1996-2007 Mitsubishi Lancer Evolution Service Manual Pack

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Common Name: Evo Product Type: Service Manual Pack Product Format: PDF Download Codes Vehicle Generation Covered: VII, VIII, IX Vehicle Model Years Covered: 1996-2007 (with specific focus on Evo VII-IX) Primary Engine Codes Covered: 4G63, 4G63T (DOHC Turbocharged) 👋 Introduction Market Position Segment: Performance Compact Sedan (rally homologation special) Target Audience: Enthusiasts, tuners, and owners of Mitsubishi Lancer Evolution VII, VIII, and IX models seeking in-depth repair and maintenance information. Competitive Analysis Competitors: Subaru WRX STI, Ford Focus RS, Honda Civic Type R (later generations), Volkswagen Golf R Usp: Renowned for its sophisticated All-Wheel Drive system (S-AWC), potent turbocharged engine, and rally-bred performance. Key Features Performance Focus: Engineered for high-performance driving, track use, and rallying. Technology: Advanced drivetrain and suspension technologies for superior handling and traction. Manual Value: Provides detailed factory procedures essential for maintaining and repairing these complex vehicles accurately. 📋 Manual Details Coverage Areas Primary Coverage: Mitsubishi Lancer Evolution VII, VIII, IX Workshop Service Manuals Additional Coverage: General Lancer Evolution service information from 1996-2007 Page Count Estimated Total Pages: Likely over 1000 pages (combining multiple detailed manuals) Manual Type Primary Type: Workshop Service Manual Secondary Type: Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system Engine Performance: Fuel injection system, ignition system, turbocharger system, emission control system, engine management (ECU) Transmission Manual: Manual gearbox assembly, disassembly, clutch, gear shift mechanism, transfer case Transmission Automatic: Automatic gearbox assembly, disassembly, torque converter, control system (if applicable to specified models) Drivetrain: All-Wheel Drive (AWD) system, Active Yaw Control (AYC), propeller shaft, differential units (front, rear, center) Suspension: Front and rear suspension components, struts, shock absorbers, springs, control arms, anti-roll bars, bushings Steering: Power steering system, steering rack, steering column, tie rods, wheel alignment specifications Brakes: Brake system hydraulics, disc brakes (front and rear), ABS (Anti-lock Braking System), brake pads, rotors, calipers, bleeding procedures Electrical System: Battery, alternator, starter motor, lighting system, fuse boxes, relays, wiring diagrams, ECU diagnosis Body Exterior: Body panel removal and installation, doors, hood, trunk, bumpers, glass, trim Body Interior: Dashboard, seats, interior trim panels, airbags (SRS), climate control system components Heating Ventilation Air Conditioning HVAC: HVAC system components, refrigerant, operation, troubleshooting Diagnostic Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, testing procedures for various components Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid level checks and top-offs, tire rotation Engine Repair: Complete engine rebuilds, head gasket replacement, piston ring replacement, bearing replacement, turbocharger servicing Transmission Repair: Clutch replacement, gearbox overhaul, differential servicing, AYC unit maintenance Suspension And Steering Repair: Component replacement (shocks, struts, ball joints, tie rods), power steering pump replacement, wheel bearing replacement Brake System Service: Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS sensor diagnostics Electrical Diagnostics: Wiring harness inspection, sensor testing, ECU reprogramming/replacement, starter and alternator testing Bodywork And Trim Replacement: Panel alignment, trim piece removal and installation, minor body repair guidance Air Conditioning Service: Refrigerant recharge, leak detection, component replacement (compressor, condenser) Troubleshooting Guides: Step-by-step diagnostic trees for common and complex issues Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine and transmission overhauls, including detailed diagnostic procedures. Diagnostic Level: Advanced: Includes specifications for sensors, actuators, ECU data, and troubleshooting using diagnostic tools. Specification Detail: High: Provides detailed torque specifications, clearances, fluid capacities, pressures, and electrical resistance values. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within the PDF for easy navigation. Print Quality Quality: High-resolution scans of original factory manuals, ensuring clarity of text and diagrams. Binding Type Binding: Not applicable (PDF Download) Paper Type Paper: Not applicable (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: Inline 4-cylinder, DOHC, 16-valve, turbocharged Displacement: 2.0 Liters (1997 cc) Performance Horsepower Evo Vii: Approx. 280 PS (276 hp) @ 6500 rpm (JDM spec, often higher in export models) Torque Evo Vii: Approx. 373 Nm (275 lb-ft) @ 3000 rpm (JDM spec) Horsepower Evo Viii Ix: Evo VIII: Approx. 270-280 PS (267-276 hp). Evo IX: Approx. 280 PS (276 hp) to 290 PS (286 hp) (MIVEC models). Torque Evo Viii Ix: Evo VIII: Approx. 373 Nm (275 lb-ft). Evo IX: Approx. 392 Nm (289 lb-ft). Fuel System Fuel Delivery: Multi-point fuel injection (MPI) with Electronic Fuel Control (EFC) Fuel Type: Unleaded gasoline, premium octane recommended (95 RON / 91 AKI or higher) Turbocharger: Mitsubishi TD04 or similar performance turbocharger, intercooled Variable Valve Timing: MIVEC (Mitsubishi Innovative Valve timing Electronic Control) introduced on Evo IX, primarily on intake camshaft. 🔧 Transmission Standard Type: 5-speed manual (Evo VII), 6-speed manual (Evo VIII GSR, Evo IX GSR) Optional Type: 5-speed automatic (Evo VIII RS, MR variants - less common) Features Drivetrain Type: Symmetrical...

