2005 Mitsubishi Lancer Evolution 9 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Year: 2005 Generation Chassis Code: CT9A Codes Engine Code: 4G63T 👋 Introduction Market Position Vehicle Type: Performance Compact Sedan (Rally Homologation Special) Competitive Analysis Key Competitors 2005: Subaru Impreza WRX STI, Mitsubishi Lancer Evolution VIII (predecessor), Subaru Impreza WRX Key Features Performance Focus: Renowned for its advanced Super All-Wheel Control (S-AWC) system, aggressive turbocharged engine, and rally-bred chassis, making it a highly capable performance vehicle. Manual Advantage: Consolidates all necessary repair and maintenance information into a single, easily accessible digital format, eliminating the need for multiple physical manuals and providing a superior user experience for DIY enthusiasts and professional mechanics alike. 📋 Manual Details Coverage Areas Covered Models: 2005 Mitsubishi Lancer Evolution IX Specific Sections Listed: Yaw Rate Sensor, Wiring Diagrams, Wire Harness Repair, Wiper Rubber, Wiper And Washer System, Windshield Wiper Switch Assy, Windshield Wiper Motor Assy, Windshield Glass, Window Defogger System, Wheel And Tire System, Water Pump Assy, Washer Nozzle, Valve Clearance, Transmission Wire, Transmission Valve Body, Transmission Revolution Sensor, Transmission Control Cable, Torque Converter Clutch, Tire & Wheel, Throttle Body Assy, Thermostat, Supplemental Restraint System, Sun Roof System, Steering System, Steering Sensor, Steering Column, Starting System, Starter Switch, Starter Assy, Spiral Cable Sub-Assy, Speed Sensor Front, Skid Control Sensor, Side Turn Signal Lamp Assy, Side Mudguard, Side Air Bag Sensor Assy, Shift Lock System, Shift & Select Lever Shaft, Sfi System, Seat Position Air Bag Sensor, Seat Belt Warning System, Seat Belt, Seat, Roof Headlining, Roof Drip Side Finish Moulding, Roof Antenna Pole Sub-Assy, Receiver Condenser Assy, Rear Wiper Rubber, Rear Wiper Motor Assy, Rear Wheel Alignment, Rear Suspension System, Rear Suspension, Rear Speaker Assy, Rear Shock Absorber Assy, Rear Seat Belt, Rear Door Window Frame Moulding, Rear Door Glass Weatherstrip, Rear Door, Rear Combination Lamp Assy, Rear Coil Spring, Rear Bumper, Rear Brake, Rear Axle Hub, Rear Axle Beam, Radio Receiver Assy, Radiator Assy, Quarter Window Assy, Pulley Compressor Assy, Preparation, Power Window Control System, Power Steering Link Assy, Power Steering, Power Source, Power Mirror Control System, Power Door Lock Control System, Passenger Air Bag Assy, Partial Engine, Park Neutral Position Switch, Parking Brake Lever, Parking Brake Cable, Parking Brake, Output Shaft Assy, Outer Rear View Mirror Assy, Oil Pump, Oil Filter, Name Plate, Manual Transaxle System, Manual Transaxle Oil, Manual Transaxle Assy, Maintenance, Lubrication System, Lighting System, License Plate Lamp Assy, Knock