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2005 Mitsubishi Lancer Evolution 9 IX Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Model Short Name: Evo IX Year: 2005 Codes Platform Code: CT9A Engine Code Primary: 4G63 Engine Code Specific: 4G63 MIVEC 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution IX (Evo IX) represents the pinnacle of the Lancers rally-bred performance lineage, offering a potent blend of turbocharged power, advanced all-wheel-drive technology, and a driver-focused experience. Competitive Analysis Competitors: Directly competed with cars like the Subaru Impreza WRX STI, Ford Focus RS, and other high-performance compact sedans of its era. Key Features Performance Focus: Renowned for its aggressive styling, exceptional handling, and sophisticated drivetrain, the Evo IX remains a highly sought-after performance vehicle. Manual Value Value Proposition: This factory service manual is an indispensable resource for owners and technicians seeking to maintain, diagnose, and repair the complex systems of the Evo IX to factory specifications. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all aspects of the 2005 Mitsubishi Lancer Evolution IX. Target Audience: Professional mechanics and advanced DIY enthusiasts. Page Count Estimated Pages: Over 2000 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 4G63 MIVEC Turbocharged inline-4: components, disassembly, assembly, diagnosis, troubleshooting, performance tuning basics. Fuel System: Fuel injection, fuel pump, injectors, fuel lines, pressure regulator, evaporative emissions control. Ignition System: Ignition coils, spark plugs, engine control module (ECM) control. Cooling System: Radiator, water pump, thermostat, hoses, fan, coolant specifications. Exhaust System: Exhaust manifolds, catalytic converter, muffler, oxygen sensors. Transmission: 6-speed manual transmission (Getrag MS-6S-50BG): clutch, gearbox, differentials, fluid specifications, removal, installation, internal components. Drivetrain: All-Wheel Drive (AWD) system: electronically controlled active center differential (ACD), Super Active Yaw Control (S-AYC), propeller shaft, driveshafts, wheel hubs. Brakes: Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS system, brake fluid specifications, bleeding procedures, component replacement. Steering: Power-assisted rack and pinion, steering column, steering wheel, alignment specifications. Suspension: Front MacPherson struts, rear multi-link independent suspension, springs, dampers, bushings, wheel bearing replacement, alignment. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, power distribution. Engine Control System: ECU, sensors (MAP, MAF, O2, knock, crank, cam), actuators (throttle body, wastegate solenoid), diagnostic trouble codes (DTCs). Body And Chassis: Body panels, doors, fenders, hood, trunk, interior trim, structural components, corrosion protection. Climate Control: HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls. Safety Systems: Airbags, seat belts, SRS system diagnosis, ABS, ACD, S-AYC. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection. Engine Repair: Head gasket replacement, turbocharger overhaul, piston and ring installation, valve stem seal replacement, timing belt/chain service. Transmission Repair: Clutch replacement, gearbox rebuild, differential service, synchronizer replacement. Drivetrain Service: ACD and S-AYC system service and calibration, driveshaft and CV joint inspection/replacement. Brake System Repair: Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS module diagnosis. Suspension And Steering Repair: Shock absorber and strut replacement, bushing replacement, power steering pump and rack service, wheel alignment procedures. Electrical Diagnostics: Troubleshooting electrical faults, wiring harness repair, component testing, use of diagnostic tools. Bodywork And Interior: Panel alignment, door hinge adjustment, interior trim removal/installation, glass replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Specifications: Torque specifications for all fasteners, clearance measurements, fluid capacities, and types. Technical Depth Depth: Full factory-level repair procedures, including component teardown, assembly, and specialized tool usage. Diagnostic Capability: Detailed information on diagnosing electronic control systems, sensor readings, and actuator functions. Rebuild Procedures: Comprehensive guides for engine and transmission rebuilds, including internal component specifications and tolerances. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval. Image Quality: High-resolution diagrams, illustrations, and photographs. Print Quality Printability: Printable pages for easy reference in a workshop environment. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63 Inline-4, DOHC, 16-valve Aspiration: MIVEC Turbocharged (Mitsubishi Innovative Valve timing and lift Electronic Control) Displacement: 2.0 Liters (1997 cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Usdm: 286 hp @ 6500 rpm Torque Usdm: 289 lb-ft @ 3500 rpm Turbocharger Model: MHI TD05HR-16G6-10.5T Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Fuel Injectors: High-flow injectors (e.g., Bosch 560cc or equivalent for aftermarket upgrades often detailed in manual for tuning). 🔧 Transmission Standard Type: Getrag MS-6S-50BG 6-Speed Manual Transmission Optional Type: N/A (Only Manual Transmission Offered for Evolution IX) Features Drivetrain: All-Wheel Drive (AWD) with electronically controlled Active Center Differential (ACD) and Super Active Yaw Control (S-AYC). Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 specifications; typically a high-quality 75W-90 synthetic gear oil is recommended. Center...
