2001-2003 Mitsubishi Lancer Evolution Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (chassis designation for Lancer Evolution VII, VIII, IX) Generation Generation Designation: Evolution VII, VIII, IX (partially) Codes Chassis Codes Covered: CT9A 👋 Introduction Market Position Segment: Performance Compact Sedan (rally homologation special) Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (later generations) Competitive Analysis Key Selling Points: Advanced All-Wheel Drive (AWD) systems (ACD/AYC), powerful turbocharged engine, superb handling, rally-inspired performance Key Features Driving Dynamics: Renowned for its driver engagement and track-capable performance straight from the factory Tuning Potential: Popular platform for aftermarket tuning and motorsport modifications 📋 Manual Details Coverage Areas Years Covered: 2001, 2002, 2003 Regions Covered: Global (primary focus on JDM and relevant international markets where Evolution VII/VIII were officially sold or imported) Page Count Estimated Page Count: 1500-2000+ pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English (translation from original Japanese) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Manual transmission (Getrag 6-speed), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), front differential, rear differential, driveshafts, axles Suspension: Front suspension (MacPherson strut), Rear suspension (multi-link), steering system, wheel alignment specifications Brakes: Front and rear brake systems (including Brembo calipers on some models), ABS, brake fluid specifications Electrical: Battery, charging system, starting system, lighting, power accessories, instrument cluster, SRS (airbag) system, ECU/ECM diagnosis Body: Body panels, interior trim, doors, windows, HVAC system, safety restraints Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake, transmission, differential), filter replacements, spark plug replacement Repair: Engine component overhauls, transmission rebuilds, suspension component replacement, brake caliper servicing, electrical component troubleshooting and replacement Diagnostics: Troubleshooting guides based on symptoms, DTC (Diagnostic Trouble Code) interpretation, circuit diagrams, sensor testing Special Tools: Identification and usage of specialized tools required for specific procedures Technical Depth Depth: Comprehensive factory-level detail, including torque specifications, clearances, assembly instructions, and wiring diagrams 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable PDF for quick information retrieval Print Quality Image Resolution: High-resolution scans of original factory documentation Clarity: Clear diagrams, illustrations, and text for easy comprehension Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (DOHC, 16-valve, Inline-4, turbocharged, intercooled) Displacement: 2.0 Liters (1997cc) Performance Horsepower Evolution Viii: 271 hp @ 6500 rpm (JDM/UKDM variants, others may vary slightly) Torque Evolution Viii: 273 lb-ft @ 3500 rpm (JDM/UKDM variants, others may vary slightly) Horsepower Evolution Vii: 276 hp @ 6500 rpm (JDM variants) Torque Evolution Vii: 282 lb-ft @ 3000 rpm (JDM variants) Fuel System Induction: Multi-point Fuel Injection (MPI) with Garrett turbocharger and intercooler Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU Type: ECU controlled engine management system 🔧 Transmission Standard Type: 6-Speed Manual Transmission (Getrag) Optional Type: Not Applicable (Manual transmission was standard for Evolution models) Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning Clutch: Hydraulically actuated single-plate dry clutch 📐 Dimensions Exterior Length: Approx. 4490 mm (176.8 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1415 mm (55.7 in) Wheelbase: Approx. 2625 mm (103.3 in) Weights Curb Weight: Approx. 1450-1500 kg (3197-3307 lbs), depending on specification 🛡️ Safety Features Ratings Crash Test Results: Refer to specific market NCAP or IIHS ratings for the Lancer platform; Evolution models were performance-oriented with less emphasis on standard safety features of the time Active Features AWD Systems: Active Center Differential (ACD), Super Active Yaw Control (S-AYC) for enhanced traction and cornering stability ABS: Anti-lock Braking System (ABS) Passive Features Airbags: Driver and front passenger airbags, SRS system maintenance detailed in the manual Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory CD player with AM/FM radio, potential for optional premium sound systems depending on trim and market Instrument Cluster: Digital odometer, tachometer, speedometer, boost gauge (on some models), and various warning lights Driver Assistance AWD Control: Advanced electronic control of the AWD system (ACD/AYC) is a key technological feature Connectivity Diagnostics Port: OBD-II (On-Board Diagnostics II) compliant port for engine diagnostics 🔧 Maintenance Service Intervals Oil Change: Typically every 3,000-5,000 miles or 6 months (severe driving conditions may require shorter intervals, as detailed in the manual) Timing Belt: Crucial component for the 4G63T; replacement typically recommended every 60,000-90,000 miles or 7 years, refer to manual for exact interval and part number Spark Plugs: Recommended replacement every 30,000-60,000 miles depending on plug type (iridium plugs can extend life) Fluid Specifications Engine Oil: API SN or higher, SAE 5W-30 or 5W-40 recommended (check manual for specific OEM recommendation and viscosity based on climate) Coolant: Mitsubishi...