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Sku: 38611

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Tags: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Car Cars Lancer Evolution Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Common Name:

Product Type:

Service Manual Pack

Product Format:

PDF Download

Codes

Vehicle Generation Covered:

VII, VIII, IX

Vehicle Model Years Covered:

1996-2007 (with specific focus on Evo VII-IX)

Primary Engine Codes Covered:

4G63, 4G63T (DOHC Turbocharged)

👋 Introduction

Market Position

Segment:

Performance Compact Sedan (rally homologation special)

Target Audience:

Enthusiasts, tuners, and owners of Mitsubishi Lancer Evolution VII, VIII, and IX models seeking in-depth repair and maintenance information.

Competitive Analysis

Competitors:

Subaru WRX STI, Ford Focus RS, Honda Civic Type R (later generations), Volkswagen Golf R

Renowned for its sophisticated All-Wheel Drive system (S-AWC), potent turbocharged engine, and rally-bred performance.

Key Features

Performance Focus:

Engineered for high-performance driving, track use, and rallying.

Technology:

Advanced drivetrain and suspension technologies for superior handling and traction.

Manual Value:

Provides detailed factory procedures essential for maintaining and repairing these complex vehicles accurately.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mitsubishi Lancer Evolution VII, VIII, IX Workshop Service Manuals

Additional Coverage:

General Lancer Evolution service information from 1996-2007

Page Count

Estimated Total Pages:

Likely over 1000 pages (combining multiple detailed manuals)

Manual Type

Primary Type:

Workshop Service Manual

Secondary Type:

Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system

Engine Performance:

Fuel injection system, ignition system, turbocharger system, emission control system, engine management (ECU)

Transmission Manual:

Manual gearbox assembly, disassembly, clutch, gear shift mechanism, transfer case

Transmission Automatic:

Automatic gearbox assembly, disassembly, torque converter, control system (if applicable to specified models)

Drivetrain:

All-Wheel Drive (AWD) system, Active Yaw Control (AYC), propeller shaft, differential units (front, rear, center)

Suspension:

Front and rear suspension components, struts, shock absorbers, springs, control arms, anti-roll bars, bushings

Steering:

Power steering system, steering rack, steering column, tie rods, wheel alignment specifications

Brakes:

Brake system hydraulics, disc brakes (front and rear), ABS (Anti-lock Braking System), brake pads, rotors, calipers, bleeding procedures

Electrical System:

Battery, alternator, starter motor, lighting system, fuse boxes, relays, wiring diagrams, ECU diagnosis

Body Exterior:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, trim

Body Interior:

Dashboard, seats, interior trim panels, airbags (SRS), climate control system components