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2005 Mitsubishi Lancer Evolution 9 IX Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Model Short Name:
Evo IX
Year:
2005
Codes
Platform Code:
CT9A
Engine Code Primary:
4G63
Engine Code Specific:
4G63 MIVEC
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution IX (Evo IX) represents the pinnacle of the Lancers rally-bred performance lineage, offering a potent blend of turbocharged power, advanced all-wheel-drive technology, and a driver-focused experience.
Competitive Analysis
Competitors:
Directly competed with cars like the Subaru Impreza WRX STI, Ford Focus RS, and other high-performance compact sedans of its era.
Key Features
Performance Focus:
Renowned for its aggressive styling, exceptional handling, and sophisticated drivetrain, the Evo IX remains a highly sought-after performance vehicle.
Manual Value
Value Proposition:
This factory service manual is an indispensable resource for owners and technicians seeking to maintain, diagnose, and repair the complex systems of the Evo IX to factory specifications.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all aspects of the 2005 Mitsubishi Lancer Evolution IX.
Target Audience:
Professional mechanics and advanced DIY enthusiasts.
Page Count
Estimated Pages:
Over 2000
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
4G63 MIVEC Turbocharged inline-4: components, disassembly, assembly, diagnosis, troubleshooting, performance tuning basics.
Fuel System:
Fuel injection, fuel pump, injectors, fuel lines, pressure regulator, evaporative emissions control.
Ignition System:
Ignition coils, spark plugs, engine control module (ECM) control.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications.
Exhaust System:
Exhaust manifolds, catalytic converter, muffler, oxygen sensors.
Transmission:
6-speed manual transmission (Getrag MS-6S-50BG): clutch, gearbox, differentials, fluid specifications, removal, installation, internal components.
Drivetrain:
All-Wheel Drive (AWD) system: electronically controlled active center differential (ACD), Super Active Yaw Control (S-AYC), propeller shaft, driveshafts, wheel hubs.
Brakes:
Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS system, brake fluid specifications, bleeding procedures, component replacement.
Steering:
Power-assisted rack and pinion, steering column, steering wheel, alignment specifications.
Suspension:
Front MacPherson struts, rear multi-link independent suspension, springs, dampers, bushings, wheel bearing replacement, alignment.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, power distribution.
Engine Control System:
ECU, sensors (MAP, MAF, O2, knock, crank, cam), actuators (throttle body, wastegate solenoid), diagnostic trouble codes (DTCs).
Body And Chassis:
Body panels, doors, fenders, hood, trunk, interior trim, structural components, corrosion protection.
Climate Control:
HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls.
Safety Systems:
Airbags, seat belts, SRS system diagnosis, ABS, ACD, S-AYC.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection.
Engine Repair:
Head gasket replacement, turbocharger overhaul, piston and ring installation, valve stem seal replacement, timing belt/chain service.
Transmission Repair:
Clutch replacement, gearbox rebuild, differential service, synchronizer replacement.
Drivetrain Service:
ACD and S-AYC system service and calibration, driveshaft and CV joint inspection/replacement.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS module diagnosis.
Suspension And Steering Repair:
Shock absorber and strut replacement, bushing replacement, power steering pump and rack service, wheel alignment procedures.
Electrical Diagnostics:
Troubleshooting electrical faults, wiring harness repair, component testing, use of diagnostic tools.
Bodywork And Interior:
Panel alignment, door hinge adjustment, interior trim removal/installation, glass replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Specifications:
Torque specifications for all fasteners, clearance measurements, fluid capacities, and types.
Technical Depth
Depth:
Full factory-level repair procedures, including component teardown, assembly, and specialized tool usage.
Diagnostic Capability:
Detailed information on diagnosing electronic control systems, sensor readings, and actuator functions.
Rebuild Procedures:
Comprehensive guides for engine and transmission rebuilds, including internal component specifications and tolerances.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Image Quality:
High-resolution diagrams, illustrations, and photographs.
Print Quality
Printability:
Printable pages for easy reference in a workshop environment.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63 Inline-4, DOHC, 16-valve
Aspiration:
MIVEC Turbocharged (Mitsubishi Innovative Valve timing and lift Electronic Control)
Displacement:
2.0 Liters (1997 cc)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Usdm:
286 hp @ 6500 rpm
Torque Usdm:
289 lb-ft @ 3500 rpm
Turbocharger Model:
MHI TD05HR-16G6-10.5T
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
Fuel Injectors:
High-flow injectors (e.g., Bosch 560cc or equivalent for aftermarket upgrades often detailed in manual for tuning).
