Mitsubishi Lancer 2000-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Product Name: Mitsubishi Lancer 2000-2007 Service Repair Manual Product Description: Mitsubishi Lancer 2000 2001 2002 2003 2004 2005 2006 2007 Service Repair Manual PDF Codes Chassis Codes Covered: CS (specific variations may apply across years/regions) Engine Codes Covered: 4G13, 4G15, 4G63, 4G64 (depending on market and specific model variants) 👋 Introduction Market Position Segment: Compact Sedan / Hatchback Target Audience: Economy-conscious buyers, enthusiasts (especially for performance variants), DIY mechanics Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Nissan Sentra Segment Strengths: Affordability, sporty handling (especially performance models), availability of AWD (in some markets/variants), robust engine options (e.g., 4G63 in performance trims) Key Features Platform: Mitsubishi's global compact car platform (CS platform for this generation) Design Philosophy: Aerodynamic styling, functional interior, balanced ride and handling Performance Variants: Notable for the Lancer Evolution (Evo) models, known for rally-bred performance, AWD, and turbocharged engines 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Region Applicability: Global (primarily North America, Europe, Asia - confirm specific market codes if needed) Trim Levels Covered: ES, LS, OZ Rally, GTS, Ralliart, Evolution (MR, GSR - specific Evo coverage may vary, focus on standard Lancer models) Page Count Estimated Pages: 1500-2500+ (typical for comprehensive factory-level service manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, emissions control systems Engine Control: Engine Control Module (ECM) diagnostics, sensor operations (MAF, O2, TPS, CKP, CMP), actuator controls, diagnostic trouble codes (DTCs) Transmission Manual: Clutch system, gear shifting mechanisms, internal components, torque specifications, fluid recommendations, repair procedures Transmission Automatic: Automatic transmission operation, valve body, torque converter, hydraulic control, electronic controls, shift solenoids, repair and overhaul procedures Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems (if applicable to specific models), differentials, driveshafts, CV joints, wheel bearings Suspension: Front suspension (MacPherson strut), rear suspension (multi-link or torsion beam depending on model), shock absorbers, springs, control arms, anti-roll bars, wheel alignment specifications Brakes: Front and rear brake systems (disc brakes standard), ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, caliper and rotor replacement, parking brake system Steering: Power steering system (hydraulic or electric depending on variant), steering column, steering rack, tie rod ends, power steering fluid Electrical System: Battery, alternator, starter motor, lighting systems (headlights, taillights, interior), power windows, central locking, fuse box diagrams, wiring schematics HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant types, compressor, condenser, evaporator, blower motor, climate control panel Body And Frame: Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, rust prevention, underbody coatings Safety Systems: Airbag system (SRS) operation, diagnostics, and replacement procedures, seat belts Procedures Included General Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, tire rotation, cabin air filter replacement Engine Repair: Engine tune-ups, head gasket replacement, timing belt/chain service, piston ring replacement, bearing replacement, complete engine overhaul Transmission Repair: Clutch replacement (manual), transmission fluid and filter service (automatic), seal replacement, internal component repair and replacement Brake Service: Brake pad and rotor replacement, caliper service, brake line bleeding, ABS system bleeding, parking brake adjustment Suspension And Steering Service: Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel alignment procedures Electrical Troubleshooting: Diagnosis of starting and charging system issues, lighting faults, accessory malfunctions, using wiring diagrams for pinpoint testing Diagnostics: OBD-II (On-Board Diagnostics II) scanning, interpretation of diagnostic trouble codes (DTCs), live data stream analysis, system-specific diagnostic flowcharts Body And Trim Repair: Removal and installation of interior panels, exterior trim pieces, door mechanisms, window regulators, mirror assemblies Body Panel Replacement: Replacement of fenders, doors, hoods, trunk lids, and bumper covers Air Conditioning Service: Refrigerant evacuation and recharge, component replacement (compressor, condenser, expansion valve), leak detection Technical Depth Depth: Comprehensive (factory-level detail suitable for professional technicians and advanced DIYers) Diagrams Illustrations: Includes detailed diagrams, exploded views, and step-by-step illustrations for most procedures Specifications: Provides detailed torque specifications, fluid capacities, clearances, and diagnostic parameters Troubleshooting: Extensive troubleshooting guides and flowcharts for common and uncommon issues 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically) Printable: Yes (allows printing of individual pages or sections) Print Quality Quality: High-resolution, typically sourced from original factory documentation Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Family Common: 4G series (e.g., 4G15, 4G64) Engine Displacement Typical: 1.5L (4G15), 2.0L (4G63/4G64), 2.4L (4G69) Performance Horsepower Range Typical: 100 hp - 160 hp (naturally aspirated models) Torque Range Typical: 100 lb-ft - 150...

