Mitsubishi Lancer 2000-2007 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Generation: 8th Generation (CS/CT) Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Codes: CS2A, CS2W, CS5A, CS5W, CS6A, CS6W, CT9A (Evolution variants) 👋 Introduction Market Position Segment: Compact/Small Family Car, Performance Sedan (Evolution models) Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Subaru Impreza WRX/STI (for Evolution), Mazda3 Key Features Vehicle Strengths: Reliability, fuel efficiency (standard models), sporty handling, performance (Evolution variants), affordability Manual Value Proposition: Provides DIY mechanics and professional technicians with the complete technical information required for all aspects of vehicle maintenance, repair, and diagnostics. 📋 Manual Details Coverage Areas Regions Covered: Global (applicable to models sold worldwide within the specified years, with potential regional variations noted) Page Count Total Pages: 4000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (4G1x, 4G6x, 6G7x series), engine electrical, fuel system, exhaust system, cooling system, lubrication system, turbocharger (where applicable) Drivetrain: Manual transmission (W5MG1, W6MG1), automatic transmission (INVECS-II), all-wheel drive system (AWC/ACD - for Evolution), drive shafts, differentials, axles Suspension And Steering: Front suspension (MacPherson strut), rear suspension (multi-link), power steering system, steering column, steering gear Brakes: Front and rear brake systems (disc brakes, including Brembo for Evolution), Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD) Electrical: 12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting system, interior/exterior electronics, fuse box diagrams, wiring schematics, diagnostic connectors (OBD-II) Body And Interior: Body panels, doors, windows, glass, seats, interior trim, dashboard, HVAC system, airbags Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid replacement, coolant flush, belt replacement Repair: Engine overhaul, transmission rebuild, clutch replacement, suspension component replacement, brake caliper service, power steering pump replacement, electrical component diagnosis and repair Troubleshooting: Diagnostic procedures, fault code interpretation, common problem diagnosis and solutions Diagnostics: OBD-II scanning, sensor testing, actuator testing, circuit testing Technical Depth Depth: Comprehensive: from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical troubleshooting. 📊 Manual Specifications File Format File Type: Digital (PDF) Searchability: Searchable text content Print Quality Printability: Printable pages for hard copy reference Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 1.6L (4G18), 1.8L (4G93), 2.0L (4G63/4G63T), 2.4L (4G69), 3.0L V6 (6G72 - in some markets/special editions), 2.0L Turbocharged (4G63T - Evolution models) Performance Horsepower Range: Approx. 105 hp (1.6L) to 270-280 hp (Evolution VIII/IX), with higher outputs for specialized Evolution models. Torque Range: Approx. 145 Nm (1.6L) to 350-400 Nm (Evolution variants) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI/GDI where applicable) Fuel Type: Unleaded gasoline (91 AKI or higher recommended for performance models) Technical Details Valvetrain: SOHC or DOHC, 16-valve (variable valve timing - MIVEC - on some later models) Block Material: Cast iron or Aluminum alloy Cylinder Head Material: Aluminum alloy 🔧 Transmission Standard Transmission Type: 5-speed manual transmission (e.g., W5MG1) Optional Transmission Type Optional: 4-speed automatic transmission (e.g., INVECS-II) Features All Wheel Drive: Available on Evolution models (ACD - Active Center Differential, AYC - Active Yaw Control) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, viscosity SAE 75W-90 (refer to specific model for exact spec) Automatic Transmission Fluid: DIA-Queen ATF-SP II M or equivalent (refer to specific model for exact spec) 📐 Dimensions Exterior Length: Approx. 4450-4535 mm (depending on model/market) Width: Approx. 1730-1740 mm Height: Approx. 1440-1470 mm Weights Curb Weight: Approx. 1200-1400 kg (depending on engine and trim) Gross Vehicle Weight Rating: Varies by model, consult manual for specific rating. Wheels And Tires Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Standard Tire Size: Typically 205/50R16 or 215/45R17 (Evolution models may have larger/different sizes, e.g., 235/45R17) 🛡️ Safety Features Ratings NHTSA Ratings: Varies by model year and specific crash test; typically performed well for its class in its era. Consult individual model year test results. Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Traction Control System (TCL), Active Stability Control (ASC) - availability varies by trim level and market. Passive Features Passive Safety Features: Front airbags, side airbags (optional), front seatbelt pretensioners, crumple zones 💡 Technology Features Infotainment Infotainment Systems: Basic AM/FM/CD players, optional premium audio systems (e.g., Rockford Fosgate on some trims), navigation systems were less common and often aftermarket during this period. Driver Assistance Driver Assistance Features: Cruise control (standard on many trims), limited availability of advanced electronic aids compared to modern vehicles. Connectivity Connectivity Options: Typically limited to audio input (e.g., AUX jack on later models) and power outlets. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for specific engine/oil type). Engine Air Filter Replacement: Every 15,000-30,000 miles...
