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Mitsubishi LANCER EVOLUTION EVO 9 IX Service Repair Workshop Manual 2005 2006 2007

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Nickname: Evo 9 Codes Platform: Mitsubishi GS platform (derived from Lancer C10/C60/C70) Chassis Code: CT9A 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Reputation: Legendary performance, rallying heritage, advanced drivetrain technology. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (performance variants) Key Features Vehicle Performance Focus: All-wheel drive, turbocharged engine, advanced differentials, potent braking system. Rally Heritage: Direct descendant of Mitsubishi's World Rally Championship (WRC) lineage. Key Features Manual Value Proposition: Essential resource for owners and technicians seeking accurate, detailed repair and maintenance information. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007 Page Count Estimated Pages: Approx. 2000-3000+ pages (typical for comprehensive workshop manuals) Manual Type Type: Factory Service Manual / Workshop Repair Manual Language Language: English Format Format: Digital (likely PDF, potentially searchable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair (4G63 MIVEC) Engine Electrical: Ignition system, fuel injection system, emission control system, starter, alternator, sensors Fuel System: Fuel pump, injectors, fuel lines, EVAP system Cooling System: Radiator, water pump, thermostat, cooling fan operation Lubrication System: Oil pump, oil passages, oil filter replacement Transmission Manual: 6-speed manual transmission (Type-MR), clutch system, flywheel Transmission Automatic: Not applicable to standard Evo 9 models covered by this manual Drivetrain Awc: Active Center Differential (ACD), Super Active Yaw Control (S-AYC), propeller shaft, driveshafts, differentials Suspension Front: MacPherson struts, control arms, anti-roll bar, wheel bearings Suspension Rear: Multi-link independent suspension, shock absorbers, springs, anti-roll bar Steering: Power steering system, steering rack, steering column Brakes Front: Brembo 4-piston calipers, ventilated discs, ABS system Brakes Rear: Brembo 2-piston calipers, ventilated discs, ABS system Body Exterior: Body panels, doors, hood, trunk, bumpers, fenders, aerodynamic components Body Interior: Seats, dashboard, trim panels, airbags, interior lighting Electrical Body: Lighting system (headlights, taillights, interior), power windows, central locking, mirrors, wipers, horn HVAC: Air conditioning system, heater, climate control Safety Systems: Airbags (driver, passenger, side), seat belts, SRS system Diagnostics: OBD-II troubleshooting, diagnostic trouble codes (DTCs), sensor data interpretation Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, timing belt/chain inspection Engine Repair: Head gasket replacement, piston ring replacement, valve stem seals, turbocharger inspection and repair Transmission Repair: Gearbox overhaul, synchronizer replacement, clutch replacement, differential servicing Brake Service: Brake pad and rotor replacement, caliper service, brake fluid bleeding, ABS component testing Suspension Repair: Shock absorber replacement, spring replacement, bushing replacement, wheel alignment specifications Electrical Diagnostics: Wiring diagrams, component testing, fuse and relay identification, ECU diagnostics Bodywork Repair: Panel alignment, dent repair, rust prevention, glass replacement HVAC Service: Refrigerant handling, component replacement (compressor, condenser), leak detection Troubleshooting: Symptom-based diagnostic flowcharts for various issues Torque Specifications: Detailed torque values for all critical fasteners Technical Depth Depth: Comprehensive; suitable for DIY mechanics and professional technicians. Covers everything from routine maintenance to major component overhauls. Diagnostics Level: Advanced diagnostics, including electronic system troubleshooting and component testing procedures. Rebuild Procedures: Detailed procedures for complete engine and transmission rebuilds. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Typically searchable text within PDF for quick access to information. Print Quality Print Recommendation: Printable on standard office printers. High-resolution images and diagrams. Binding Type Digital Binding: N/A (Digital Format) Paper Type Digital Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 MIVEC Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged with intercooler Displacement: 2.0 Liters (1997 cc) Performance Horsepower: 286 hp @ 6500 rpm (approx. varies by region/spec) Torque: 289 lb-ft @ 3500 rpm (approx. varies by region/spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) Fuel Type: Unleaded Premium (91+ Octane recommended) Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based) Lubrication System Oil Type: Synthetic SAE 5W-40 or 10W-40 (check manual for specific conditions) Oil Capacity: Approx. 4.5 Liters (4.8 US quarts) with filter change 🔧 Transmission Standard Type: 6-Speed Manual Transmission (Getrag Type-MR) Optional Type: Not applicable for Evo 9 (all featured manual transmission) Features Awc Integration: Integrated with ACD (Active Center Differential) and S-AYC (Super Active Yaw Control) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 synthetic gear oil (check manual for specific Mitsubishi recommendation) Clutch Type: Hydraulically actuated, multi-plate wet clutch (ACD) and single dry plate clutch 📐 Dimensions Exterior Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1450 mm (57.1 in) Wheelbase: 2625 mm (103.3 in) Weights Curb Weight: Approx. 1400-1450 kg (3086-3197 lbs) depending on trim and options Wheels Tires Wheel Size: 17 x 8.0 inch alloy (standard), 17 x 8.5 inch alloy (optional/performance trims) Tire Size: 235/45R17 (standard), 235/40R18 (optional/performance trims) Bolt Pattern: 5x114.3 mm (5x4.5 inches) 🛡️ Safety Features Ratings NHTSA Ratings: Information...
