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2003-2005 Mitsubishi Lancer Evolution Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: CT9A (Evo VIII/IX) Years Covered: 2003, 2004, 2005 Codes Chassis Code: CT9A 👋 Introduction Market Position Market Segment: High-performance compact sedan, rally-bred homologation special Target Audience: Enthusiasts, tuners, owners seeking detailed repair and maintenance information Competitive Analysis Key Competitors: Subaru Impreza WRX/STI, Ford Focus RS, Volkswagen Golf R32 Key Features Performance Focus: Emphasizes the performance aspects of the Lancer Evolution, including engine tuning, drivetrain management, and suspension setup Technical Accuracy: Provides official factory specifications and procedures, ensuring accuracy for repairs and diagnostics Completeness: Presents itself as the most complete manual, covering all aspects of servicing and repair 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: Downloadable (likely PDF) Page Count Estimated Page Count: Likely extensive, typically 1000+ pages for full factory service manuals 📖 Manual Coverage Systems Covered Engine: 4G63T DOHC Turbocharged Inline-4 (2.0L) Transmission: 6-speed Manual (G6M31TWAAC) and 5-speed Automatic (F5M33) Drivetrain: All-Wheel Drive (S-AWC - Super All Wheel Control), Active Center Differential (ACD), Active Yaw Control (AYC), Helical Front Limited Slip Differential (LSD), Limited Slip Rear Differential (LSD) Suspension: Front: MacPherson Struts with Stabilizer Bar; Rear: Multi-link Brakes: Front: Brembo 4-piston calipers with 320mm vented discs; Rear: Brembo 2-piston calipers with 300mm vented discs (Evo VIII MR/IX), ABS Electrical: Complete Wiring Diagrams, ECU, Sensors, Ignition System, Charging System, Lighting, Instruments Body: Chassis, Body Panels, Doors, Glass, Interior Trim, Body Sealing Cooling System: Radiator, Fans, Hoses, Thermostat, Coolant Specifications Fuel System: Fuel Pump, Injectors, Fuel Lines, Fuel Filter, Fuel Pressure Regulator Exhaust System: Manifold, Catalytic Converter, Muffler, Pipes HVAC: Air Conditioning, Heating, Ventilation, Cabin Filter Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plugs, Belts, Fluids, Inspections Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Service, Electrical Diagnostics and Repair Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides Assembly Disassembly: Detailed step-by-step procedures for component removal and installation Wiring Diagrams: Comprehensive electrical schematics for all systems Technical Depth Depth Level: Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts Diagnostics: In-depth diagnostic procedures, including signal tracing and component testing Specifications: Torque specifications, clearances, pressures, fluid capacities, and tolerances for all components 📊 Manual Specifications File Format File Type: PDF (Downloadable) Searchable Text: Likely includes searchable text for easy navigation Print Quality Printability: Designed for printing specific sections or the entire manual Binding Type Binding For Printed: N/A (Downloadable) Paper Type Paper Quality For Printed: N/A (Downloadable) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 (Evo VIII), 8.8:1 (Evo IX - some variations) Performance Horsepower Output Evo Viii: 271 hp @ 6500 rpm Torque Output Evo Viii: 273 lb-ft @ 3500 rpm Horsepower Output Evo Ix: 286 hp @ 6500 rpm Torque Output Evo Ix: 289 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Turbocharger: MHI TD05H-16G (Evo VIII), MHI TD05H-16G (Evo IX - often with revised turbine housing or MIVEC intake cam) 🔧 Transmission Standard Transmission Type: 6-speed Manual (G6M31TWAAC) Optional Transmission Type Optional: 5-speed Automatic (F5M33) Features Clutch Type: Hydraulically actuated, single dry plate (manual) Manual Transmission Fluid Spec: MITSU-SPEC GL-3 or GL-4 equivalent (e.g., Red Line Gear Oil 75W90) Automatic Transmission Fluid Spec: DIA-QUEEN ATF SP-III 📐 Dimensions Exterior Wheelbase: 2625 mm (103.3 in) Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Weights Curb Weight Manual: Approximately 1450-1500 kg (3197-3307 lbs) Wheel Bolt Pattern: 5x114.3 mm Tire Size Stock: 235/45R17 (Evo VIII), 235/45R17 or 235/40R18 (Evo IX) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars Active Features ABS: Standard (4-channel, 4-sensor) Traction Control: ACD (Active Center Differential) and AYC (Active Yaw Control) are integral to handling and stability Passive Features Airbags: Driver and Front Passenger Airbags (standard), Optional Side Airbags Seatbelts: 3-point ELR with pretensioners and force limiters 💡 Technology Features Infotainment Audio System: Factory CD/MP3 player with AM/FM radio, optional Rockford Fosgate premium audio system Display: Multi-information display in instrument cluster showing trip computer, fuel economy, and system status Driver Assistance Active Handling Systems: S-AWC (Super All Wheel Control) integrating ACD, AYC, ABS, and ASC (Active Stability Control) for unparalleled traction and cornering ability. Connectivity Bluetooth: Not typically standard on these model years; aftermarket solutions common. Auxiliary Input: May be present on some models for audio devices 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions) Air Filter Replacement: Every 15,000 miles (24,000 km) Spark Plug Replacement: Platinum: 60,000 miles (96,000 km); Iridium: 105,000 miles (168,000 km) (refer to specific plug type) Timing Belt Replacement: Every 60,000 miles...
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2003-2005 Mitsubishi Lancer Evolution Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Generation:
CT9A (Evo VIII/IX)
Years Covered:
2003, 2004, 2005
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Market Segment:
High-performance compact sedan, rally-bred homologation special
Target Audience:
Enthusiasts, tuners, owners seeking detailed repair and maintenance information
Competitive Analysis
Key Competitors:
Subaru Impreza WRX/STI, Ford Focus RS, Volkswagen Golf R32
Key Features
Performance Focus:
Emphasizes the performance aspects of the Lancer Evolution, including engine tuning, drivetrain management, and suspension setup
Technical Accuracy:
Provides official factory specifications and procedures, ensuring accuracy for repairs and diagnostics
Completeness:
Presents itself as the most complete manual, covering all aspects of servicing and repair
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
Downloadable (likely PDF)
Page Count
Estimated Page Count:
Likely extensive, typically 1000+ pages for full factory service manuals
📖 Manual Coverage
Systems Covered
Engine:
4G63T DOHC Turbocharged Inline-4 (2.0L)
Transmission:
6-speed Manual (G6M31TWAAC) and 5-speed Automatic (F5M33)
Drivetrain:
All-Wheel Drive (S-AWC - Super All Wheel Control), Active Center Differential (ACD), Active Yaw Control (AYC), Helical Front Limited Slip Differential (LSD), Limited Slip Rear Differential (LSD)
Suspension:
Front: MacPherson Struts with Stabilizer Bar; Rear: Multi-link
Brakes:
Front: Brembo 4-piston calipers with 320mm vented discs; Rear: Brembo 2-piston calipers with 300mm vented discs (Evo VIII MR/IX), ABS
Electrical:
Complete Wiring Diagrams, ECU, Sensors, Ignition System, Charging System, Lighting, Instruments
Body:
Chassis, Body Panels, Doors, Glass, Interior Trim, Body Sealing
Cooling System:
Radiator, Fans, Hoses, Thermostat, Coolant Specifications
Fuel System:
Fuel Pump, Injectors, Fuel Lines, Fuel Filter, Fuel Pressure Regulator
Exhaust System:
Manifold, Catalytic Converter, Muffler, Pipes
HVAC:
Air Conditioning, Heating, Ventilation, Cabin Filter
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plugs, Belts, Fluids, Inspections
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Service, Electrical Diagnostics and Repair
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides
Assembly Disassembly:
Detailed step-by-step procedures for component removal and installation
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts
Diagnostics:
In-depth diagnostic procedures, including signal tracing and component testing
Specifications:
Torque specifications, clearances, pressures, fluid capacities, and tolerances for all components
📊 Manual Specifications
File Format
File Type:
PDF (Downloadable)
Searchable Text:
Likely includes searchable text for easy navigation
Print Quality
Printability:
Designed for printing specific sections or the entire manual
