Mitsubishi Lancer Evolution 1992-2008 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Product Type: Service Repair Workshop Manual Product Format: PDF Download 👋 Introduction Market Position Automotive Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale, Toyota Celica GT-Four Key Features Performance Orientation: Engineered for rally sport homologation, featuring advanced AWD, turbocharged engine, and robust chassis. Technical Innovation: Pioneering use of Active Center Differential (ACD) and Active Yaw Control (AYC) in production vehicles. Target Audience Owner Profile: Enthusiasts, tuners, mechanics specializing in performance Mitsubishi vehicles. 📋 Manual Details Coverage Areas Model Years Covered: 1992-2008 Generations Covered: I (CD9A), II (CE9A), III (CE9A), IV (CN9A), V (CP9A), VI (CP9A), VII (CT9A), VIII (CT9A), IX (CT9A) Page Count Estimated Page Count: Thousands of pages (comprehensive factory data) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Digital Format: Searchable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63 variants: DOHC Turbocharged), Transmission (5-speed manual, 6-speed manual, optional automatic), Drivetrain (All-Wheel Drive with Active Center Differential, Active Yaw Control) Chassis: Suspension (MacPherson strut front, multi-link rear), Steering (Power assisted rack and pinion), Brakes (Ventilated discs front/rear, ABS), Wheels and Tires Electrical: Engine Control System (ECU, sensors, actuators), Ignition System, Fuel System, Lighting System, Instrumentation, Body Electrical (power windows, locks, mirrors), Audio System, HVAC Controls Body: Exterior Body Panels, Interior Trim, Bumpers, Doors, Hood, Trunk, Glass, Sealing Diagnostics: On-Board Diagnostics (OBD-II), Diagnostic Trouble Codes (DTCs), Troubleshooting Flowcharts, Component Testing Procedures Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement Repair: Engine overhaul, transmission rebuild, differential service, brake system repair, suspension component replacement, electrical system diagnostics and repair, body panel repair and replacement Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, circuit diagrams, component symptom analysis Specifications: Torque specifications for all fasteners, clearances, measurements, wiring diagrams, exploded views, part identification Technical Depth Depth: Comprehensive factory-level detail covering everything from basic fluid checks to complete engine and transmission rebuilds, including complex electronic system diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Image Resolution: High-resolution, clear diagrams and text suitable for printing. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Searchability Text Search: Fully searchable text for quick access to information. Licensing Licensing Terms: No expiry dates, unlimited access. ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (various iterations) Configuration: Inline-4, DOHC, 16-valve, Turbocharged, Intercooled Performance Displacement Cc: 1997 Horsepower Range Ps: 250-280 PS (varies by generation and market) Torque Range Nm: 314-370 Nm (varies by generation and market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI) Ignition System: Electronic Ignition (DIS - Direct Ignition System on later models) Cooling System Cooling Type: Water-cooled, pressurized system with thermostatically controlled fan. Lubrication System Oil Type Specification: API SG/SH/SJ or higher, SAE 10W-30 / 10W-40 / 15W-40 (check manual for specific model/climate recommendations) 🔧 Transmission Standard Transmission Type: 5-Speed Manual (early generations), 6-Speed Manual (later generations) Optional Optional Transmission: 4-Speed Automatic (less common, usually on non-performance variants or specific markets) Features Drivetrain System: Symmetrical All-Wheel Drive (S-AWC) with Active Center Differential (ACD) and optional Active Yaw Control (AYC). Fluid Specifications Manual Transmission Fluid Spec: API GL-3 or GL-4 SAE 75W-90 (check manual for specific model/generation) Transfer Case Fluid Spec: API GL-4 SAE 75W-90 (check manual for specific model/generation) Rear Differential Fluid Spec: API GL-5 SAE 80W-90 (check manual for specific model/generation) 📐 Dimensions Exterior Length Mm: Approx. 4,350 - 4,490 mm (varies by generation) Width Mm: Approx. 1,770 - 1,810 mm (varies by generation) Height Mm: Approx. 1,400 - 1,450 mm (varies by generation) Wheelbase Mm: Approx. 2,600 - 2,630 mm (varies by generation) Weights Curb Weight Kg: Approx. 1,300 - 1,450 kg (varies by generation and trim) Gross Vehicle Weight Rating Kg: N/A (Specific to model variants, refer to manual) Cargo Trunk Volume Liters: Approx. 250-300 Liters (varies by generation and chassis) 🛡️ Safety Features Ratings NHTSA Ratings: N/A (Ratings vary significantly by year and market; early models predate standardized testing as we know it) IIHS Ratings: N/A (See NHTSA) Active Features ABS: Standard on most models, advanced versions on later generations. Ayc: Active Yaw Control (AYC) available on performance variants for enhanced cornering stability. Acd: Active Center Differential (ACD) for intelligent torque distribution to front and rear axles. Passive Features Airbags: Driver and passenger airbags standard from mid-generation onwards; side airbags available on later models. Seatbelts: Three-point inertia reel seatbelts with pre-tensioners. Body Structure: Reinforced body structure designed for rally safety standards, including front strut tower bracing. 💡 Technology Features Infotainment Infotainment Systems: Basic AM/FM/CD players with limited screen functionality on earlier models. Later models saw upgrades to more integrated systems with basic navigation on...