Sensor, Introduction, Instrument Panel, Input Shaft Assy, Inner Rear View Mirror Assy, Ignition System, Horn Button Assy, Horn, Hood, Heater Radiator Assy, Heater Or Boost Ventilator Control, Heater & Air Conditioner, Headlamp Protector Retainer, Headlamp Dimmer Switch Assy, Headlamp Assy, Generator Assy, Fuel Tank, Fuel System, Fuel Pump, Fuel Injector, Front Wheel Alignment, Front Suspension System, Front Suspension Arm, Front Suspension, Front Stabilizer Bar, Front Speaker Assy, Front Shock Absorber, Front Seat Belt, Front Seat Airbag Assy, Front Marker Lamp Assy, Front Drive Shaft, Front Door Glass Weatherstrip, Front Door, Front Differential Oil Seal, Front Bumper, Front Brake, Front Axle Hub, Floor Shift Parking Lock Cable, Floor Shift Assy, Fender Panel Mudguard, Exhaust Pipe, Exhaust, Engine Mechanical, Engine Coolant, Engine Control System, Emission Control Systems, Drive Shaft, Drive Belt, Differential Case Assy, Cylinder Head Assy, Cylinder Head, Cylinder Block Assy, Curtain Shield Air Bag Assy, Cooling System, Cooling Fan System, Combination Meter, Clutch Unit, Clutch System, Clutch Start Switch Assy, Clutch Release Cylinder Assy, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Cigarette Lighter Assy, Charging System, Charcoal Canister, Chain Sub-Assy, Center Stop Lamp Assy, Center Cluster Module Switch, Center Air Bag Sensor Assy, Camshaft Position Sensor, Camshaft, Brake System, Brake Pedal, Brake Master Cylinder, Brake Fluid, Brake Booster, Brake Actuator, Body Repair, Back Door Glass, Back Door Garnish, Back Door, Automatic Transaxle Fluid, Automatic Transaxle Assy, Audio & Visual System, Antenna Cord Sub-Assy, Amplifier Antenna Assy, Air Conditioning System, Air Conditioning Blower Assy, Air Conditioning Amplifier Assy, Air Conditioner Refrigerant, Air Bag Sensor Rear, Air Bag Sensor Front Page Count Estimated Page Count: Varies by specific workshop manual compilation; comprehensive manuals often exceed 1500 pages. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Control System, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Turbocharger System Drivetrain: Manual Transaxle System, Automatic Transaxle System (if applicable to specific model variants covered by the manual), Drive Shaft, Front Differential, Rear Differential, Clutch System Chassis: Front Suspension System, Rear Suspension System, Steering System, Brake System, Wheel and Tire System Electrical: Charging System, Starting System, Lighting System, Instrument Panel, Power Window Control System, Power Door Lock Control System, Audio & Visual System, Supplemental Restraint System (SRS), Wiper and Washer System Body: Body Repair, Exterior Panels (Hood, Doors, Bumpers, Fenders), Interior Trim, Sun Roof System, Glass Systems, Seals and Weatherstripping Procedures Included Repair...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IX

