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Mitsubishi Lancer 2005 Full Service Repair Manual

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The Lancer, model year 2005, is a compact car known for its sporty styling and reliable engineering, built on the Project Global (PG) platform. Available in sedan and sportback body styles, it offered a range of engine options, including the robust 4G63 turbocharged engine found in performance variants, and came with either a 5-speed manual, 4-speed automatic, or less commonly, a CVT transmission. Its aggressive design language and practical interior made it a competitive choice in its segment, praised for its handling and enthusiast appeal, particularly in its higher-performance configurations. This comprehensive service repair manual provides detailed information for the diagnosis, repair, and maintenance of the 2005 Lancer. It covers all major vehicle systems, including engine mechanicals, transmission, drivetrain, suspension, steering, brakes, and electrical systems. The manual includes step-by-step procedures for routine maintenance, complex repairs, and overhauls, along with diagnostic flowcharts, torque specifications, and electrical schematics. Its purpose is to assist owners and technicians in keeping the vehicle in optimal working condition and performing accurate repairs. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2005 Chassis Code: CS/CT (Global) Platform: Mitsubishi Project Global (PG) Codes Engine Codes Common: 4G13, 4G15, 4G18, 4G94, 4G63 (Turbocharged EVO variants) Transmission Codes Common: F5M42 (5-speed manual), F4A42 (4-speed automatic), W1C1 (CVT - less common) 👋 Introduction Market Position Segment: Compact car / Small family car Competitors 2005: Honda Civic, Toyota Corolla, Nissan Sentra, Mazda3, Ford Focus, Subaru Impreza Competitive Analysis Strengths: Sporty styling (especially in higher trims), available all-wheel drive (AWD) on some models, enthusiast appeal (especially with 4G63 engine), reliability Weaknesses: Interior materials could be perceived as less premium than some rivals, base engine performance modest Key Features Styling: Aggressive, sporty design language with sharp lines and prominent grille Performance Options: Available turbocharged engines (e.g., 4G63 in Lancer Ralliart/Evolution variants) offering significant performance gains Practicality: Available as a sedan or sportback (hatchback), offering good passenger space and cargo versatility 📋 Manual Details Coverage Areas Primary Markets Covered: Global (North America, Europe, Asia, Australia) Vehicle Variants Covered: All Lancer Sedan and Sportback models (excluding high-performance Evolution variants unless specified within the manual's scope) Page Count Estimated Page Count: 1000+ Manual Type Type: Full Service Repair Manual Purpose: Diagnostic, repair, maintenance, overhaul, and rebuilding procedures Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, starting system, charging system, emission control systems (OBD-II diagnostics) Engine Management: ECU operation, sensor inputs/outputs, diagnostic trouble codes (DTCs), fuel control strategies, ignition timing control Transmission Manual: Clutch system, gear shifting mechanisms, internal components, lubrication, removal and installation Transmission Automatic: Torque converter, planetary gear sets, valve body operation, hydraulic control, transmission fluid, electronic controls, removal and installation Drivetrain: Front-wheel drive system, drive shafts, CV joints, rear differential (if applicable) Suspension: Front and rear suspension components (struts, shocks, springs, control arms, bushings), alignment specifications Steering: Power steering system (hydraulic), steering rack, tie rods, steering column, wheel alignment Brakes: Front and rear brake systems (disc/drum), hydraulic components, ABS system (if equipped), parking brake Electrical System: Battery, charging system, starting system, lighting system, fuses, relays, wiring diagrams, ignition system Body And Interior: Body panel removal/installation, interior trim, seats, HVAC system, doors, windows, locks, mirrors Comfort And Convenience: Air conditioning, heating, power windows, power locks, cruise control Safety Systems: Airbags, seat belts, ABS operation Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad replacement, tire rotation Diagnostics: Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation, component testing procedures Repair: Component removal, overhaul, and reassembly for all major systems Rebuilding: Detailed instructions for engine and transmission overhauls Installation: Replacement of major components, accessories, and body parts Calibration And Adjustment: Wheel alignment, throttle body cleaning and adjustment, idle speed control Technical Depth Depth: Comprehensive, from basic preventative maintenance to complete engine and transmission rebuilds Detail Level: Step-by-step instructions, torque specifications, clearance measurements, electrical schematics, diagnostic flowcharts 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text content Print Quality Printability: Printable for at-home or workshop use Resolution: High-resolution for clear diagrams and text Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Displacement Common 1: 1.6 L (1584 cc) 4G18 I4 SOHC Engine Displacement Common 2: 1.8 L (1834 cc) 4G93/4G94 I4 SOHC/DOHC Engine Displacement Performance: 2.0 L (1997 cc) 4G63T I4 DOHC Turbocharged (specific variants) Performance Horsepower Typical Base: Approx. 103-118 hp (81-88 kW) for 1.6L/1.8L engines Horsepower Turbocharged: Approx. 265-290 hp (198-216 kW) for 4G63T engines (depending on specific model/tune) Torque Typical Base: Approx. 100-115 lb-ft (136-156 Nm) for 1.6L/1.8L engines Torque Turbocharged: Approx. 253-260 lb-ft (343-353 Nm) for 4G63T engines Fuel...
