Mitsubishi Lancer 2000-2007 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Generation Code: CS/CT Platform: Mitsubishi Project Global (later shared with Dodge Caliber, Jeep Compass, Jeep Patriot) 👋 Introduction Market Position Segment: Compact sedan/hatchback Target Audience: Budget-conscious buyers, first-time car owners, enthusiasts seeking affordable performance Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Nissan Sentra Key Features Value Proposition: Reliability, affordability, sporty handling (especially with performance variants), practicality Manual Value: Essential for maintaining a Lancer of this era, covering a wide range of potential issues and repairs 📋 Manual Details Coverage Applicable Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Coverage Areas: All major mechanical, electrical, and body systems Manual Type: Workshop Service Manual / Repair Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Engine Service: Detailed diagnosis, repair, and overhaul for all engine variants Transmission Service: Repair and maintenance for manual and automatic transmissions Drivetrain Service: Front-wheel drive (FWD) and all-wheel drive (AWD) system repair Suspension And Steering: Diagnosis, repair, and alignment procedures Brake System: ABS, disc brake, drum brake service and troubleshooting Electrical System: Wiring diagrams, component testing, diagnostic procedures HVAC System: Air conditioning, heating, and ventilation system repair Body And Chassis: Panel repair, door mechanisms, interior trim, structural components Fuel System: Fuel injection, fuel pump, tank service Cooling System: Radiator, thermostat, water pump, coolant specifications Exhaust System: Muffler, catalytic converter, pipe repair and replacement Safety Systems: Airbag system service and diagnosis Procedures Routine Maintenance: Oil changes, filter replacements, fluid checks, tune-ups Troubleshooting Guides: Diagnostic flowcharts and symptom-based troubleshooting Repair Procedures: Step-by-step instructions for component removal, installation, and repair Diagnostic Codes: OBD-II trouble code explanations and resolution strategies Specifications Data: Torque values, clearances, fluid capacities, and diagnostic parameters Technical Depth Level Of Detail: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts Rebuild Procedures: Detailed instructions for engine and transmission rebuilds Wiring Diagrams: Full electrical system schematics with component locations 📊 Manual Specifications File File Format: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval Print Quality: High-resolution, suitable for printing individual pages or sections Interactivity: Clickable table of contents and internal links (if applicable) Physical Binding Type: N/A (Digital PDF) Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Options Engine 1 Code: 4G15 Engine 1 Type: Inline-4, SOHC, 16-valve Engine 1 Displacement: 1.5 Liters (1498 cc) Engine 1 Bore X Stroke: 75.5 mm x 83.0 mm Engine 1 Compression Ratio: 9.0:1 (typical) Engine 1 Horsepower: 90-100 PS (approx.) Engine 1 Torque: 120-130 Nm (approx.) Engine 2 Code: 4G18 Engine 2 Type: Inline-4, SOHC, 16-valve Engine 2 Displacement: 1.6 Liters (1584 cc) Engine 2 Bore X Stroke: 76.0 mm x 87.3 mm Engine 2 Compression Ratio: 9.5:1 (typical) Engine 2 Horsepower: 100-110 PS (approx.) Engine 2 Torque: 140-150 Nm (approx.) Engine 3 Code: 4G93 Engine 3 Type: Inline-4, DOHC, 16-valve, MIVEC (on some variants) Engine 3 Displacement: 1.8 Liters (1830 cc) Engine 3 Bore X Stroke: 81.0 mm x 89.0 mm Engine 3 Compression Ratio: 10.0:1 (typical) Engine 3 Horsepower: 125-140 PS (approx.) Engine 3 Torque: 160-175 Nm (approx.) Engine 4 Code: 4G63 Engine 4 Type: Inline-4, DOHC, 16-valve, Turbocharged (on Ralliart/Evolution variants) Engine 4 Displacement: 2.0 Liters (1997 cc) Engine 4 Bore X Stroke: 85.0 mm x 88.0 mm Engine 4 Compression Ratio: 8.5:1 (Turbocharged) Engine 4 Horsepower: 200-260 PS (approx. for turbo variants) Engine 4 Torque: 280-350 Nm (approx. for turbo variants) Performance Fuel Induction: Multi-point Fuel Injection (MPI) or GDI (Gasoline Direct Injection) on some later models Fuel Type: Unleaded gasoline Emission Controls: Catalytic converter, O2 sensors, EGR (Exhaust Gas Recirculation) Engine Cooling: Liquid-cooled, pressurized system with thermostatic control Ignition System: Electronic Ignition (Distributorless Ignition System - DIS on many variants) 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission (5MT) Optional Transmission Type 2: 4-speed Automatic Transmission (4AT) Features Clutch Type: Hydraulically actuated single dry plate clutch Transmission Fluid Type: Manual: API GL-4 SAE 75W-90 (or similar specified grade); Automatic: Dia Queen ATF-SPII (or equivalent) Final Drive Ratio: Varies by engine and transmission (e.g., 4.300, 4.529) Drivetrain Options: Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) available on some performance variants (e.g., Ralliart) 📐 Dimensions Exterior Sedan Length: Approx. 4480 mm (176.4 in) Width: Approx. 1740 mm (68.5 in) Height: Approx. 1430 mm (56.3 in) Wheelbase: Approx. 2600 mm (102.4 in) Front Track: Approx. 1500 mm (59.1 in) Rear Track: Approx. 1490 mm (58.7 in) Ground Clearance: Approx. 150 mm (5.9 in) Curb Weight: Approx. 1150-1400 kg (2535-3086 lbs) depending on configuration Exterior Hatchback Length: Approx. 4265 mm (167.9 in) Width: Approx. 1740 mm (68.5 in) Height: Approx. 1445 mm (56.9 in) Wheelbase: Approx. 2600 mm (102.4 in) Cargo Trunk Volume Sedan: Approx. 450 Liters (15.9 cu ft) Cargo Volume Hatchback: Approx. 340 Liters (12.0 cu ft) with seats up, expandable Wheels And Tires Standard Wheel Size: 15-inch...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Generation Code:

CS/CT

Platform:

Mitsubishi Project Global (later shared with Dodge Caliber, Jeep Compass, Jeep Patriot)

👋 Introduction

Market Position

Segment:

Compact sedan/hatchback

Target Audience:

Budget-conscious buyers, first-time car owners, enthusiasts seeking affordable performance

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Nissan Sentra

Key Features

Value Proposition:

Reliability, affordability, sporty handling (especially with performance variants), practicality

Manual Value:

Essential for maintaining a Lancer of this era, covering a wide range of potential issues and repairs

📋 Manual Details

Coverage

Applicable Years:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Coverage Areas:

All major mechanical, electrical, and body systems

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems

Engine Service:

Detailed diagnosis, repair, and overhaul for all engine variants

Transmission Service:

Repair and maintenance for manual and automatic transmissions

Drivetrain Service:

Front-wheel drive (FWD) and all-wheel drive (AWD) system repair

Suspension And Steering:

Diagnosis, repair, and alignment procedures

Brake System:

ABS, disc brake, drum brake service and troubleshooting

Electrical System:

Wiring diagrams, component testing, diagnostic procedures

HVAC System:

Air conditioning, heating, and ventilation system repair

Body And Chassis:

Panel repair, door mechanisms, interior trim, structural components

Fuel System:

Fuel injection, fuel pump, tank service

Cooling System:

Radiator, thermostat, water pump, coolant specifications

Exhaust System:

Muffler, catalytic converter, pipe repair and replacement

Safety Systems:

Airbag system service and diagnosis

Procedures

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tune-ups

Troubleshooting Guides:

Diagnostic flowcharts and symptom-based troubleshooting

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair

Diagnostic Codes:

OBD-II trouble code explanations and resolution strategies

Specifications Data:

Torque values, clearances, fluid capacities, and diagnostic parameters

Technical Depth

Level Of Detail:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts

Rebuild Procedures:

Detailed instructions for engine and transmission rebuilds

Wiring Diagrams:

Full electrical system schematics with component locations

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval

Print Quality:

High-resolution, suitable for printing individual pages or sections

Interactivity:

Clickable table of contents and internal links (if applicable)

Physical

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine Options

Engine 1 Code:

Engine 1 Type:

Inline-4, SOHC, 16-valve

Engine 1 Displacement:

1.5 Liters (1498 cc)

Engine 1 Bore X Stroke:

75.5 mm x 83.0 mm

Engine 1 Compression Ratio:

9.0:1 (typical)

Engine 1 Horsepower:

90-100 PS (approx.)