Year:

Generation

Chassis Code:

Codes

Engine Code:

4G63T

👋 Introduction

Market Position

Vehicle Type:

Performance Compact Sedan (Rally Homologation Special)

Competitive Analysis

Key Competitors 2005:

Subaru Impreza WRX STI, Mitsubishi Lancer Evolution VIII (predecessor), Subaru Impreza WRX

Key Features

Performance Focus:

Renowned for its advanced Super All-Wheel Control (S-AWC) system, aggressive turbocharged engine, and rally-bred chassis, making it a highly capable performance vehicle.

Manual Advantage:

Consolidates all necessary repair and maintenance information into a single, easily accessible digital format, eliminating the need for multiple physical manuals and providing a superior user experience for DIY enthusiasts and professional mechanics alike.

📋 Manual Details

Coverage Areas

Covered Models:

2005 Mitsubishi Lancer Evolution IX

Specific Sections Listed:

Yaw Rate Sensor, Wiring Diagrams, Wire Harness Repair, Wiper Rubber, Wiper And Washer System, Windshield Wiper Switch Assy, Windshield Wiper Motor Assy, Windshield Glass, Window Defogger System, Wheel And Tire System, Water Pump Assy, Washer Nozzle, Valve Clearance, Transmission Wire, Transmission Valve Body, Transmission Revolution Sensor, Transmission Control Cable, Torque Converter Clutch, Tire & Wheel, Throttle Body Assy, Thermostat, Supplemental Restraint System, Sun Roof System, Steering System, Steering Sensor, Steering Column, Starting System, Starter Switch, Starter Assy, Spiral Cable Sub-Assy, Speed Sensor Front, Skid Control Sensor, Side Turn Signal Lamp Assy, Side Mudguard, Side Air Bag Sensor Assy, Shift Lock System, Shift & Select Lever Shaft, Sfi System, Seat Position Air Bag Sensor, Seat Belt Warning System, Seat Belt, Seat, Roof Headlining, Roof Drip Side Finish Moulding, Roof Antenna Pole Sub-Assy, Receiver Condenser Assy, Rear Wiper Rubber, Rear Wiper Motor Assy, Rear Wheel Alignment, Rear Suspension System, Rear Suspension, Rear Speaker Assy, Rear Shock Absorber Assy, Rear Seat Belt, Rear Door Window Frame Moulding, Rear Door Glass Weatherstrip, Rear Door, Rear Combination Lamp Assy, Rear Coil Spring, Rear Bumper, Rear Brake, Rear Axle Hub, Rear Axle Beam, Radio Receiver Assy, Radiator Assy, Quarter Window Assy, Pulley Compressor Assy, Preparation, Power Window Control System, Power Steering Link Assy, Power Steering, Power Source, Power Mirror Control System, Power Door Lock Control System, Passenger Air Bag Assy, Partial Engine, Park Neutral Position Switch, Parking Brake Lever, Parking Brake Cable, Parking Brake, Output Shaft Assy, Outer Rear View Mirror Assy, Oil Pump, Oil Filter, Name Plate, Manual Transaxle System, Manual Transaxle Oil, Manual Transaxle Assy, Maintenance, Lubrication System, Lighting System, License Plate Lamp Assy, Knock Sensor, Introduction, Instrument Panel, Input Shaft Assy, Inner Rear View Mirror Assy, Ignition System, Horn Button Assy, Horn, Hood, Heater Radiator Assy, Heater Or Boost Ventilator Control, Heater & Air Conditioner, Headlamp Protector Retainer, Headlamp Dimmer Switch Assy, Headlamp Assy, Generator Assy, Fuel Tank, Fuel System, Fuel Pump, Fuel Injector, Front Wheel Alignment, Front Suspension System, Front Suspension Arm, Front Suspension, Front Stabilizer Bar, Front Speaker Assy, Front Shock Absorber, Front Seat Belt, Front Seat Airbag Assy, Front Marker Lamp Assy, Front Drive Shaft, Front Door Glass Weatherstrip, Front Door, Front Differential Oil Seal, Front Bumper, Front Brake, Front Axle Hub, Floor Shift Parking Lock Cable, Floor Shift Assy, Fender Panel Mudguard, Exhaust Pipe, Exhaust, Engine Mechanical, Engine Coolant, Engine Control System, Emission Control Systems, Drive Shaft, Drive Belt, Differential Case Assy, Cylinder Head Assy, Cylinder Head, Cylinder Block Assy, Curtain Shield Air Bag Assy, Cooling System, Cooling Fan System, Combination Meter, Clutch Unit, Clutch System, Clutch Start Switch Assy, Clutch Release Cylinder Assy, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Cigarette Lighter Assy, Charging System, Charcoal Canister, Chain Sub-Assy, Center Stop Lamp Assy, Center Cluster Module Switch, Center Air Bag Sensor Assy, Camshaft Position Sensor, Camshaft, Brake System, Brake Pedal, Brake Master Cylinder, Brake Fluid, Brake Booster, Brake Actuator, Body Repair, Back Door Glass, Back Door Garnish, Back Door, Automatic Transaxle Fluid, Automatic Transaxle Assy, Audio & Visual System, Antenna Cord Sub-Assy, Amplifier Antenna Assy, Air Conditioning System, Air Conditioning Blower Assy, Air Conditioning Amplifier Assy, Air Conditioner Refrigerant, Air Bag Sensor Rear, Air Bag Sensor Front

Page Count

Estimated Page Count:

Varies by specific workshop manual compilation; comprehensive manuals often exceed 1500 pages.