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement
Repair:
Engine overhaul, transmission rebuild, differential service, brake system repair, suspension component replacement, electrical system diagnostics and repair, body panel repair and replacement
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, circuit diagrams, component symptom analysis
Specifications:
Torque specifications for all fasteners, clearances, measurements, wiring diagrams, exploded views, part identification
Technical Depth
Depth:
Comprehensive factory-level detail covering everything from basic fluid checks to complete engine and transmission rebuilds, including complex electronic system diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Image Resolution:
High-resolution, clear diagrams and text suitable for printing.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
Searchability
Text Search:
Fully searchable text for quick access to information.
4-Speed Automatic (less common, usually on non-performance variants or specific markets)
Features
Drivetrain System:
Symmetrical All-Wheel Drive (S-AWC) with Active Center Differential (ACD) and optional Active Yaw Control (AYC).
Fluid Specifications
Manual Transmission Fluid Spec:
API GL-3 or GL-4 SAE 75W-90 (check manual for specific model/generation)
Transfer Case Fluid Spec:
API GL-4 SAE 75W-90 (check manual for specific model/generation)
Rear Differential Fluid Spec:
API GL-5 SAE 80W-90 (check manual for specific model/generation)
📐 Dimensions
Exterior
Length Mm:
Approx. 4,350 - 4,490 mm (varies by generation)
Width Mm:
Approx. 1,770 - 1,810 mm (varies by generation)
Height Mm:
Approx. 1,400 - 1,450 mm (varies by generation)
Wheelbase Mm:
Approx. 2,600 - 2,630 mm (varies by generation)
Weights
Curb Weight Kg:
Approx. 1,300 - 1,450 kg (varies by generation and trim)
Gross Vehicle Weight Rating Kg:
N/A (Specific to model variants, refer to manual)
Cargo
Trunk Volume Liters:
Approx. 250-300 Liters (varies by generation and chassis)
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A (Ratings vary significantly by year and market; early models predate standardized testing as we know it)
IIHS Ratings:
N/A (See NHTSA)
Active Features
ABS:
Standard on most models, advanced versions on later generations.
Ayc:
Active Yaw Control (AYC) available on performance variants for enhanced cornering stability.
Acd:
Active Center Differential (ACD) for intelligent torque distribution to front and rear axles.
Passive Features
Airbags:
Driver and passenger airbags standard from mid-generation onwards; side airbags available on later models.
Seatbelts:
Three-point inertia reel seatbelts with pre-tensioners.
Body Structure:
Reinforced body structure designed for rally safety standards, including front strut tower bracing.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM/CD players with limited screen functionality on earlier models. Later models saw upgrades to more integrated systems with basic navigation on some trims.
Driver Assistance
ABS:
Standard anti-lock braking system.
Ayc Acd Control:
Proprietary advanced torque vectoring and distribution systems.
Connectivity
Connectivity Features:
Limited by era; basic audio system connectivity. Later models may have basic auxiliary inputs or rudimentary Bluetooth on select trims/aftermarket.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km or 6 months (whichever comes first), more frequent under severe driving conditions (refer to manual).
Air Filter Replacement Interval:
Every 15,000-30,000 km (check manual).
Spark Plug Replacement Interval:
Every 60,000-100,000 km (depending on plug type - iridium recommended, check manual).
Timing Belt Replacement Interval:
Every 90,000-105,000 km or 7 years (critical maintenance, check manual).
Fluid Specifications
Engine Coolant Specification:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent (e.g., Prestone Extended Life) - typically a pink or red ethylene glycol-based coolant.
Brake Fluid Specification:
DOT 3 or DOT 4 (check manual for specific model/generation).
Power Steering Fluid Specification:
Dexron III ATF or equivalent (check manual).
Known Issues
Engine Wear:
Bearing failure on high-mileage or poorly maintained 4G63T engines, piston ring wear, valve stem seal deterioration.
Turbocharger:
Oil starvation due to clogged banjo bolt screens (especially on older models), turbo seal failure leading to oil consumption or smoke.
Clutch:
Wear and tear on the clutch assembly, especially in spirited driving.
Electrical Gremlins:
Corrosion on connectors, aging wiring harnesses, issues with ECU or sensors on older vehicles.
Rust:
Common rust points include wheel arches, sills, and subframes, especially in regions with road salt.
📚 Vehicle History
Brand Heritage
Brand Origin:
Japan
Motorsport Legacy:
Directly derived from Mitsubishi's successful World Rally Championship (WRC) Lancer rally cars.
Model Evolution
Generation I:
1992-1993 (CD9A): Introduction of the performance variant based on the Lancer platform.
Generation Ii:
1994-1995 (CE9A): Refined chassis, aerodynamic enhancements, introduction of AYC.
Generation Iii:
1996 (CE9A): Minor updates, enhanced styling.
Generation Iv:
1996-1998 (CN9A): Complete redesign, more aggressive styling, introduction of ACD, twin-scroll turbo.
Generation V:
1998-1999 (CP9A): Further styling refinements, larger intercooler, revised suspension.
2001-2003 (CT9A): Complete platform change, more modern styling, available 5-speed auto, new AWD system.
Generation Viii:
2003-2005 (CT9A): Introduction to North American market, revised turbocharger, new DCCD (Driver Controlled Center Differential) on MR models, Bilstein suspension.
Generation Ix:
2005-2007 (CT9A): MIVEC variable valve timing on intake camshaft, improved turbocharger, revised styling, further enhancements to AWD system.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Named to Car and Driver's 10Best list multiple times, particularly for the VIII and IX generations.
Wrc Titles:
While the manual covers production cars, the Lancer Evolution's lineage is built on numerous WRC Constructors' and Drivers' Championships.
Ratings
Motortrend Car Of The Year Contender:
Often a strong contender and praised by automotive journalists for its performance and handling.
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