Provides DIY mechanics and professional technicians with the complete technical information required for all aspects of vehicle maintenance, repair, and diagnostics.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (applicable to models sold worldwide within the specified years, with potential regional variations noted)
Comprehensive: from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical troubleshooting.
Approx. 105 hp (1.6L) to 270-280 hp (Evolution VIII/IX), with higher outputs for specialized Evolution models.
Torque Range:
Approx. 145 Nm (1.6L) to 350-400 Nm (Evolution variants)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI/GDI where applicable)
Fuel Type:
Unleaded gasoline (91 AKI or higher recommended for performance models)
Technical Details
Valvetrain:
SOHC or DOHC, 16-valve (variable valve timing - MIVEC - on some later models)
Block Material:
Cast iron or Aluminum alloy
Cylinder Head Material:
Aluminum alloy
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission (e.g., W5MG1)
Optional
Transmission Type Optional:
4-speed automatic transmission (e.g., INVECS-II)
Features
All Wheel Drive:
Available on Evolution models (ACD - Active Center Differential, AYC - Active Yaw Control)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, viscosity SAE 75W-90 (refer to specific model for exact spec)
Automatic Transmission Fluid:
DIA-Queen ATF-SP II M or equivalent (refer to specific model for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 4450-4535 mm (depending on model/market)
Width:
Approx. 1730-1740 mm
Height:
Approx. 1440-1470 mm
Weights
Curb Weight:
Approx. 1200-1400 kg (depending on engine and trim)
Gross Vehicle Weight Rating:
Varies by model, consult manual for specific rating.
Wheels And Tires
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Standard Tire Size:
Typically 205/50R16 or 215/45R17 (Evolution models may have larger/different sizes, e.g., 235/45R17)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by model year and specific crash test; typically performed well for its class in its era. Consult individual model year test results.
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Traction Control System (TCL), Active Stability Control (ASC) - availability varies by trim level and market.
Passive Features
Passive Safety Features:
Front airbags, side airbags (optional), front seatbelt pretensioners, crumple zones
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM/CD players, optional premium audio systems (e.g., Rockford Fosgate on some trims), navigation systems were less common and often aftermarket during this period.
Driver Assistance
Driver Assistance Features:
Cruise control (standard on many trims), limited availability of advanced electronic aids compared to modern vehicles.
Connectivity
Connectivity Options:
Typically limited to audio input (e.g., AUX jack on later models) and power outlets.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for specific engine/oil type).
Engine Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Cabin Air Filter Replacement:
Every 12,000-15,000 miles (19,000-24,000 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).
Fluid Specifications
Engine Oil Type:
API SN/SP, ILSAC GF-5/GF-6. Viscosity: 5W-30 or 5W-40 (refer to manual for specific engine and climate).
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent green ethylene glycol-based coolant with demineralized water).
Timing belt replacement on non-turbo 4G6x engines is critical at specified intervals (approx. 60,000 miles).
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation has a long history in automotive manufacturing, known for both practical sedans and rally-bred performance vehicles.
Model Evolution
Previous Generations:
The Lancer nameplate has existed since the 1970s, evolving through various iterations and platform changes.
Key Evolution Points 8Th Gen:
Introduction of the highly acclaimed Lancer Evolution VIII and IX models, featuring advanced all-wheel-drive systems and turbocharged engines. Significant interior and exterior styling updates throughout the generation.
Production
Manufacturing Locations:
Primarily Japan (Mizushima Plant, Okazaki Plant) and other global assembly plants.
🏆 Awards & Recognition
Recognitions
Rally Heritage:
The Lancer Evolution models are legendary in the motorsport world, with multiple WRC championships, contributing to the model's performance image.
Ratings
Consumer Satisfaction:
Generally well-regarded for reliability and performance value, especially the Evolution variants. Customer reviews often highlight handling and engine performance.
Certifications
Emissions Standards:
Designed to meet emissions standards prevalent during its production years (e.g., EPA, Euro standards).