Binding Type
Binding For Printed:
N/A (Downloadable)
Paper Type
Paper Quality For Printed:
N/A (Downloadable)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1 (Evo VIII), 8.8:1 (Evo IX - some variations)
Performance
Horsepower Output Evo Viii:
271 hp @ 6500 rpm
Torque Output Evo Viii:
273 lb-ft @ 3500 rpm
Horsepower Output Evo Ix:
286 hp @ 6500 rpm
Torque Output Evo Ix:
289 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Turbocharger:
MHI TD05H-16G (Evo VIII), MHI TD05H-16G (Evo IX - often with revised turbine housing or MIVEC intake cam)
🔧 Transmission
Standard
Transmission Type:
6-speed Manual (G6M31TWAAC)
Optional
Transmission Type Optional:
5-speed Automatic (F5M33)
Features
Clutch Type:
Hydraulically actuated, single dry plate (manual)
Manual Transmission Fluid Spec:
MITSU-SPEC GL-3 or GL-4 equivalent (e.g., Red Line Gear Oil 75W90)
Automatic Transmission Fluid Spec:
DIA-QUEEN ATF SP-III
📐 Dimensions
Exterior
Wheelbase:
2625 mm (103.3 in)
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Weights
Curb Weight Manual:
Approximately 1450-1500 kg (3197-3307 lbs)
Wheel Bolt Pattern:
5x114.3 mm
Tire Size Stock:
235/45R17 (Evo VIII), 235/45R17 or 235/40R18 (Evo IX)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
Active Features
ABS:
Standard (4-channel, 4-sensor)
Traction Control:
ACD (Active Center Differential) and AYC (Active Yaw Control) are integral to handling and stability
Passive Features
Airbags:
Driver and Front Passenger Airbags (standard), Optional Side Airbags
Seatbelts:
3-point ELR with pretensioners and force limiters
💡 Technology Features
Infotainment
Audio System:
Factory CD/MP3 player with AM/FM radio, optional Rockford Fosgate premium audio system
Display:
Multi-information display in instrument cluster showing trip computer, fuel economy, and system status
Driver Assistance
Active Handling Systems:
S-AWC (Super All Wheel Control) integrating ACD, AYC, ABS, and ASC (Active Stability Control) for unparalleled traction and cornering ability.
Connectivity
Bluetooth:
Not typically standard on these model years; aftermarket solutions common.
Auxiliary Input:
May be present on some models for audio devices
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions)
Air Filter Replacement:
Every 15,000 miles (24,000 km)
Spark Plug Replacement:
Platinum: 60,000 miles (96,000 km); Iridium: 105,000 miles (168,000 km) (refer to specific plug type)
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T engine)
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30; API SJ or SL, SAE 10W-30 recommended for normal use.
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Type:
Mitsubishi Dia-Queen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with anti-corrosive additives)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gasket Failures:
Common concern, especially with modified engines or poor maintenance. Manual provides procedures for inspection and replacement.
Acd/Ayc System Faults:
Potential for sensor failures or hydraulic unit issues. Manual covers diagnostics and bleeding procedures.
Turbocharger Wear:
Wear and tear on the turbocharger's seals and bearings is possible, especially with high mileage or aggressive use. Manual details inspection and replacement.
Clutch Wear:
Clutch wear is normal with manual transmissions, with replacement procedures and specifications detailed.
📚 Vehicle History
Brand Heritage
Rally Roots:
Direct lineage from Mitsubishi's dominant World Rally Championship (WRC) cars
Model Evolution
Viii Ix Transition:
Evo VIII (2003-2005 model years) and Evo IX (introduced in 2005), representing the CT9A chassis evolution
Key Evo Ix Enhancements:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on the intake camshaft for improved torque and powerband, larger turbocharger and intercooler for some variants, revised styling.
Production
Production Location:
Mizushima, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Frequently cited by automotive publications as a benchmark for performance and handling in its class.
Ratings
Handling Dynamics:
Universally praised for its razor-sharp handling, precise steering, and advanced all-wheel-drive system.
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