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Tipo: Car

Proveedor:

SKU: 500511

Colecciones: ALL Mitsubishi

Disponibilidad: En stock

Etiquetas: 2000 2001 2002 2003 2004 2005 2006 2007 Car Cars Lancer Misc Mitsubishi

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Product Name:

Mitsubishi Lancer 2000-2007 Service Repair Manual

Product Description:

Mitsubishi Lancer 2000 2001 2002 2003 2004 2005 2006 2007 Service Repair Manual PDF

Codes

Chassis Codes Covered:

CS (specific variations may apply across years/regions)

Engine Codes Covered:

4G13, 4G15, 4G63, 4G64 (depending on market and specific model variants)

👋 Introduction

Market Position

Segment:

Compact Sedan / Hatchback

Target Audience:

Economy-conscious buyers, enthusiasts (especially for performance variants), DIY mechanics

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Nissan Sentra

Segment Strengths:

Affordability, sporty handling (especially performance models), availability of AWD (in some markets/variants), robust engine options (e.g., 4G63 in performance trims)

Key Features

Platform:

Mitsubishi's global compact car platform (CS platform for this generation)

Design Philosophy:

Aerodynamic styling, functional interior, balanced ride and handling

Performance Variants:

Notable for the Lancer Evolution (Evo) models, known for rally-bred performance, AWD, and turbocharged engines

📋 Manual Details

Coverage Areas

Covered Years:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Region Applicability:

Global (primarily North America, Europe, Asia - confirm specific market codes if needed)

Trim Levels Covered:

ES, LS, OZ Rally, GTS, Ralliart, Evolution (MR, GSR - specific Evo coverage may vary, focus on standard Lancer models)

Page Count

Estimated Pages:

1500-2500+ (typical for comprehensive factory-level service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, emissions control systems

Engine Control:

Engine Control Module (ECM) diagnostics, sensor operations (MAF, O2, TPS, CKP, CMP), actuator controls, diagnostic trouble codes (DTCs)

Transmission Manual:

Clutch system, gear shifting mechanisms, internal components, torque specifications, fluid recommendations, repair procedures

Transmission Automatic:

Automatic transmission operation, valve body, torque converter, hydraulic control, electronic controls, shift solenoids, repair and overhaul procedures

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems (if applicable to specific models), differentials, driveshafts, CV joints, wheel bearings

Suspension:

Front suspension (MacPherson strut), rear suspension (multi-link or torsion beam depending on model), shock absorbers, springs, control arms, anti-roll bars, wheel alignment specifications

Brakes:

Front and rear brake systems (disc brakes standard), ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, caliper and rotor replacement, parking brake system

Steering:

Power steering system (hydraulic or electric depending on variant), steering column, steering rack, tie rod ends, power steering fluid

Electrical System:

Battery, alternator, starter motor, lighting systems (headlights, taillights, interior), power windows, central locking, fuse box diagrams, wiring schematics

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant types, compressor, condenser, evaporator, blower motor, climate control panel

Body And Frame:

Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, rust prevention, underbody coatings

Safety Systems:

Airbag system (SRS) operation, diagnostics, and replacement procedures, seat belts

Procedures Included

General Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, tire rotation, cabin air filter replacement