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Mitsubishi Lancer 2005 Full Service Repair ManualMitsubishi Lancer 2005 Full Service Repair ManualMitsubishi Lancer 2005 Full Service Repair ManualMitsubishi Lancer 2005 Full Service Repair Manual
The Lancer, model year 2005, is a compact car known for its sporty styling and reliable engineering, built on the Project Global (PG) platform. Available in sedan and sportback body styles, it offered a range of engine options, including the robust 4G63 turbocharged engine found in performance variants, and came with either a 5-speed manual, 4-speed automatic, or less commonly, a CVT transmission. Its aggressive design language and practical interior made it a competitive choice in its segment, praised for its handling and enthusiast appeal, particularly in its higher-performance configurations. This comprehensive service repair manual provides detailed information for the diagnosis, repair, and maintenance of the 2005 Lancer. It covers all major vehicle systems, including engine mechanicals, transmission, drivetrain, suspension, steering, brakes, and electrical systems. The manual includes step-by-step procedures for routine maintenance, complex repairs, and overhauls, along with diagnostic flowcharts, torque specifications, and electrical schematics. Its purpose is to assist owners and technicians in keeping the vehicle in optimal working condition and performing accurate repairs.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Year:
2005
Chassis Code:
CS/CT (Global)
Platform:
Mitsubishi Project Global (PG)
Codes
Engine Codes Common:
4G13, 4G15, 4G18, 4G94, 4G63 (Turbocharged EVO variants)
Transmission Codes Common:
F5M42 (5-speed manual), F4A42 (4-speed automatic), W1C1 (CVT - less common)
👋 Introduction
Market Position
Segment:
Compact car / Small family car
Competitors 2005:
Honda Civic, Toyota Corolla, Nissan Sentra, Mazda3, Ford Focus, Subaru Impreza
Competitive Analysis
Strengths:
Sporty styling (especially in higher trims), available all-wheel drive (AWD) on some models, enthusiast appeal (especially with 4G63 engine), reliability
Weaknesses:
Interior materials could be perceived as less premium than some rivals, base engine performance modest
Key Features
Styling:
Aggressive, sporty design language with sharp lines and prominent grille
Performance Options:
Available turbocharged engines (e.g., 4G63 in Lancer Ralliart/Evolution variants) offering significant performance gains
Practicality:
Available as a sedan or sportback (hatchback), offering good passenger space and cargo versatility
📋 Manual Details
Coverage Areas
Primary Markets Covered:
Global (North America, Europe, Asia, Australia)
Vehicle Variants Covered:
All Lancer Sedan and Sportback models (excluding high-performance Evolution variants unless specified within the manual's scope)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Full Service Repair Manual
Purpose:
Diagnostic, repair, maintenance, overhaul, and rebuilding procedures
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, starting system, charging system, emission control systems (OBD-II diagnostics)
Engine Management:
ECU operation, sensor inputs/outputs, diagnostic trouble codes (DTCs), fuel control strategies, ignition timing control
Transmission Manual:
Clutch system, gear shifting mechanisms, internal components, lubrication, removal and installation
Transmission Automatic:
Torque converter, planetary gear sets, valve body operation, hydraulic control, transmission fluid, electronic controls, removal and installation
Drivetrain:
Front-wheel drive system, drive shafts, CV joints, rear differential (if applicable)
Suspension:
Front and rear suspension components (struts, shocks, springs, control arms, bushings), alignment specifications
Steering:
Power steering system (hydraulic), steering rack, tie rods, steering column, wheel alignment
Brakes:
Front and rear brake systems (disc/drum), hydraulic components, ABS system (if equipped), parking brake
Electrical System:
Battery, charging system, starting system, lighting system, fuses, relays, wiring diagrams, ignition system
Body And Interior:
Body panel removal/installation, interior trim, seats, HVAC system, doors, windows, locks, mirrors
Comfort And Convenience:
Air conditioning, heating, power windows, power locks, cruise control
Safety Systems:
Airbags, seat belts, ABS operation
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad replacement, tire rotation
Diagnostics:
Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation, component testing procedures
Repair:
Component removal, overhaul, and reassembly for all major systems
Rebuilding:
Detailed instructions for engine and transmission overhauls
Installation:
Replacement of major components, accessories, and body parts
Calibration And Adjustment:
Wheel alignment, throttle body cleaning and adjustment, idle speed control
Technical Depth
Depth:
Comprehensive, from basic preventative maintenance to complete engine and transmission rebuilds
Detail Level:
Step-by-step instructions, torque specifications, clearance measurements, electrical schematics, diagnostic flowcharts
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Searchable text content
Print Quality
Printability:
Printable for at-home or workshop use
