes Electrical System Power Accessories: Yes Audio Entertainment: Yes Security Alarm Immobilizer: Yes Driver Assistance Systems: Yes Troubleshooting Diagnostics: Yes Wiring Diagrams: Yes Torque Specifications: Yes Maintenance Procedures: Yes Repair Procedures: Yes Disassembly Assembly: Yes Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered All Major Systems: Comprehensive coverage of all major vehicle systems Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Diagnostics: Systematic troubleshooting guides, fault code interpretation, diagnostic tool usage Repair: Detailed step-by-step repair instructions for all major components Rebuilds: Engine, transmission, and differential rebuild procedures Adjustment Calibration: Alignment, sensor calibration, clutch adjustment Technical Depth Depth: Factory-level detail suitable for professional technicians and advanced DIY enthusiasts Diagnostic Codes: Includes specific OBD-II diagnostic trouble codes (DTCs) and their meanings Electrical Troubleshooting: In-depth electrical troubleshooting utilizing wiring diagrams and component testing 📊 Manual Specifications File Format Searchable: Yes (typically searchable PDF) Printable: Yes Print Quality Quality: High-resolution, clear text and diagrams Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (various iterations) Engine Type: Inline-4, DOHC, 16-valve, Turbocharged & Intercooled Displacement: 2.0 Liters (1997 cc) Performance Horsepower Range: Approx. 271 hp to 286 hp (depending on specific Evo VII, VIII, IX model and market) Torque Range: Approx. 273 lb-ft to 289 lb-ft (depending on specific Evo VII, VIII, IX model and market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Port Fuel Injection (MPFI) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Turbocharger Turbo Model: Mitsubishi Heavy Industries (MHI) TD04-15G, TD05-16G, or similar, depending on variant 🔧 Transmission Standard Type: 6-Speed Manual Transmission (Getrag MSF-100) Optional Type: No Automatic Transmission option for these performance-oriented models Features Drivetrain: Advanced Symmetrical All-Wheel Drive (AWD) with Active Center Differential (ACD) Torque Vectoring: Super Active Yaw Control (S-AYC) rear differential on many models 📐 Dimensions Exterior Length: Approx. 4,490 mm (176.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight Range: Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs) Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size: Typically 17x8.0 or 18x8.5 inches 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star (for similar models of the era, specific ratings may vary by year and test) IIHS Side Impact: Good (for similar models of the era, specific ratings may vary by year and test) Active Features ABS: Yes, with EBD (Electronic Brakeforce Distribution) Traction Control: Yes (Active Traction Control - ATC) Electronic Stability Control: Yes (Active Stability Control - ASC) Passive Features Airbags Driver: Yes Airbags Passenger: Yes Seatbelts: 3-point front and rear seatbelts with pretensioners Body Structure: Reinforced body structure for enhanced impact protection 💡 Technology Features Infotainment Head Unit: Factory CD Player with AM/FM Radio, some models may have upgraded Rockford Fosgate audio systems. Navigation: Optional GPS Navigation system available on some higher trims. Driver Assistance All Wheel Drive System: Advanced AWD with ACD and S-AYC offering selectable modes (Tarmac, Gravel, Snow) Performance Controls: Driver-selectable ACD modes, ACD/AYC status indicators Connectivity Auxiliary Input: Some models may feature an auxiliary audio input jack. 🔧 Maintenance Service Intervals Oil Change: Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use) Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months Spark Plugs: Every 30,000 miles (48,000 km) (Platinum or Iridium recommended) Timing Belt: Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T) Fluid Specifications Engine Oil: API SN/SM/SL, ACEA A3/B4, Viscosity: 5W-30 or 0W-30 (check owner's manual for specific recommendations, high-performance synthetic recommended) Coolant: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix) Transmission Fluid Mt: GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil) Transfer Case Fluid: GL-4 (75W-85W...
Mitsubishi Heavy Industries (MHI) TD04-15G, TD05-16G, or similar, depending on variant
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission (Getrag MSF-100)
Optional
Type:
No Automatic Transmission option for these performance-oriented models
Features
Drivetrain:
Advanced Symmetrical All-Wheel Drive (AWD) with Active Center Differential (ACD)
Torque Vectoring:
Super Active Yaw Control (S-AYC) rear differential on many models
📐 Dimensions
Exterior
Length:
Approx. 4,490 mm (176.8 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,630 mm (103.5 in)
Weights
Curb Weight Range:
Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs)
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size:
Typically 17x8.0 or 18x8.5 inches
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star (for similar models of the era, specific ratings may vary by year and test)
IIHS Side Impact:
Good (for similar models of the era, specific ratings may vary by year and test)
Active Features
ABS:
Yes, with EBD (Electronic Brakeforce Distribution)
Traction Control:
Yes (Active Traction Control - ATC)
Electronic Stability Control:
Yes (Active Stability Control - ASC)
Passive Features
Airbags Driver:
Yes
Airbags Passenger:
Yes
Seatbelts:
3-point front and rear seatbelts with pretensioners
Body Structure:
Reinforced body structure for enhanced impact protection
💡 Technology Features
Infotainment
Head Unit:
Factory CD Player with AM/FM Radio, some models may have upgraded Rockford Fosgate audio systems.
Navigation:
Optional GPS Navigation system available on some higher trims.
Driver Assistance
All Wheel Drive System:
Advanced AWD with ACD and S-AYC offering selectable modes (Tarmac, Gravel, Snow)
Performance Controls:
Driver-selectable ACD modes, ACD/AYC status indicators
Connectivity
Auxiliary Input:
Some models may feature an auxiliary audio input jack.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use)
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plugs:
Every 30,000 miles (48,000 km) (Platinum or Iridium recommended)
Timing Belt:
Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T)
Fluid Specifications
Engine Oil:
API SN/SM/SL, ACEA A3/B4, Viscosity: 5W-30 or 0W-30 (check owner's manual for specific recommendations, high-performance synthetic recommended)
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix)
Transmission Fluid Mt:
GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)
Transfer Case Fluid:
GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)
Rear Differential Fluid Lsd:
GL-5 (75W-90 or 80W-90) API GL-5 compliant with LSD additive (e.g., DiaQueen LSD Gear Oil)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
4G63T engine generally robust, but can suffer from rod bearing failure under high load/poor maintenance. Turbocharger lifespan can be affected by oil quality and heat cycling.
Drivetrain Wear:
S-AYC system can develop issues; ACD pump can fail. Clutch wear is normal for spirited driving.
Rust Corrosion:
Can be prone to rust, especially around wheel wells and sills, if not properly maintained or living in corrosive environments.
Suspension Components:
Bushings and ball joints can wear over time, leading to imprecise handling.
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Direct lineage from Mitsubishi's successful WRC (World Rally Championship) program
Model Evolution
Eighth Generation:
Built on the Lancer Cedia platform, significantly re-engineered for performance
Evo Vii:
Introduction of Active Center Differential (ACD) and Active Yaw Control (AYC) integration
Introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system for improved power and efficiency, updated turbocharger (IX MR featured twin-scroll turbo)
Production
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Years:
2001-2007 (Evo VII: 2001-2003, Evo VIII: 2003-2005, Evo IX: 2005-2007)
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
Eighth generation Lancer Evolution models were frequently recognized on Car and Driver's '10Best' lists.
Enthusiast Following:
Cult following among automotive enthusiasts for its performance and rally heritage.
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