Engine Repair:

Engine tune-ups, head gasket replacement, timing belt/chain service, piston ring replacement, bearing replacement, complete engine overhaul

Transmission Repair:

Clutch replacement (manual), transmission fluid and filter service (automatic), seal replacement, internal component repair and replacement

Brake Service:

Brake pad and rotor replacement, caliper service, brake line bleeding, ABS system bleeding, parking brake adjustment

Suspension And Steering Service:

Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel alignment procedures

Electrical Troubleshooting:

Diagnosis of starting and charging system issues, lighting faults, accessory malfunctions, using wiring diagrams for pinpoint testing

Diagnostics:

OBD-II (On-Board Diagnostics II) scanning, interpretation of diagnostic trouble codes (DTCs), live data stream analysis, system-specific diagnostic flowcharts

Body And Trim Repair:

Removal and installation of interior panels, exterior trim pieces, door mechanisms, window regulators, mirror assemblies

Body Panel Replacement:

Replacement of fenders, doors, hoods, trunk lids, and bumper covers

Air Conditioning Service:

Refrigerant evacuation and recharge, component replacement (compressor, condenser, expansion valve), leak detection

Technical Depth

Depth:

Comprehensive (factory-level detail suitable for professional technicians and advanced DIYers)

Diagrams Illustrations:

Includes detailed diagrams, exploded views, and step-by-step illustrations for most procedures

Specifications:

Provides detailed torque specifications, fluid capacities, clearances, and diagnostic parameters

Troubleshooting:

Extensive troubleshooting guides and flowcharts for common and uncommon issues

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typically)

Printable:

Yes (allows printing of individual pages or sections)

Print Quality

Quality:

High-resolution, typically sourced from original factory documentation

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Family Common:

4G series (e.g., 4G15, 4G64)

Engine Displacement Typical:

1.5L (4G15), 2.0L (4G63/4G64), 2.4L (4G69)

Performance

Horsepower Range Typical:

100 hp - 160 hp (naturally aspirated models)

Torque Range Typical:

100 lb-ft - 150 lb-ft (naturally aspirated models)

Performance Engine Evo:

4G63T (2.0L Turbocharged inline-4), 271-286 hp range for this generation (Evo VIII/IX)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Emission Controls:

Catalytic converter, EGR (Exhaust Gas Recirculation), evaporative emission control system

🔧 Transmission

Standard

Manual Transmission:

5-speed manual transmission standard on most models

Optional

Automatic Transmission:

4-speed automatic transmission available on many models

Features

Sportronic Transmission:

Some models offered a 'Sportronic' automatic with manual shifting capability

Evo Transmission:

6-speed manual transmission standard on Lancer Evolution models

Evo AWD System:

Advanced All-Wheel Drive (AWD) systems (e.g., Super All-Wheel Control - S-AWC on later Evo models, Active Center Differential - ACD, Sport ABS)

📐 Dimensions

Exterior

Length Typical:

Approx. 177-180 inches (sedan)

Width Typical:

Approx. 67-70 inches

Height Typical:

Approx. 56-58 inches

Wheelbase Typical:

Approx. 103 inches

Cargo

Trunk Volume Typical:

Approx. 13-14 cubic feet (sedan)

Weights

Curb Weight Range:

Approx. 2700-3100 lbs (non-turbo models); 3200-3400 lbs (Evo models)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star (typical for this era, verify specific year/model)

NHTSA Side Impact:

4-star (typical for this era, verify specific year/model)

IIHS Front Offset:

Good (typical for this era, verify specific year/model)

Active Features

Standard on most models, optional on base trims in early years

Traction Control:

Available on higher trims and performance models

Electronic Stability Control:

Available on some later models and performance variants

Passive Features

Airbags:

Front airbags standard; side curtain airbags and side torso airbags available on higher trims/later models

Seatbelts:

Three-point front and rear seat belts, pretensioners for front seats

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with 4-6 speakers. Higher trims may offer premium Rockford Fosgate audio systems.