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Mitsubishi LANCER EVOLUTION EVO 9 IX Service Repair Workshop Manual 2005 2006 2007
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Nickname:
Evo 9
Codes
Platform:
Mitsubishi GS platform (derived from Lancer C10/C60/C70)
Chassis Code:
CT9A
👋 Introduction
Market Position
Segment:
Performance Compact Sedan / Rally Homologation Special
Reputation:
Legendary performance, rallying heritage, advanced drivetrain technology.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (performance variants)
Key Features Vehicle
Performance Focus:
All-wheel drive, turbocharged engine, advanced differentials, potent braking system.
Rally Heritage:
Direct descendant of Mitsubishi's World Rally Championship (WRC) lineage.
Key Features Manual
Value Proposition:
Essential resource for owners and technicians seeking accurate, detailed repair and maintenance information.
📋 Manual Details
Coverage Areas
Years Covered:
2005, 2006, 2007
Page Count
Estimated Pages:
Approx. 2000-3000+ pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Factory Service Manual / Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, potentially searchable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair (4G63 MIVEC)
Engine Electrical:
Ignition system, fuel injection system, emission control system, starter, alternator, sensors
Fuel System:
Fuel pump, injectors, fuel lines, EVAP system
Cooling System:
Radiator, water pump, thermostat, cooling fan operation
Lubrication System:
Oil pump, oil passages, oil filter replacement
Transmission Manual:
6-speed manual transmission (Type-MR), clutch system, flywheel
Transmission Automatic:
Not applicable to standard Evo 9 models covered by this manual
Drivetrain Awc:
Active Center Differential (ACD), Super Active Yaw Control (S-AYC), propeller shaft, driveshafts, differentials
Suspension Front:
MacPherson struts, control arms, anti-roll bar, wheel bearings
Suspension Rear:
Multi-link independent suspension, shock absorbers, springs, anti-roll bar
Steering:
Power steering system, steering rack, steering column
Brakes Front:
Brembo 4-piston calipers, ventilated discs, ABS system
Brakes Rear:
Brembo 2-piston calipers, ventilated discs, ABS system
Body Exterior:
Body panels, doors, hood, trunk, bumpers, fenders, aerodynamic components
Body Interior:
Seats, dashboard, trim panels, airbags, interior lighting
Electrical Body:
Lighting system (headlights, taillights, interior), power windows, central locking, mirrors, wipers, horn
HVAC:
Air conditioning system, heater, climate control
Safety Systems:
Airbags (driver, passenger, side), seat belts, SRS system
Diagnostics:
OBD-II troubleshooting, diagnostic trouble codes (DTCs), sensor data interpretation
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, timing belt/chain inspection
Engine Repair:
Head gasket replacement, piston ring replacement, valve stem seals, turbocharger inspection and repair
Transmission Repair:
Gearbox overhaul, synchronizer replacement, clutch replacement, differential servicing
Brake Service:
Brake pad and rotor replacement, caliper service, brake fluid bleeding, ABS component testing
Suspension Repair:
Shock absorber replacement, spring replacement, bushing replacement, wheel alignment specifications
Electrical Diagnostics:
Wiring diagrams, component testing, fuse and relay identification, ECU diagnostics
Bodywork Repair:
Panel alignment, dent repair, rust prevention, glass replacement
HVAC Service:
Refrigerant handling, component replacement (compressor, condenser), leak detection
Troubleshooting:
Symptom-based diagnostic flowcharts for various issues
Torque Specifications:
Detailed torque values for all critical fasteners
Technical Depth
Depth:
Comprehensive; suitable for DIY mechanics and professional technicians. Covers everything from routine maintenance to major component overhauls.