Heating Ventilation Air Conditioning HVAC:

HVAC system components, refrigerant, operation, troubleshooting

Diagnostic Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, testing procedures for various components

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid level checks and top-offs, tire rotation

Engine Repair:

Complete engine rebuilds, head gasket replacement, piston ring replacement, bearing replacement, turbocharger servicing

Transmission Repair:

Clutch replacement, gearbox overhaul, differential servicing, AYC unit maintenance

Suspension And Steering Repair:

Component replacement (shocks, struts, ball joints, tie rods), power steering pump replacement, wheel bearing replacement

Brake System Service:

Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS sensor diagnostics

Electrical Diagnostics:

Wiring harness inspection, sensor testing, ECU reprogramming/replacement, starter and alternator testing

Bodywork And Trim Replacement:

Panel alignment, trim piece removal and installation, minor body repair guidance

Air Conditioning Service:

Refrigerant recharge, leak detection, component replacement (compressor, condenser)

Troubleshooting Guides:

Step-by-step diagnostic trees for common and complex issues

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and transmission overhauls, including detailed diagnostic procedures.

Diagnostic Level:

Advanced: Includes specifications for sensors, actuators, ECU data, and troubleshooting using diagnostic tools.

Specification Detail:

High: Provides detailed torque specifications, clearances, fluid capacities, pressures, and electrical resistance values.

📊 Manual Specifications

File Format

Format:

Searchability:

Typically searchable text within the PDF for easy navigation.

Print Quality

Quality:

High-resolution scans of original factory manuals, ensuring clarity of text and diagrams.

Binding Type

Binding:

Not applicable (PDF Download)

Paper Type

Paper:

Not applicable (PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

Inline 4-cylinder, DOHC, 16-valve, turbocharged

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Evo Vii:

Approx. 280 PS (276 hp) @ 6500 rpm (JDM spec, often higher in export models)

Torque Evo Vii:

Approx. 373 Nm (275 lb-ft) @ 3000 rpm (JDM spec)

Horsepower Evo Viii Ix:

Evo VIII: Approx. 270-280 PS (267-276 hp). Evo IX: Approx. 280 PS (276 hp) to 290 PS (286 hp) (MIVEC models).

Torque Evo Viii Ix:

Evo VIII: Approx. 373 Nm (275 lb-ft). Evo IX: Approx. 392 Nm (289 lb-ft).

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI) with Electronic Fuel Control (EFC)

Fuel Type:

Unleaded gasoline, premium octane recommended (95 RON / 91 AKI or higher)

Turbocharger:

Mitsubishi TD04 or similar performance turbocharger, intercooled

Variable Valve Timing:

MIVEC (Mitsubishi Innovative Valve timing Electronic Control) introduced on Evo IX, primarily on intake camshaft.

🔧 Transmission

Standard

Type:

5-speed manual (Evo VII), 6-speed manual (Evo VIII GSR, Evo IX GSR)

Optional

Type:

5-speed automatic (Evo VIII RS, MR variants - less common)

Features

Drivetrain Type:

Symmetrical All-Wheel Drive (S-AWC) with Active Yaw Control (AYC) and/or Active Center Differential (ACD)

Clutch Type:

Hydraulically operated, single dry plate (manual transmission)

Fluid Specifications

Manual Transmission Fluid Type:

GL-4 or GL-5 Hypoid gear oil, viscosity typically 75W-90

Transfer Case Fluid Type:

GL-5 Hypoid gear oil, viscosity typically 75W-90

Fluid Capacities

Manual Transmission Capacity:

Approx. 2.4 - 2.7 liters (check specific model manual)

📐 Dimensions

Exterior

Length Evo Vii:

Approx. 4360 mm (171.7 in)

Width Evo Vii:

Approx. 1770 mm (69.7 in)

Height Evo Vii:

Approx. 1415 mm (55.7 in)

Wheelbase Evo Vii:

Approx. 2600 mm (102.4 in)

Wheel Bolt Pattern:

5x114.3 (5x4.5 inch)

Wheel Size:

Typically 17-inch alloy wheels (e.g., 17x8J)

Tire Size

Standard Tire:

235/45R17

Weights

Curb Weight Evo Vii Manual:

Approx. 1450 kg (3197 lbs)

Curb Weight Evo Viii Manual:

Approx. 1450-1500 kg (3197-3307 lbs) depending on trim

Curb Weight Evo Ix Manual:

Approx. 1460-1500 kg (3219-3307 lbs) depending on trim

🛡️ Safety Features

Ratings

Crash Test Ratings:

Information may vary by region and testing agency; comprehensive official ratings for this era are less standardized than modern vehicles.