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Control System, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Turbocharger System

Drivetrain:

Manual Transaxle System, Automatic Transaxle System (if applicable to specific model variants covered by the manual), Drive Shaft, Front Differential, Rear Differential, Clutch System

Chassis:

Front Suspension System, Rear Suspension System, Steering System, Brake System, Wheel and Tire System

Electrical:

Charging System, Starting System, Lighting System, Instrument Panel, Power Window Control System, Power Door Lock Control System, Audio & Visual System, Supplemental Restraint System (SRS), Wiper and Washer System

Body:

Body Repair, Exterior Panels (Hood, Doors, Bumpers, Fenders), Interior Trim, Sun Roof System, Glass Systems, Seals and Weatherstripping

Procedures Included

Repair Procedures:

Detailed step-by-step repair procedures for all major vehicle systems, including engine overhaul, transmission rebuild, suspension component replacement, brake caliper service, electrical component diagnosis and repair, body panel alignment and repair.

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation.

Diagnostic Procedures:

Troubleshooting guides, diagnostic flowcharts, symptom-based repair advice, information on using diagnostic scan tools, sensor testing procedures.

Technical Specifications:

Torque specifications for all fasteners, fluid capacities and types, engine timing settings, component specifications, electrical system data, dimensional measurements.

Wiring Diagrams:

Extensive, detailed wiring diagrams covering all electrical systems, including engine control, chassis electronics, lighting, and interior components. Crucial for diagnosing electrical faults.

Torque Specifications:

Detailed torque specifications for engine components (cylinder head bolts, main bearing caps, connecting rod bolts), drivetrain fasteners, suspension mounting points, brake caliper bolts, and wheel lug nuts are provided to ensure proper assembly and prevent component failure.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance and troubleshooting to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair. Includes detailed wiring diagrams and exploded views.

Component Disassembly Assembly:

Step-by-step instructions with accompanying diagrams for the complete disassembly and reassembly of all major components, including engine internals (pistons, connecting rods, crankshaft, cylinder head), transmission gears, differentials, suspension arms, steering rack, and brake assemblies.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF with printable pages. Ensures clear visibility of diagrams and text.

Print Quality

Print Ability:

Designed for easy printing of individual pages or sections, ideal for use in a workshop environment without risking damage to the original digital file.

Binding Type

Binding For Print:

N/A (Digital PDF format; if printed, would typically be a comb or ring binding for ease of use).

Paper Type

Paper Type For Print:

N/A (Digital PDF format; for print use, standard printer paper is suitable).

⚙️ Engine Specifications

Primary Engine

Engine Type:

2.0L Inline-4 DOHC 16-Valve turbocharged MIVEC

Engine Name:

4G63T

Performance

Horsepower:

286 hp @ 6500 rpm (JDM/European Spec), 276 hp @ 6500 rpm (US Spec)

Torque:

289 lb-ft @ 3500 rpm (JDM/European Spec), 286 lb-ft @ 3500 rpm (US Spec)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with Electronic Fuel Control (ECU) and Turbocharger

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Cooling System

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with proper corrosion inhibitors)

Lubrication System

Oil Type Capacity:

API SG or SH, ILSAC GF-II or GF-III, SAE 10W-30 (preferred), SAE 5W-30, 10W-40, 15W-40, 20W-50; Capacity: 4.7 US qts (4.5 L) with filter change

Engine Mechanical

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valve Train:

DOHC, 16 valves, MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

🔧 Transmission

Standard

Type:

6-speed manual transaxle

Optional

Type:

Not typically offered or very rare for the Evolution IX performance variants. Standard was the 6-speed manual.

Features

Clutch Type:

Hydraulically operated, single dry plate clutch

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5 SAE 75W-85 or SAE 75W-90 gear oil. Mitsubishi DiaQueen LSD Gear Oil GL-5 SAE 75W-85 is recommended for the limited-slip differentials.

Differential Fluid

Front Rear Differential Fluid:

API GL-5 SAE 75W-90 or SAE 80W-90. For LSD equipped vehicles, a GL-5 SAE 75W-85 with limited-slip additive is often recommended or integrated into GL-5 LSD fluids.

Transmission Type

Acd Ayc Function:

Active Center Differential (ACD) and Active Yaw Control (AYC) are integral to the Super All-Wheel Control (S-AWC) system, managing torque distribution between front and rear axles and providing differential braking for enhanced cornering.