Resolution:
High-resolution for clear diagrams and text
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Displacement Common 1:
1.6 L (1584 cc) 4G18 I4 SOHC
Engine Displacement Common 2:
1.8 L (1834 cc) 4G93/4G94 I4 SOHC/DOHC
Engine Displacement Performance:
2.0 L (1997 cc) 4G63T I4 DOHC Turbocharged (specific variants)
Performance
Horsepower Typical Base:
Approx. 103-118 hp (81-88 kW) for 1.6L/1.8L engines
Horsepower Turbocharged:
Approx. 265-290 hp (198-216 kW) for 4G63T engines (depending on specific model/tune)
Torque Typical Base:
Approx. 100-115 lb-ft (136-156 Nm) for 1.6L/1.8L engines
Torque Turbocharged:
Approx. 253-260 lb-ft (343-353 Nm) for 4G63T engines
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Ignition System:
Electronic ignition with coil-on-plug or distributor (model dependent)
Cooling System
Cooling Type:
Water-cooled
Lubrication System
Oil Capacity Engine:
Approx. 4.0 - 4.5 liters (4.2 - 4.8 US quarts) with filter (consult manual for specific engine)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission (F5M42)
Optional
Optional Transmission 1:
4-speed automatic transmission (F4A42)
Optional Transmission 2:
Continuously Variable Transmission (CVT) - less common, often on specific markets/trims
Features
AWD Availability:
All-Wheel Drive (AWD) available on certain performance-oriented trims (e.g., Lancer Ralliart), typically paired with specific engines and transmissions
Fluid Specs
Automatic Transmission Fluid Type:
DIAQueen SPIII (or equivalent ATF SP-III)
Manual Transmission Fluid Type:
Gear oil API GL-4, SAE 75W-90 (verify specific viscosity)
📐 Dimensions
Exterior
Length:
Approx. 4525-4570 mm (178.1-179.9 in)
Width:
Approx. 1740-1770 mm (68.5-69.7 in)
Height:
Approx. 1445-1485 mm (56.9-58.5 in)
Wheelbase:
Approx. 2635 mm (103.7 in)
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Tire Sizes Common:
195/60R15, 205/50R16, 215/45R17 (vary by trim)
Weights
Curb Weight:
Approx. 1200-1350 kg (2645-2976 lbs) (varies by engine, transmission, and trim)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for comparable models/years)
NHTSA Front Impact Passenger:
Good (for comparable models/years)
IIHS Frontal Offset:
Good (for comparable models/years)
Active Features
ABS:
Standard or optional depending on trim level
Traction Control:
Optional on some models
Electronic Stability Control:
Rarely standard, may be optional on higher trims
Passive Features
Airbags Front:
Standard dual front airbags
Airbags Side:
Optional front side-impact airbags, optional side-curtain airbags on some models
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD player, optional premium audio systems (e.g., Rockford Fosgate on some trims)
Display:
Basic digital or analog displays for audio and climate control
Driver Assistance
Cruise Control:
Available on most trims
Keyless Entry:
Available on higher trims
Connectivity
Auxiliary Input:
Rarely standard, typically not available on factory units from this era
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (depending on driving conditions and oil type used; consult manual for specific recommendation)
Air Filter Replacement Interval:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection
Spark Plug Replacement Interval:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (standard vs. platinum/iridium)
Timing Belt Replacement Interval:
Recommended every 60,000-90,000 miles (96,000-144,000 km) for engines with timing belts. Check specific engine for belt or chain.
Fluid Specifications
Engine Oil Specification:
API SN or ILSAC GF-5, SAE 5W-30 or 5W-40 (verify based on climate and specific engine, check manual)
Coolant Type:
Mitsubishi DiaQueen SUPER LONG LIFE COOLANT (Green) or equivalent long-life ethylene glycol coolant
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Hesitation Common:
Can occur due to dirty throttle body, failing O2 sensors, or fuel system issues.
Transmission Slipping:
Potential issue with automatic transmissions if fluid is low or dirty, or due to internal wear.
Suspension Noises:
Worn bushings, ball joints, or struts can lead to clunks or rattles, especially over bumps.
Exhaust Leaks:
Common wear item, particularly at manifold gaskets or flex pipes.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation (MMC)
Automotive History:
Mitsubishi has a long history in automotive manufacturing, known for innovation and robust engineering, particularly in rally sport heritage.
Model Evolution
Lancer Generations:
The 2005 Lancer belongs to the seventh generation (2000-2007), often referred to as the CS/CT generation, which represented a significant design and engineering update over its predecessor.
Design Philosophy:
This generation emphasized a more global design approach, with shared platforms and styling cues across different markets.
Production
Manufacturing Locations:
Primarily Japan, but also assembled in various international plants (e.g., Australia, Thailand, North America depending on market)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Often received good ratings in frontal crash tests from agencies like NHTSA and IIHS for its class and era.
Performance Awards:
Lancer Evolution variants are highly acclaimed in motorsports and performance car reviews.
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