Diagnostics Level:
Advanced diagnostics, including electronic system troubleshooting and component testing procedures.
Rebuild Procedures:
Detailed procedures for complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Typically searchable text within PDF for quick access to information.
Print Quality
Print Recommendation:
Printable on standard office printers. High-resolution images and diagrams.
Binding Type
Digital Binding:
N/A (Digital Format)
Paper Type
Digital Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63 MIVEC
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged with intercooler
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower:
286 hp @ 6500 rpm (approx. varies by region/spec)
Torque:
289 lb-ft @ 3500 rpm (approx. varies by region/spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with MIVEC (Mitsubishi Innovative Valve timing Electronic Control)
Fuel Type:
Unleaded Premium (91+ Octane recommended)
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based)
Lubrication System
Oil Type:
Synthetic SAE 5W-40 or 10W-40 (check manual for specific conditions)
Oil Capacity:
Approx. 4.5 Liters (4.8 US quarts) with filter change
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission (Getrag Type-MR)
Optional
Type:
Not applicable for Evo 9 (all featured manual transmission)
Features
Awc Integration:
Integrated with ACD (Active Center Differential) and S-AYC (Super Active Yaw Control)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil (check manual for specific Mitsubishi recommendation)
Clutch
Type:
Hydraulically actuated, multi-plate wet clutch (ACD) and single dry plate clutch
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1450 mm (57.1 in)
Wheelbase:
2625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1400-1450 kg (3086-3197 lbs) depending on trim and options
Wheels Tires
Wheel Size:
17 x 8.0 inch alloy (standard), 17 x 8.5 inch alloy (optional/performance trims)
Tire Size:
235/45R17 (standard), 235/40R18 (optional/performance trims)
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Information may vary by region and specific crash test protocols for the era. Generally considered a safe vehicle for its class.
Active Features
Traction Control:
Yes, integrated with AYC and ACD systems
ABS:
Yes, 4-wheel Anti-lock Braking System with EBD (Electronic Brakeforce Distribution)
Passive Features
Airbags:
Driver, Passenger, Side Impact Airbags (SRS)
Seat Belts:
3-point front and rear seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, often with Rockford Fosgate premium option. Aux input may vary by market.
Driver Assistance
Drivetrain Modes:
Driver-selectable modes for ACD (Tarmac, Gravel, Snow) influencing torque distribution.
Connectivity
Bluetooth:
Typically not standard on most Evo 9 models of this era, but aftermarket solutions were common.
Instrumentation
Gauges:
Comprehensive dashboard with tachometer, speedometer, boost gauge, oil pressure, and water temperature gauges.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, especially under spirited driving conditions.
Engine Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type (standard or platinum/iridium).
Timing Belt Chain Inspection:
The 4G63 uses a timing belt. Inspection and replacement typically recommended around 60,000-90,000 miles (96,000-144,000 km). Manual will specify.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for precise specification)
Power Steering Fluid:
Dexron III ATF or equivalent power steering fluid (verify with manual)
Known Issues
Head Gasket:
While improved over earlier Evos, high-performance use can stress head gaskets. Regular coolant level checks are vital.
Rear Differential:
S-AYC pump and related components can require maintenance or rebuilding over time.
Turbocharger:
Proper warm-up and cool-down procedures are critical to turbo longevity. Check for oil leaks and boost leaks.
Clutch:
Wear is dependent on driving style. Regular inspection for slipping and proper engagement is advised.
📚 Vehicle History
Brand Heritage
Rally History:
Mitsubishi's deep roots in the World Rally Championship (WRC) with multiple manufacturer and driver titles, directly influencing the Lancer Evolution line.
Model Evolution
Evolution Series:
The Evo 9 is the ninth iteration of the legendary Lancer Evolution, building upon the successful Evo VIII platform.
Key Advancements Evo9:
MIVEC engine technology, updated turbocharger, improved ACD and S-AYC systems, revised aerodynamics, and interior enhancements.
Production
Production Years Evo9:
2005-2007
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently praised in automotive press for its handling, performance, and rally-bred capabilities. Often featured in 'best driver's car' lists.
Rally Homologation:
As a homologation special, its existence is tied directly to qualifying Mitsubishi for WRC competition, a significant accolade in itself.
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