Manual transmission (Getrag 6-speed), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), front differential, rear differential, driveshafts, axles
Multi-point Fuel Injection (MPI) with Garrett turbocharger and intercooler
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
ECU Type:
ECU controlled engine management system
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission (Getrag)
Optional
Type:
Not Applicable (Manual transmission was standard for Evolution models)
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning
Clutch:
Hydraulically actuated single-plate dry clutch
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs), depending on specification
🛡️ Safety Features
Ratings
Crash Test Results:
Refer to specific market NCAP or IIHS ratings for the Lancer platform; Evolution models were performance-oriented with less emphasis on standard safety features of the time
Active Features
AWD Systems:
Active Center Differential (ACD), Super Active Yaw Control (S-AYC) for enhanced traction and cornering stability
ABS:
Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags, SRS system maintenance detailed in the manual
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory CD player with AM/FM radio, potential for optional premium sound systems depending on trim and market
Instrument Cluster:
Digital odometer, tachometer, speedometer, boost gauge (on some models), and various warning lights
Driver Assistance
AWD Control:
Advanced electronic control of the AWD system (ACD/AYC) is a key technological feature
Connectivity
Diagnostics Port:
OBD-II (On-Board Diagnostics II) compliant port for engine diagnostics
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles or 6 months (severe driving conditions may require shorter intervals, as detailed in the manual)
Timing Belt:
Crucial component for the 4G63T; replacement typically recommended every 60,000-90,000 miles or 7 years, refer to manual for exact interval and part number
Spark Plugs:
Recommended replacement every 30,000-60,000 miles depending on plug type (iridium plugs can extend life)
Fluid Specifications
Engine Oil:
API SN or higher, SAE 5W-30 or 5W-40 recommended (check manual for specific OEM recommendation and viscosity based on climate)
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant
Transmission Fluid:
DiaQueen LSD Gear Oil GL-5 75W-90 for the gearbox and ACD unit (specific DiaQueen fluids are crucial)
Differential Fluid:
DiaQueen LSD Gear Oil GL-5 75W-90 for the rear differential
Known Issues
Engine:
Cracked cylinder heads (especially on highly modified engines), piston ring land failure, turbocharger oil starvation if maintenance is neglected
Transmission:
Wear in the 2nd gear synchro, potential failure of the ACD pump or solenoid if fluid is neglected
Suspension:
Worn control arm bushings, strut mounts
Maintenance Tips
Fuel Quality:
Always use high-quality fuel to prevent detonation and maintain performance
Cooling System:
Regular flushing and inspection of the cooling system is vital to prevent engine overheating
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Directly derived from Mitsubishi's successful World Rally Championship (WRC) program
Model Evolution
Evolution Vii Introduction:
Introduced in 2001, featuring a significant redesign of the Lancer platform and enhanced AWD system
Evolution Viii Introduction:
Launched in 2003 for the US market, marking the first official US-spec Evolution, with performance and styling updates
Evolution Ix Introduction:
While the manual covers up to 2003, the Evolution IX (launched 2005) is the subsequent model, featuring MIVEC variable valve timing
Production
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently lauded by automotive publications for its performance and handling characteristics, often cited as a benchmark for AWD sports cars
Rally Heritage:
Success in WRC cemented its reputation as a true performance machine
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