Mitsubishi Lancer Evolution 7 Evo Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VII (Evo 7) Model Short: Evo 7 Generation Generation Designation: CT9A Codes Chassis Code: CT9A Engine Code Primary: 4G63T 👋 Introduction Market Position Vehicle Class: Compact Sports Sedan / Rally Homologation Special Target Audience: Enthusiasts, tuners, rally participants, performance-oriented drivers. Competitive Analysis Direct Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (other generations), Ford Focus RS, Subaru Legacy GT. Key Features Performance Focus: Legendary rally-bred performance, advanced all-wheel-drive system, potent turbocharged engine. Technical Innovation: Active Center Differential (ACD), Super Active Yaw Control (S-AYC) on some variants. Manual Utility Primary Users: DIY mechanics, independent workshops, performance tuners. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Service and Repair Page Count Page Count: Over 1000 pages (typical for this type of manual) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Service: Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control system, engine electrical. Transmission Service: Manual transmission (5-speed & 6-speed options), clutch system, drivetrain components (front/rear differentials, driveshafts, ACD). Suspension Steering: Front and rear suspension, steering gear, power steering system. Brakes: Front and rear brake systems (including Brembo options), ABS, EBD. Electrical: Wiring diagrams, lighting, instruments, audio system, power windows, power locks, HVAC controls, ECUs. Body Chassis: Body construction, exterior panels, interior trim, doors, glass, safety systems (airbags). Procedures Included Maintenance Procedures: Scheduled maintenance intervals, fluid checks and changes, filter replacements, spark plug replacement, belt inspection/replacement. Repair Procedures: Engine component replacement (pistons, valves, turbocharger), transmission overhaul, brake caliper replacement, strut replacement, radiator service. Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, fuel pressure testing. Technical Specifications Data: Torque specifications, clearances, component dimensions, electrical resistance values. Technical Depth Diagnostic Tools: Information on using Mitsubishi's diagnostic tools (e.g., MUT-III or equivalent for the era), scan tool procedures. Rebuild Instructions: Detailed instructions for engine and transmission rebuilding, including bearing clearances and assembly procedures. Special Tools: Identification and usage of specialized tools required for specific repair tasks. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Image Quality: High-resolution diagrams, illustrations, and photographs. Print Quality Printability: Designed for printing specific sections or the entire manual. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Displacement: 2.0 Liters (1997 cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Turbocharger Model: Mitsubishi TD05HRA-16G 8cm² (typical) Performance Horsepower Ps Jpdm: 280 PS @ 6500 rpm (JDM spec) Horsepower Hp Export: 276 hp @ 6500 rpm (Export spec, typically) Torque Kgf M Jpdm: 34.2 kgf·m @ 3000 rpm (JDM spec) Torque Lb Ft Export: 280 lb-ft @ 3000 rpm (Export spec, typically) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Premium (95 RON / 91+ AKI recommended) Ignition System: Electronic Ignition, Distributorless (Coil-on-plug on some variations) Fluid Specifications Engine Oil Capacity: Approx. 4.5 Liters (with filter) Engine Oil Viscosity: 10W-40 or 15W-50 (depending on climate/usage, consult manual for specifics) 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Transmission (Type R) Optional Transmission Type Opt: 6-speed Manual Transmission (Type RS, GSR models) Features Drivetrain Type: All-Wheel Drive (AWD) with Active Center Differential (ACD) Rear Differential: Mechanical Limited Slip Differential (LSD) or Active Yaw Control (S-AYC) on RS models. Fluid Specifications Manual Transmission Fluid: GL-4 SAE 75W-90 (typical, consult manual for exact type and capacity) 📐 Dimensions Exterior Length: 4435 mm Width: 1770 mm Height: 1415 mm Wheelbase: 2625 mm Weights Curb Weight: Approx. 1450 kg (varies by trim) 🛡️ Safety Features Ratings Crash Test Ratings: Not extensively rated by modern global bodies like NHTSA/Euro NCAP due to its era and homologation nature. Primarily focused on rally-derived safety. Active Features Active Aero: Rear spoiler, front air dam for aerodynamic stability. AWD System: Advanced AWD system with ACD and S-AYC for enhanced traction and handling. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: 3-point inertia-reel seatbelts with pretensioners. Chassis Construction: Reinforced chassis, roll cage (optional or standard on some race variants). 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, often with premium speaker options. Navigation: Optional factory navigation system on some higher trims. Driver Assistance ABS: Anti-lock Braking System (ABS) Ebd: Electronic Brakeforce Distribution (EBD) Traction Control: Traction Control System (TCS) available, often linked with AWD performance. Connectivity Remote Keyless Entry: Standard on most trims. Power Accessories: Power windows, power door locks, power mirrors. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-10,000 km or 6-12 months (whichever comes first), depending on usage (severe vs. normal). Spark Plug Replacement: Approx. 60,000-100,000 km (depending on plug type and usage) Timing Belt Replacement: Approx. 90,000-120,000 km or 5-7 years (critical replacement)...