📐 Dimensions

Exterior

Length:

Approx. 179.5 inches (4560 mm)

Width:

Approx. 70.1 inches (1780 mm)

Height:

Approx. 56.3 inches (1430 mm)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Weights

Curb Weight:

Approx. 3,296 lbs (1,495 kg)

Gross Vehicle Weight Rating:

Approx. 4,365 lbs (1,980 kg)

Towing Capacity:

Not specified or recommended for towing.

Interior

Passenger Volume:

Approx. 89.4 cubic feet (2530 L)

Cargo

Cargo Volume:

Approx. 12.4 cubic feet (350 L) with rear seats up

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star driver, 5-star passenger (for contemporary Lancer models, specific Evo IX ratings may vary or be less documented)

IIHS Frontal Offset:

Acceptable (for contemporary Lancer models)

Active Features

Traction Control:

Active via Super All-Wheel Control (S-AWC) system, ACD (Active Center Differential), AYC (Active Yaw Control), ASC (Active Stability Control)

Braking System:

4-wheel Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD)

Active Stability Control:

ASC (Active Stability Control) helps prevent skidding and loss of control by reducing engine power and applying brakes to individual wheels.

Limited Slip Differential:

Front Helical Limited Slip Differential (LSD) and Rear Active Yaw Control (AYC) are part of the S-AWC system, providing enhanced traction and stability.

Passive Features

Airbags:

Front dual-stage airbags, optional side airbags

Seatbelts:

3-point front and rear seat belts with pretensioners and load limiters

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD stereo system with optional premium sound and subwoofer. Speaker configurations varied by trim level.

Driver Assistance

Active Handling Systems:

Super All-Wheel Control (S-AWC) integrating ACD, AYC, ASC, and ABS for unparalleled traction and cornering ability.

All Wheel Drive System:

Mitsubishi's Super All-Wheel Control (S-AWC) is a sophisticated system that integrates various electronic controls to optimize traction and handling across a wide range of conditions.

Connectivity

Cruise Control:

Standard cruise control functionality.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first, especially for spirited driving or track use. Refer to manual for severe service conditions.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months for manual transmission and differentials. Inspect and replace as needed based on driving conditions.

Engine Coolant Change:

Every 45,000 miles (72,000 km) or 48 months. Check level regularly.

Spark Plug Replacement:

Refer to manual. Typically around 60,000 miles (96,000 km) for iridium-tipped plugs, but can vary. High-performance applications may require more frequent checks.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 compliant synthetic brake fluid.

Power Steering Fluid:

Use only specified Mitsubishi power steering fluid or a universal fluid that meets Dexron III H specification.

Engine Oil Capacity:

4.7 US quarts (4.5 Liters) with filter change.

Coolant Capacity:

Approx. 7.8 US quarts (7.4 Liters)

Known Issues

Common Wear Items:

Clutch wear, turbocharger seals (oil leaks), suspension bushings, differential seals, fuel pump strainers, spark plug fouling due to aggressive driving or incorrect fuel.

Engine Specific Concerns:

Head gasket failures on heavily modified engines, piston ring wear in high-mileage examples, timing belt tensioner wear (though the 4G63 in the Evo IX is a timing chain).

Turbocharger Maintenance:

Proper cool-down periods after hard driving are essential to prevent turbocharger oil coking and premature failure. Regular oil changes with quality oil are critical.

📚 Vehicle History

Brand Heritage

Rally Roots:

Mitsubishi has a storied history in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution lineage was forged and refined.

Model Evolution

Evolution Series:

The Evolution IX (CT9A) is the ninth generation of the iconic Lancer Evolution, building upon the successful formula of its predecessors with mechanical and electronic enhancements.

Key Evol Ix Features:

Introduced the MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system on the 4G63 engine, improving power delivery and efficiency. Revised S-AWC system for enhanced handling dynamics.

Production

Production Years:

2005-2007 (for Evolution IX model)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorsport Dominance:

The Lancer Evolution series, including the Evolution IX, has a strong track record of success in global rally championships and various forms of motorsport.

Ratings

Car And Driver Ranking:

Consistently ranked among the best performance cars for its handling and driving dynamics by automotive publications.