Mitsubishi Lancer Evolution 2006 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Variant: Evolution VIII MR / Evolution IX Year: 2006 Codes Chassis Code: CT9A (Evolution VIII MR / Evolution IX) Engine Code: 4G63 (various configurations) 👋 Introduction Market Position Market Segment: Performance Compact Sedan (WRC Homologation Special) Competitive Analysis Key Competitors 2006: Subaru Impreza WRX STI, Ford Focus RS, Volkswagen Golf R32, Honda Civic Type R (depending on market). Key Features Performance Focus: All-wheel drive, turbocharged engine, advanced suspension and differential systems for high-performance handling and rally-bred capabilities. Historical Significance: Descendant of rally racing heritage, celebrated for its driver engagement and engineering prowess. 📋 Manual Details Coverage Areas Regions Covered: Global (Primarily JDM, USDM, and EUDM specifications relevant to the 2006 model year) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission controls, engine management (ECU/PCM). Drivetrain Systems: Manual transmission (5-speed/6-speed depending on variant), Active Yaw Control (AYC), Super Active Yaw Control (S-AYC), transfer case, rear differential, drive shafts, CV joints. Chassis Systems: Suspension (front struts, rear multi-link), steering system (power assisted), braking system (ABS, Brembo calipers on performance variants), wheels and tires. Electrical Systems: Battery, charging system, starting system, lighting, instrument cluster, gauges, power accessories, wiring diagrams for all circuits, ECU/PCM diagnostics. Body Systems: Body exterior, interior trim, doors, windows, locks, HVAC system, safety systems (airbags, seatbelts). Procedures Included Maintenance Procedures: Routine checks, fluid changes (oil, coolant, brake, clutch, transmission, differential), filter replacements, spark plug service, belt inspections. Repair Procedures: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul, turbocharger diagnostics and replacement, fuel injector servicing, turbo system leak testing. Diagnostic Procedures: Troubleshooting guides based on symptoms, DTC (Diagnostic Trouble Code) lookup and interpretation, sensor testing, actuator testing, ECU data logging and analysis. Electrical Troubleshooting: Step-by-step diagnostics using wiring diagrams, continuity testing, voltage drop testing, component resistance checks. Technical Depth Depth: Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, complex electrical diagnostics, and body repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution: High-resolution scans optimized for digital viewing and printing. Searchability: Searchable text for quick access to specific topics and keywords. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (DOHC, 16-valve, Turbocharged Inline-4) Displacement: 2.0 Liters (1997cc) Performance Horsepower: Approx. 270-286 HP (depending on market and specific model variant - e.g., Evolution IX GT) Torque: Approx. 270-295 lb-ft (depending on market and specific model variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MPI) Turbocharger: Mitsubishi TD05H-16G (Evolution VIII MR) or TD05HRA-15G (Evolution IX) Twin-Scroll Turbocharger with intercooler. Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent. Capacity: Approx. 7.4 Liters (15.6 US Pints). Lubrication System Engine Oil Type: API SG/SH/SJ/SL, ACEA A2/A3 or higher. Viscosity: 5W-30 or 10W-30 recommended (check manual for specific conditions). Capacity: Approx. 4.5 Liters (9.5 US Pints) with filter. 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (Getrag-based, on most 2006 models, replacing the 5-speed from earlier Evo VIII). Optional Optional Transmission: N/A (Performance variants typically featured manual transmissions exclusively). Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC). Transfer Case Fluid: Mitsubishi DiaQueen LSD Gear Oil GL-5 SAE 75W-90. Capacity: Approx. 0.7 Liters (1.5 US Pints). Rear Differential Fluid: Mitsubishi DiaQueen LSD Gear Oil GL-5 SAE 75W-90. Capacity: Approx. 1.0 Liters (2.1 US Pints). 📐 Dimensions Exterior Length: Approx. 4490 mm (176.8 inches) Width: Approx. 1770 mm (69.7 inches) Height: Approx. 1415 mm (55.7 inches) Wheelbase: Approx. 2625 mm (103.3 inches) Weights Curb Weight: Approx. 1400-1450 kg (3086-3197 lbs) depending on trim and options. 🛡️ Safety Features Ratings NHTSA Ratings: Refer to specific market regulations. Typically performed well in its class for the era. Active Features Active Safety: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Active Yaw Control (AYC)/Super Active Yaw Control (S-AYC). Passive Features Passive Safety: Driver and front passenger airbags, side airbags (optional), pre-tensioning seatbelts, reinforced chassis structure. 💡 Technology Features Infotainment Infotainment System: Basic factory radio/CD player with AM/FM. Higher trims may have optional premium audio systems (e.g., Rockford Fosgate). Driver Assistance Driver Assistance Features: ABS, EBD, AYC/S-AYC. Limited by the era, no modern electronic driver aids like adaptive cruise control or lane keeping assist. Connectivity Connectivity Features: Minimal. Factory option for limited aftermarket Bluetooth integration on some units. Primarily focuses on core vehicle performance. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Consider shorter intervals for aggressive driving/track use. Air...
Manual transmission (5-speed/6-speed depending on variant), Active Yaw Control (AYC), Super Active Yaw Control (S-AYC), transfer case, rear differential, drive shafts, CV joints.