Navigation:

Optional factory navigation system available on select higher trim levels.

Driver Assistance

Cruise Control:

Standard on most models.

As mentioned in safety section, standard or optional.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors are common features, especially on mid to high trims.

Keyless Entry:

Available on higher trim levels.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 miles or 6 months, whichever comes first (check owner's manual for specific recommendations based on driving conditions)

Engine Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 30,000 miles)

Cabin Air Filter:

Replace every 15,000 - 30,000 miles or as needed, depending on environment

Spark Plugs:

Replace every 60,000 - 100,000 miles (depending on plug type - standard vs. iridium, consult manual)

Transmission Fluid Auto:

Replace fluid and filter every 30,000 - 60,000 miles (severe service may require more frequent changes)

Transmission Fluid Manual:

Inspect every 30,000 miles, replace as needed (typically every 60,000 - 100,000 miles)

Coolant Flush:

Replace coolant every 30,000 - 50,000 miles or 2-3 years

Timing Belt:

Critical item for 4G63/4G64 engines. Replace every 60,000 - 90,000 miles or 5-7 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

API SN or newer, ILSAC GF-5 or newer. Viscosity typically 5W-20 or 5W-30 (refer to owner's manual for specific engine variant)

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with proper inhibitors). Typically a pink/red color.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Transmission Fluid Auto:

DiaQueen SPIII (or equivalent ATF SP-III specification)

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, SAE 75W-90 (check specific manual for accuracy)

Power Steering Fluid:

Dexron III (or equivalent ATF fluid for hydraulic systems)

Known Issues

Engine Mounts:

Premature wear of engine and transmission mounts can lead to excessive vibration and noise.

O2 Sensors:

Oxygen sensors can become fouled or fail, leading to poor fuel economy and check engine lights.

Evaporative Emission Control System:

Issues with the EVAP system (e.g., purge valve, vent solenoid, charcoal canister) can trigger check engine lights.

Suspension Components:

Worn ball joints, tie rod ends, and wheel bearings are common with mileage, affecting steering and ride quality.

Exhaust Manifold Cracks:

Some 4G63/4G64 engines may develop cracks in the exhaust manifold, leading to exhaust leaks and ticking noises.

Power Window Regulators:

Window regulator failure is a common electrical/mechanical issue, often related to the motor or plastic guides.

Automatic Transmission Harsh Shifting:

Some early automatic transmissions may exhibit occasional harsh shifts or delayed engagement, often related to solenoid issues or fluid degradation.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Long history in automotive manufacturing, known for reliable and often performance-oriented vehicles, strong rally heritage

Model Evolution

Lancer Generations:

This period (2000-2007) covers the seventh generation of the Mitsubishi Lancer (CS platform), a significant redesign from the previous generation.

Lancer Sportback:

Hatchback (Sportback) variants were also offered during this generation, increasing practicality.

Lancer Evolution:

The seventh generation saw the introduction and continued development of the legendary Lancer Evolution (Evo VII, VIII, IX), which cemented the Lancer's performance reputation globally.

Production

Production Locations:

Primarily Japan (Mizushima Plant, Kurashiki), but also significant production in other global facilities depending on market

Sales Performance:

Sold well globally, particularly popular in North America and Europe, with strong sales for performance-oriented trims and AWD models.

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Lancer Evolution models consistently received accolades for performance, handling, and rally prowess, often being lauded as benchmark sports sedans.

Initial Quality:

The Lancer generally offered good value and reliability for its segment, though specific quality awards varied by year and reporting agency.

Ratings

Consumer Reports:

Consumer Reports ratings for this generation of Lancer were generally average to above average, with praise for handling and value, but some concerns regarding fuel economy and long-term reliability on certain components.

Certifications

Epa Fuel Economy:

EPA fuel economy ratings varied significantly by engine and transmission, typically ranging from 20-25 MPG city and 27-33 MPG highway for naturally aspirated models. Performance models had lower ratings.