2003 Mitsubishi Lancer Evolution Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 2003 Codes Chassis Code: CT9A Chassis Code Variant: GSR, RS 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Focus RS, Lancia Delta Integrale (historical) Key Features Vehicle Philosophy: Legendary rally-bred performance, advanced all-wheel-drive system, powerful turbocharged engine. Manual Value Proposition: Empowers owners and independent technicians with factory-level repair and maintenance knowledge, reducing reliance on expensive dealerships and minimizing the risk of incorrect repairs. 📋 Manual Details Coverage Areas Engine: 4G63 (2.0L Turbocharged Inline-4) Transmission: 6-speed Manual Drivetrain: All-Wheel Drive (S-AWC) Body Style: Sedan Page Count Estimated Page Count: Approx. 2000+ pages (typical for comprehensive service manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63), Turbocharger System, Fuel & Emissions, Cooling System, Lubrication System, Ignition System, Exhaust System Drivetrain: Manual Transmission, Clutch System, Transfer Case, Front Differential, Rear Differential, Driveshafts, Axles, Super Active Yaw Control (S-AWC) System Chassis: Suspension (Front & Rear), Steering System, Brake System (ABS, EBD), Wheels & Tires Electrical: Engine Control Module (ECM), Body Control Module (BCM), Lighting System, Instrument Cluster, Audio System, Power Accessories, Wiring Diagrams, Diagnostic Trouble Codes (DTCs) Body And Interior: Body Panels, Doors, Windows, Seats, HVAC System, Airbags, Interior Trim Procedures Included Maintenance: Routine Checks, Fluid Changes (Oil, Coolant, Brake Fluid, Transmission Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection & Replacement Diagnostics And Troubleshooting: Systematic Diagnosis of Common Faults, DTC Interpretation, Component Testing Procedures Repair And Rebuild: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Caliper Overhaul, Turbocharger Reconditioning Electrical Repairs: Wiring Harness Repair, Component Testing & Replacement (Sensors, Actuators), ECU Diagnosis Technical Depth Depth: Comprehensive: Covers basic to advanced diagnostics, component removal/installation, overhaul procedures, and specifications for nearly every system on the vehicle. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text Content Print Quality Printability: Printable pages on demand Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L (1997cc) DOHC 16-Valve Turbocharged Inline-4 Performance Horsepower Us Spec: 271 hp @ 6500 rpm (approximate) Torque Us Spec: 273 lb-ft @ 3500 rpm (approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Port Injection Turbocharger: Mitsubishi TD05HR-16G6-10.5T Twin-Scroll Turbocharger Cooling System Coolant Capacity: 7.6 Liters (8.0 US Quarts) Lubrication System Oil Capacity With Filter: 4.5 Liters (4.8 US Quarts) Recommended Oil Viscosity: 10W-30 (API SG or higher) 🔧 Transmission Standard Type: 6-speed Manual Transmission (RM01A) Optional Type: N/A (Evo VII GSR was exclusively manual) Features Gear Ratios: Specific gear ratios are detailed within the manual for each gear. Transmission Fluid Capacity: Approx. 2.0 Liters (2.1 US Quarts) for transmission and transfer case Transmission Fluid Type: API GL-3 or GL-4, SAE 75W-90 Synthetic Gear Oil (Refer to manual for precise OEM specifications) 📐 Dimensions Exterior Length: 4400 mm (173.2 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2625 mm (103.3 in) Weights Curb Weight: Approx. 1450 kg (3197 lbs) for GSR Gross Weight: Refer to specific vehicle VIN plate. 🛡️ Safety Features Ratings NHTSA Rating: Not consistently tested by NHTSA for this specific generation and market. Manual provides system safety information. Active Features Driver Assistance: Active Center Differential (ACD), Active Yaw Control (AYC), Super Active Yaw Control (S-AWC) integrating ACD and AYC, Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD) Passive Features Airbags: Driver and Passenger Front Airbags, Side Airbags (optional/specific trims) Structural Enhancements: Reinforced body structure for rally homologation. 💡 Technology Features Infotainment Audio System: Factory-fitted Mitsubishi AM/FM CD Player, typically with 6 speakers. Limited advanced features compared to modern vehicles. Driver Assistance Performance Aids: Advanced electronic control systems for drivetrain (S-AWC) significantly enhance traction and handling in various conditions. Connectivity Bluetooth: Not available from factory. 🔧 Maintenance Service Intervals Engine Oil And Filter: Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Under severe driving conditions, reduce interval to 3,750 miles (6,000 km). Air Filter: Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km). Spark Plugs: Replace every 60,000 miles (96,000 km) for standard plugs, or refer to manual for performance plug recommendations. Timing Belt: Replace every 60,000 miles (96,000 km) or 5 years, whichever comes first. Critical for 4G63 engine longevity. Fluid Specifications Brake Fluid: DOT 3 or DOT 4 Power Steering Fluid: Dexron II or equivalent ATF Known Issues Engine: Head gasket failures (especially on modified engines), turbocharger wear, piston ring land failure in extreme cases. Regular maintenance is crucial. Drivetrain: ACD/AYC pump failures, differential wear with aggressive use. Proper fluid changes are vital. Electrical: Corrosion in connectors, issues with ACD pump relays, sensor failures (e.g., crank position sensor)....