Information on using Mitsubishi's diagnostic tools (e.g., MUT-III or equivalent for the era), scan tool procedures.
Rebuild Instructions:
Detailed instructions for engine and transmission rebuilding, including bearing clearances and assembly procedures.
Special Tools:
Identification and usage of specialized tools required for specific repair tasks.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Image Quality:
High-resolution diagrams, illustrations, and photographs.
Print Quality
Printability:
Designed for printing specific sections or the entire manual.
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
2.0 Liters (1997 cc)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Turbocharger Model:
Mitsubishi TD05HRA-16G 8cm² (typical)
Performance
Horsepower Ps Jpdm:
280 PS @ 6500 rpm (JDM spec)
Horsepower Hp Export:
276 hp @ 6500 rpm (Export spec, typically)
Torque Kgf M Jpdm:
34.2 kgf·m @ 3000 rpm (JDM spec)
Torque Lb Ft Export:
280 lb-ft @ 3000 rpm (Export spec, typically)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Premium (95 RON / 91+ AKI recommended)
Ignition System:
Electronic Ignition, Distributorless (Coil-on-plug on some variations)
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 Liters (with filter)
Engine Oil Viscosity:
10W-40 or 15W-50 (depending on climate/usage, consult manual for specifics)
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual Transmission (Type R)
Optional
Transmission Type Opt:
6-speed Manual Transmission (Type RS, GSR models)
Features
Drivetrain Type:
All-Wheel Drive (AWD) with Active Center Differential (ACD)
Rear Differential:
Mechanical Limited Slip Differential (LSD) or Active Yaw Control (S-AYC) on RS models.
Fluid Specifications
Manual Transmission Fluid:
GL-4 SAE 75W-90 (typical, consult manual for exact type and capacity)
📐 Dimensions
Exterior
Length:
4435 mm
Width:
1770 mm
Height:
1415 mm
Wheelbase:
2625 mm
Weights
Curb Weight:
Approx. 1450 kg (varies by trim)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not extensively rated by modern global bodies like NHTSA/Euro NCAP due to its era and homologation nature. Primarily focused on rally-derived safety.
Active Features
Active Aero:
Rear spoiler, front air dam for aerodynamic stability.
AWD System:
Advanced AWD system with ACD and S-AYC for enhanced traction and handling.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners.
Chassis Construction:
Reinforced chassis, roll cage (optional or standard on some race variants).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with premium speaker options.
Navigation:
Optional factory navigation system on some higher trims.
Driver Assistance
ABS:
Anti-lock Braking System (ABS)
Ebd:
Electronic Brakeforce Distribution (EBD)
Traction Control:
Traction Control System (TCS) available, often linked with AWD performance.
Connectivity
Remote Keyless Entry:
Standard on most trims.
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km or 6-12 months (whichever comes first), depending on usage (severe vs. normal).
Spark Plug Replacement:
Approx. 60,000-100,000 km (depending on plug type and usage)
Timing Belt Replacement:
Approx. 90,000-120,000 km or 5-7 years (critical replacement)
Fluid Specifications
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent) - typically a pink ethylene glycol-based coolant.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system components, turbocharger wear, potential for ringland failure on heavily modified engines.
Electronics Faults:
Occasional issues with ABS sensors, ACD pump failure, and ECU problems, particularly with age.
Maintenance Focus
Performance Maintenance:
Emphasis on maintaining the high-performance drivetrain, including regular ACD fluid changes, differential fluid changes, and meticulous engine oil management.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's dominant success in the World Rally Championship (WRC) heavily influenced the Lancer Evolution series.
Model Evolution
Predecessor:
Mitsubishi Lancer Evolution VI (Evo 6)
Successor:
Mitsubishi Lancer Evolution VIII (Evo 8)
Key Changes From Evo6:
New chassis (CT9A platform), revised engine (4G63MIVEC on some variants), introduction of ACD and S-AYC became more prevalent.
Production
Production Years:
2001-2003
Manufacturing Location:
Japan
Trim Levels
Common Trims:
GSR, RS, MR (Japanese Domestic Market)
🏆 Awards & Recognition
Recognitions
Motorsport Accolades:
Multiple WRC manufacturer and driver championships for Mitsubishi Lancer Evolution models throughout its history, directly influencing public perception and demand for road versions.
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