🔧 Transmission
Standard
Type:
Getrag MS-6S-50BG 6-Speed Manual Transmission
Optional
Type:
N/A (Only Manual Transmission Offered for Evolution IX)
Features
Drivetrain:
All-Wheel Drive (AWD) with electronically controlled Active Center Differential (ACD) and Super Active Yaw Control (S-AYC).
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 specifications; typically a high-quality 75W-90 synthetic gear oil is recommended.
Center Differential Fluid:
Refer to manual for specific ACD fluid type and capacity (often a proprietary Mitsubishi fluid or equivalent).
Clutch
Type:
Hydraulically actuated, single-plate, dry-type clutch with a high-performance flywheel.
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Front Track:
1515 mm (59.6 in)
Rear Track:
1510 mm (59.4 in)
Weights
Curb Weight:
Approx. 1450 kg (3197 lbs) - Varies by trim and options
Gross Vehicle Weight Rating:
Refer to vehicle placard; typically around 1850 kg (4078 lbs)
Towing Capacity:
Not Recommended/Specified
Cargo
Trunk Volume:
Refer to owner's manual; typically limited due to AWD components and chassis bracing.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Refer to NHTSA records for 2005 model; generally good for the era, but specific ratings may vary.
IIHS Side Impact:
Refer to IIHS records for 2005 model.
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Traction Control System (TCL)
Stability Control:
Electronic Stability Control (ESC) may be optional or standard depending on market and trim.
AWD System:
Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) for enhanced traction and cornering stability.
Passive Features
Airbags:
Front driver and passenger airbags. Side curtain airbags may be optional.
Seat Belts:
3-point front and rear seat belts with pretensioners.
Body Structure:
Reinforced body structure designed for high-performance driving and crash safety.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio system with CD player, potentially with cassette. Speaker upgrades and head unit replacements are common modifications.
Climate Control Features:
Manual or automatic climate control depending on trim level.
Driver Assistance
Advanced AWD:
ACD and S-AYC systems are key technological features providing significant handling advantages.
Connectivity
Instrument Cluster:
Performance-oriented instrument cluster with boost gauge and comprehensive engine monitoring.
Engine Management
ECU:
ECU is highly programmable for aftermarket tuning, with extensive diagnostic capabilities detailed in the manual.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,750 miles or 6 months, whichever comes first (severe driving conditions; normal conditions may extend slightly, but performance driving warrants frequent changes).
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 30,000 - 60,000 miles, depending on plug type (refer to manual for specific recommendations).
Timing Belt Inspection/Replacement:
Refer to manual; the 4G63 uses a timing belt. Inspect at 60,000 miles, replace typically around 90,000-105,000 miles or per manual.
Transmission Fluid Change:
Every 30,000 miles or 24 months (manual transmission and ACD).
Brake Fluid Flush:
Every 24,000 miles or 24 months.
Fluid Specifications
Engine Oil Type:
Refer to manual for viscosity grade and API classification. Typically 5W-30 or 10W-30 synthetic oil meeting ACEA A3/B4 or API SN/SM/SL specifications is recommended, especially for high-performance use.
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent P-HOAT/OAT coolant, typically pink or red) - 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for precise specification, high-performance driving may benefit from DOT 4).
Known Issues
Engine:
Head gasket failures (especially on modified or poorly maintained engines), turbocharger wear, crank walk (rare but critical issue on some 4G63s, often related to oil pressure or abuse).
Drivetrain:
ACD/AYC pump failure, differential issues on high-mileage vehicles if not properly maintained.
Suspension:
Wear in bushings, ball joints, and wheel bearings due to aggressive driving.
Electrical:
TPS (Throttle Position Sensor) issues, intermittent electrical gremlins due to wiring complexity.
📚 Vehicle History
Brand Heritage
Rally Icon:
Mitsubishi has a storied history in the World Rally Championship (WRC), and the Lancer Evolution series is a direct production derivative of their successful rally cars.
Model Evolution
Evolution Series:
The Evolution IX, launched in 2005, marked the final iteration of the acclaimed '4G63-powered' Evo generation, incorporating significant mechanical and electronic refinements over its predecessors.
Ninth Generation:
The Evo IX introduced MIVEC variable valve timing to the 4G63 engine, improving both power delivery and efficiency, along with revised turbocharger and cosmetic updates.
Production
Production Years:
2005-2007 (for the Evo IX generation)
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently praised by automotive publications for its handling, braking, and all-wheel-drive capabilities. Often cited as a benchmark performance sedan.
Ratings
Driving Dynamics:
High critical acclaim for its chassis dynamics, steering feel, and driver engagement.
Certifications
Factory Origin:
This manual is a direct reproduction of the official factory documentation used by authorized Mitsubishi service centers.
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