Empowers owners and independent technicians with factory-level repair and maintenance knowledge, reducing reliance on expensive dealerships and minimizing the risk of incorrect repairs.
📋 Manual Details
Coverage Areas
Engine:
4G63 (2.0L Turbocharged Inline-4)
Transmission:
6-speed Manual
Drivetrain:
All-Wheel Drive (S-AWC)
Body Style:
Sedan
Page Count
Estimated Page Count:
Approx. 2000+ pages (typical for comprehensive service manuals)
Comprehensive: Covers basic to advanced diagnostics, component removal/installation, overhaul procedures, and specifications for nearly every system on the vehicle.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text Content
Print Quality
Printability:
Printable pages on demand
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) DOHC 16-Valve Turbocharged Inline-4
Performance
Horsepower Us Spec:
271 hp @ 6500 rpm (approximate)
Torque Us Spec:
273 lb-ft @ 3500 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Port Injection
Specific gear ratios are detailed within the manual for each gear.
Transmission Fluid Capacity:
Approx. 2.0 Liters (2.1 US Quarts) for transmission and transfer case
Transmission Fluid Type:
API GL-3 or GL-4, SAE 75W-90 Synthetic Gear Oil (Refer to manual for precise OEM specifications)
📐 Dimensions
Exterior
Length:
4400 mm (173.2 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1450 kg (3197 lbs) for GSR
Gross Weight:
Refer to specific vehicle VIN plate.
🛡️ Safety Features
Ratings
NHTSA Rating:
Not consistently tested by NHTSA for this specific generation and market. Manual provides system safety information.
Active Features
Driver Assistance:
Active Center Differential (ACD), Active Yaw Control (AYC), Super Active Yaw Control (S-AWC) integrating ACD and AYC, Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD)
Passive Features
Airbags:
Driver and Passenger Front Airbags, Side Airbags (optional/specific trims)
Structural Enhancements:
Reinforced body structure for rally homologation.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted Mitsubishi AM/FM CD Player, typically with 6 speakers. Limited advanced features compared to modern vehicles.
Driver Assistance
Performance Aids:
Advanced electronic control systems for drivetrain (S-AWC) significantly enhance traction and handling in various conditions.
Connectivity
Bluetooth:
Not available from factory.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Under severe driving conditions, reduce interval to 3,750 miles (6,000 km).
Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 60,000 miles (96,000 km) for standard plugs, or refer to manual for performance plug recommendations.
Timing Belt:
Replace every 60,000 miles (96,000 km) or 5 years, whichever comes first. Critical for 4G63 engine longevity.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron II or equivalent ATF
Known Issues
Engine:
Head gasket failures (especially on modified engines), turbocharger wear, piston ring land failure in extreme cases. Regular maintenance is crucial.
Drivetrain:
ACD/AYC pump failures, differential wear with aggressive use. Proper fluid changes are vital.
Electrical:
Corrosion in connectors, issues with ACD pump relays, sensor failures (e.g., crank position sensor).
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi's extensive World Rally Championship (WRC) history significantly influenced the development and marketing of the Lancer Evolution.
Model Evolution
Generation:
This represents the Lancer Evolution VII (CT9A platform), a significant evolution from the previous generation.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Years:
Evo VII produced from 2001-2003. This manual specifically covers the 2003 model year.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists for its exceptional handling, performance, and AWD capabilities, solidifying its status as a modern classic.