Chassis Systems:
Suspension (front struts, rear multi-link), steering system (power assisted), braking system (ABS, Brembo calipers on performance variants), wheels and tires.
Electrical Systems:
Battery, charging system, starting system, lighting, instrument cluster, gauges, power accessories, wiring diagrams for all circuits, ECU/PCM diagnostics.
Body Systems:
Body exterior, interior trim, doors, windows, locks, HVAC system, safety systems (airbags, seatbelts).
Troubleshooting guides based on symptoms, DTC (Diagnostic Trouble Code) lookup and interpretation, sensor testing, actuator testing, ECU data logging and analysis.
Electrical Troubleshooting:
Step-by-step diagnostics using wiring diagrams, continuity testing, voltage drop testing, component resistance checks.
Technical Depth
Depth:
Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, complex electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Resolution:
High-resolution scans optimized for digital viewing and printing.
Searchability:
Searchable text for quick access to specific topics and keywords.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63 (DOHC, 16-valve, Turbocharged Inline-4)
Displacement:
2.0 Liters (1997cc)
Performance
Horsepower:
Approx. 270-286 HP (depending on market and specific model variant - e.g., Evolution IX GT)
Torque:
Approx. 270-295 lb-ft (depending on market and specific model variant)
Mitsubishi TD05H-16G (Evolution VIII MR) or TD05HRA-15G (Evolution IX) Twin-Scroll Turbocharger with intercooler.
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent. Capacity: Approx. 7.4 Liters (15.6 US Pints).
Lubrication System
Engine Oil Type:
API SG/SH/SJ/SL, ACEA A2/A3 or higher. Viscosity: 5W-30 or 10W-30 recommended (check manual for specific conditions). Capacity: Approx. 4.5 Liters (9.5 US Pints) with filter.
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission (Getrag-based, on most 2006 models, replacing the 5-speed from earlier Evo VIII).
Optional
Optional Transmission:
N/A (Performance variants typically featured manual transmissions exclusively).
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC).
Approx. 1400-1450 kg (3086-3197 lbs) depending on trim and options.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Refer to specific market regulations. Typically performed well in its class for the era.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Active Yaw Control (AYC)/Super Active Yaw Control (S-AYC).
Passive Features
Passive Safety:
Driver and front passenger airbags, side airbags (optional), pre-tensioning seatbelts, reinforced chassis structure.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory radio/CD player with AM/FM. Higher trims may have optional premium audio systems (e.g., Rockford Fosgate).
Driver Assistance
Driver Assistance Features:
ABS, EBD, AYC/S-AYC. Limited by the era, no modern electronic driver aids like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Features:
Minimal. Factory option for limited aftermarket Bluetooth integration on some units. Primarily focuses on core vehicle performance.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Consider shorter intervals for aggressive driving/track use.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months. Inspect more frequently for dusty conditions.
Spark Plug Replacement:
Approx. 60,000 miles (96,000 km) for iridium-tipped plugs (check manual for exact type and gap). Inspect at major services.
Timing Belt Replacement:
Crucial maintenance item. Refer to manual for specific interval (typically around 60,000-90,000 miles or 5-7 years). Failure can cause catastrophic engine damage.
Fluid Specifications
Brake Fluid Type:
FMVSS No. 116 DOT 3 or DOT 4. Recommend high-performance DOT 4 for spirited driving.
Power Steering Fluid:
Dexron III ATF or equivalent. Capacity: Approx. 1.0 Liters (2.1 US Pints).
Clutch Fluid Type:
FMVSS No. 116 DOT 3 or DOT 4 (shared with brake system). Capacity: Approx. 0.7 Liters (1.5 US Pints).
Known Issues
Engine Wear:
Piston ring wear or ringland failure at higher mileage or with aggressive tuning/abuse. Oil consumption can be an indicator.
Turbo Reliability:
Early turbo failures can occur due to improper maintenance (e.g., neglecting oil changes) or heat soak. Checking turbo oil feed and return lines is critical.
Clutch Wear:
High-performance clutches are subject to wear, especially with aggressive driving. Clutch pedal feel and engagement issues may arise.
Ayc/S-Ayc System:
Pump failures, leaks, or sensor issues can lead to warning lights and reduced handling performance. Proper maintenance and fluid changes are key.
Rust And Corrosion:
Common in older vehicles, particularly around wheel wells, rocker panels, and underbody components if not properly maintained or undercoated.
📚 Vehicle History
Brand Heritage
Rally Dominance:
Built on a legacy of World Rally Championship (WRC) success, embodying motorsport DNA.
Model Evolution
Evolution Series:
Represents a significant iteration in the Lancer Evolution lineage, bridging the gap between the Evo VIII and Evo X.
Production
Production Period:
The Evo IX was produced from 2005 to 2007. The 2006 model year encompasses variants of the Evo IX, including the MR variants.
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan.
🏆 Awards & Recognition
Recognitions
Rally Heritage:
Strong association with its World Rally Championship heritage, which significantly influenced its market appeal and performance reputation.
Performance Car Awards:
Consistently praised by automotive media for its exceptional handling, acceleration, and driver involvement, often winning 'best performance car' or 'sports car' categories in its class.
Certifications
Homologation:
Developed for homologation requirements for WRC competition, ensuring its road-going version meets stringent performance and engineering standards.