Active Features

Traction Control:

Standard on most performance variants, integrated with AWD system.

Standard Anti-lock Braking System.

Active Yaw Control (rear differential) on some models for enhanced cornering stability.

Passive Features

Airbags:

Driver and front passenger airbags (SRS - Supplemental Restraint System).

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners and load limiters.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD players, often with premium sound options (e.g., Rockford Fosgate on some trims).

Navigation:

Optional factory navigation systems were available on some higher trims, typically featuring CD-ROM or early DVD-ROM based maps.

Driver Assistance

Cruise Control:

Standard on most models.

Electronic Brake Force Distribution Ebdf:

Often integrated with the ABS system.

Connectivity

Original Connectivity:

Limited to basic audio inputs (CD, radio). No Bluetooth or USB connectivity in original form.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions (severe use may require shorter intervals).

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 100,000 miles (160,000 km) for iridium plugs (check specific type).

Timing Belt:

Replace every 60,000 - 70,000 miles (96,000 - 112,000 km) or 7-8 years, recommended to also replace tensioner and idler pulleys.

Coolant:

Drain and refill every 30,000 miles (48,000 km) or 2-3 years.

Fluid Specifications

Engine Oil Type:

API SG, SH, or SJ rated, SAE 10W-30 or 10W-40 recommended. High-performance synthetic oils are preferred for boosted engines.

Engine Oil Capacity:

Approx. 4.5 - 5.0 liters (4.7 - 5.3 US quarts) with filter change (check specific model manual).

Brake Fluid:

DOT 3 or DOT 4 high-temperature brake fluid.

Power Steering Fluid:

Dexron III or equivalent ATF (Automatic Transmission Fluid) or specific Mitsubishi power steering fluid.

Coolant:

Mitsubishi Super Long Life Coolant (LLC) or equivalent ethylene glycol-based coolant, typically 50/50 mix with distilled water.

Known Issues

Engine:

Cracked cylinder heads, piston ring land failures (especially with high mileage/modification), turbocharger wear, valve stem seals.

Drivetrain:

AYC pump failure, ACD unit issues, differential wear, clutch wear, snapped engine mounts.

Suspension:

Worn bushings, premature strut/shock absorber failure, ball joint wear.

Electrical:

Corrosion on wiring connectors, alternator failure, fuel pump issues, lambda sensor failure.

Body:

Rust, especially around wheel arches and sills; door seal degradation.

📚 Vehicle History

Brand Heritage

Rally Roots:

Developed for Group A homologation for the World Rally Championship (WRC).

Model Evolution

Generation Vii:

Launched in late 2001 (2002 model year), featuring a revised exterior, interior, and significant drivetrain upgrades including AYC.

Generation Viii:

Launched in late 2002 (2003 model year), with a distinctive 'piranha' front grille, updated interior, stronger chassis, and optional 6-speed manual transmission.

Generation Ix:

Launched in late 2004 (2005 model year), featuring the MIVEC engine for improved performance and efficiency, updated turbocharger, and revised styling. Introduced the more advanced ACD alongside AYC on certain models.

Production

Production Period:

Evo VII: 2001-2003; Evo VIII: 2003-2005; Evo IX: 2005-2007.

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Rally Success:

Multiple WRC manufacturer and driver championships throughout the 1990s and early 2000s cemented the Lancer Evolution's legendary status.

Car Magazine Accolades:

Consistently praised by automotive journalists for its exceptional handling, braking, and performance for its price point.

Performance Metrics:

Frequently ranked among the top sports sedans and affordable performance cars in its era.