Engine 1 Torque:

120-130 Nm (approx.)

Engine 2 Code:

Engine 2 Type:

Inline-4, SOHC, 16-valve

Engine 2 Displacement:

1.6 Liters (1584 cc)

Engine 2 Bore X Stroke:

76.0 mm x 87.3 mm

Engine 2 Compression Ratio:

9.5:1 (typical)

Engine 2 Horsepower:

100-110 PS (approx.)

Engine 2 Torque:

140-150 Nm (approx.)

Engine 3 Code:

Engine 3 Type:

Inline-4, DOHC, 16-valve, MIVEC (on some variants)

Engine 3 Displacement:

1.8 Liters (1830 cc)

Engine 3 Bore X Stroke:

81.0 mm x 89.0 mm

Engine 3 Compression Ratio:

10.0:1 (typical)

Engine 3 Horsepower:

125-140 PS (approx.)

Engine 3 Torque:

160-175 Nm (approx.)

Engine 4 Code:

Engine 4 Type:

Inline-4, DOHC, 16-valve, Turbocharged (on Ralliart/Evolution variants)

Engine 4 Displacement:

2.0 Liters (1997 cc)

Engine 4 Bore X Stroke:

85.0 mm x 88.0 mm

Engine 4 Compression Ratio:

8.5:1 (Turbocharged)

Engine 4 Horsepower:

200-260 PS (approx. for turbo variants)

Engine 4 Torque:

280-350 Nm (approx. for turbo variants)

Performance

Fuel Induction:

Multi-point Fuel Injection (MPI) or GDI (Gasoline Direct Injection) on some later models

Fuel Type:

Unleaded gasoline

Emission Controls:

Catalytic converter, O2 sensors, EGR (Exhaust Gas Recirculation)

Engine Cooling:

Liquid-cooled, pressurized system with thermostatic control

Ignition System:

Electronic Ignition (Distributorless Ignition System - DIS on many variants)

🔧 Transmission

Standard Transmission

Type 1:

5-speed Manual Transmission (5MT)

Optional Transmission

Type 2:

4-speed Automatic Transmission (4AT)

Features

Clutch Type:

Hydraulically actuated single dry plate clutch

Transmission Fluid Type:

Manual: API GL-4 SAE 75W-90 (or similar specified grade); Automatic: Dia Queen ATF-SPII (or equivalent)

Final Drive Ratio:

Varies by engine and transmission (e.g., 4.300, 4.529)

Drivetrain Options:

Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) available on some performance variants (e.g., Ralliart)

📐 Dimensions

Exterior Sedan

Length:

Approx. 4480 mm (176.4 in)

Width:

Approx. 1740 mm (68.5 in)

Height:

Approx. 1430 mm (56.3 in)

Wheelbase:

Approx. 2600 mm (102.4 in)

Front Track:

Approx. 1500 mm (59.1 in)

Rear Track:

Approx. 1490 mm (58.7 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Curb Weight:

Approx. 1150-1400 kg (2535-3086 lbs) depending on configuration

Exterior Hatchback

Length:

Approx. 4265 mm (167.9 in)

Width:

Approx. 1740 mm (68.5 in)

Height:

Approx. 1445 mm (56.9 in)

Wheelbase:

Approx. 2600 mm (102.4 in)

Cargo

Trunk Volume Sedan:

Approx. 450 Liters (15.9 cu ft)

Cargo Volume Hatchback:

Approx. 340 Liters (12.0 cu ft) with seats up, expandable

Wheels And Tires

Standard Wheel Size:

15-inch or 16-inch alloy or steel wheels

Optional Wheel Size:

17-inch alloy wheels on sportier trims

Standard Tire Size:

195/60R15, 205/55R16

Wheel Bolt Pattern:

4x100 or 5x114.3 mm (depending on model/variant)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

Generally rated 4 out of 5 stars (for models tested in this period)

IIHS Frontal Offset Crash Test:

Acceptable to Good (depending on year and specific test)

Active Features

Antilock Braking System:

Standard on most trims, optional on base models

Electronic Brakeforce Distribution:

Often paired with ABS

Traction Control:

Available on higher trims and AWD models

Passive Features

Airbags Front:

Driver and front passenger airbags standard

Airbags Side:

Optional or standard on higher trims

Seatbelt Pretensioners:

Standard

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium sound systems (e.g., Rockford Fosgate on higher trims).

Display Screen:

Basic digital display for radio/clock; larger color screens on later/higher trims for navigation (optional).

Driver Assistance

Cruise Control:

Standard or optional depending on trim level.

Anti Theft System:

Immobilizer system standard on most models.

Connectivity

Auxiliary Input:

Available on some models for external audio devices.

Bluetooth:

Rarely available on models from this era, typically an aftermarket addition.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first.

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km).

Cabin Air Filter Replacement:

Every 15,000-20,000 miles (24,000-32,000 km) or annually.

Spark Plug Replacement:

Every 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (standard vs. iridium).

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Transmission Fluid Change:

Manual: Inspect regularly, change as needed. Automatic: Every 30,000-60,000 miles (48,000-96,000 km) depending on driving conditions.

Fluid Specifications

Engine Oil Specification:

API SJ or higher, SAE 5W-30 or 10W-30 recommended (refer to manual for specific viscosity based on climate).

Engine Oil Capacity:

Approx. 3.8-4.3 Liters (4.0-4.5 US Quarts) with filter change, depending on engine.

Coolant Specification:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors).

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Specification:

Mitsubishi Power Steering Fluid (or equivalent Dexron III ATF).

Known Issues

Engine Mounts:

Premature wear and cracking of engine mounts, leading to vibration and clunking noises.

Oxygen Sensors:

Failure of oxygen sensors can lead to poor fuel economy and check engine light illumination.

Alternator:

Alternator failure can occur, leading to battery drain and loss of electrical power.

Rear Wheel Bearings:

Premature wear of rear wheel bearings, causing humming or grinding noises.

Catalytic Converter:

Can become clogged or fail over time, impacting performance and emissions.

Automatic Transmission Issues:

Some automatic transmissions may experience delayed shifting or harsh engagement.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Origins:

Founded in 1870, established automotive division in 1917 with the Model A.

Model Evolution Lancer

First Generation:

Introduced in 1973 as a compact car.

Current Generation Launch:

Tenth generation (CS/CT) launched for the 2000 model year (globally, some markets later).

Design Philosophy Cs Ct:

Focus on practicality, affordability, and a degree of sporty driving dynamics. Distinctive 'jet-fighter' grille design introduced in later facelifts.

Performance Variants:

Lancer Ralliart offered with a turbocharged engine and AWD; Lancer Evolution (Evo VII, VIII, IX) extremely popular in rally and performance circles, though the manual is for the standard Lancer.

Production

Manufacturing Locations:

Primarily Japan, but also assembled in various global locations due to Mitsubishi's international manufacturing network.

Production Years Covered:

2000-2007 encompasses the initial launch and several minor facelifts of the CS/CT generation.

🏆 Awards & Recognition

Recognitions

Competitive Awards:

While the standard Lancer didn't garner major individual awards, its platform shared with other Chrysler Group vehicles (like the Dodge Caliber) contributed to its market presence. The Lancer Evolution, however, is a motorsport icon.

Ratings

Reliability Rankings:

Generally considered average to good for its class, with specific reliability varying by engine and maintenance history.

Certifications

Emissions Standards:

Compliant with US EPA and CARB emission standards for its respective model years.