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Mitsubishi Lancer EVO 9 Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Model Code: CT9A Codes Engine Code Primary: 4G63 Engine Code Variant: 4G63-MIVEC 👋 Introduction Market Position Positioning: Iconic performance sedan, rally homologation special, highly sought after by enthusiasts for its raw performance and tuning potential. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (certain generations), Volkswagen Golf R. Key Features Distinguishing Features: Symmetrical All-Wheel Drive with ACD/AYC, potent 4G63 MIVEC turbocharged engine, advanced differential technologies, aggressive styling, rally-bred heritage. Manual Value Proposition: The definitive guide for owners and mechanics to maintain, diagnose, and repair the Mitsubishi Lancer Evolution IX, ensuring optimal performance and longevity of this legendary vehicle. 📋 Manual Details Coverage Areas Coverage Scope: All models and repairs A-Z Repair Types Covered: Mechanical, Electrical, Bodywork, Diagnostics, Routine Maintenance Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (Printable) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, turbocharging, MIVEC system, engine diagnostics Drivetrain Systems: Manual Transmission (GSR, RS), Transfer Case, ACD (Active Center Differential), AYC (Active Yaw Control), Driveshafts, Differentials (Front/Rear), Clutch system Suspension Steering: Front suspension (MacPherson strut), Rear suspension (Multi-link), Power steering system, Wheel alignment, Suspension components Braking Systems: Front and Rear Disc Brakes (Brembo option), ABS (Anti-lock Braking System), Brake hydraulics, Parking brake system Electrical Systems: Power distribution, Starting and charging systems, Lighting, Instruments, Wiper/Washer systems, Audio system, ECU (Engine Control Unit) and related sensors, Immobilizer, SRS (Supplemental Restraint System) Body Chassis: Body structure, Exterior panels, Doors, Windows, Hood, Trunk, Interior trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning) Procedures Included Routine Maintenance: Oil change, Filter replacement, Spark plug replacement, Belt inspection/replacement, Fluid checks and top-offs, Brake pad inspection Engine Repair: Engine overhaul, Piston/ring replacement, Cylinder head service, Timing belt/chain replacement, Turbocharger rebuild/replacement, MIVEC system diagnostics and repair Drivetrain Repair: Transmission removal/installation, Clutch replacement, Differential service, ACD/AYC system troubleshooting and repair, Driveshaft and U-joint service Suspension Steering Repair: Shock absorber/strut replacement, Bushing replacement, Ball joint replacement, Tie rod end replacement, Steering rack service Brake Repair: Brake pad/rotor replacement, Caliper service, Brake bleeding, ABS sensor replacement, ABS module troubleshooting Electrical Diagnostics: Wiring diagrams, Fuse and relay identification, Component testing, Diagnostic trouble code (DTC) interpretation, Sensor testing Bodywork Repair: Panel replacement, Dent repair, Door alignment, Glass replacement, Interior trim installation Troubleshooting: System-specific diagnostic flowcharts, Symptom-based troubleshooting guides Technical Depth Depth Of Information: Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. Detail Level: Detailed step-by-step instructions with torque specifications, clearances, and component tolerances. Illustrations: Tons of detailed pictures and diagrams 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Printability: All pages are printable Image Quality: High-resolution images and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged with MIVEC Engine Displacement: 2.0 Liters (1997cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Turbocharger Spec: Mitsubishi TD05HR-16G6-10.5T (or similar, depending on market/spec) Performance Horsepower Ps Usdm: 286 PS (approx. 282 hp) @ 6500 rpm Torque Nm Usdm: 392 Nm (approx. 289 lb-ft) @ 3500 rpm Horsepower Ps Jdm: 280 PS (approx. 276 hp) @ 6500 rpm (often underestimated) Torque Nm Jdm: 392 Nm (approx. 289 lb-ft) @ 3500 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Unleaded Gasoline (premium recommended) Fuel System Components: High-flow fuel injectors, electric fuel pump, Bosch ECU 🔧 Transmission Standard Transmission Type: 6-speed manual transmission Transmission Gear Ratios Primary: Refer to manual for specific ratios (e.g., 1st: 2.750, 2nd: 1.944, 3rd: 1.370, 4th: 1.030, 5th: 0.864, 6th: 0.760) Optional Optional Transmission: N/A (Manual transmission was standard for Evo IX) Features Drivetrain Features: Symmetrical All-Wheel Drive with Active Center Differential (ACD) and Active Yaw Control (AYC). Clutch Type: Hydraulically operated, single dry plate clutch 📐 Dimensions Exterior Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2630 mm (103.5 in) Front Track: 1515 mm (59.6 in) Rear Track: 1515 mm (59.6 in) Ground Clearance: 135 mm (5.3 in) Weights Curb Weight Kg: 1400-1450 kg (approx. 3086-3197 lbs), varies by trim Gross Vehicle Weight Rating Kg: Refer to vehicle VIN plate Cargo Trunk Volume Liters: 350 L (approx. 12.4 cu ft) 🛡️ Safety Features Ratings NHTSA Front Impact: 4-star (as per available records for similar models/years) IIHS Front Impact: Good (as per available records for similar models/years) Active Features Active Safety: ABS (Anti-lock Braking System), Active Center Differential (ACD), Active Yaw Control (AYC) Passive Features Passive Safety: Driver and front passenger airbags, Side curtain airbags (optional/market dependent), Reinforced chassis, Seatbelt pretensioners 💡 Technology...
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Mitsubishi Lancer EVO 9 Workshop Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Model Code:
CT9A
Codes
Engine Code Primary:
4G63
Engine Code Variant:
4G63-MIVEC
👋 Introduction
Market Position
Positioning:
Iconic performance sedan, rally homologation special, highly sought after by enthusiasts for its raw performance and tuning potential.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (certain generations), Volkswagen Golf R.
Key Features
Distinguishing Features:
Symmetrical All-Wheel Drive with ACD/AYC, potent 4G63 MIVEC turbocharged engine, advanced differential technologies, aggressive styling, rally-bred heritage.
Manual Value Proposition:
The definitive guide for owners and mechanics to maintain, diagnose, and repair the Mitsubishi Lancer Evolution IX, ensuring optimal performance and longevity of this legendary vehicle.
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and repairs A-Z
Repair Types Covered:
Mechanical, Electrical, Bodywork, Diagnostics, Routine Maintenance
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (Printable)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, turbocharging, MIVEC system, engine diagnostics
Drivetrain Systems:
Manual Transmission (GSR, RS), Transfer Case, ACD (Active Center Differential), AYC (Active Yaw Control), Driveshafts, Differentials (Front/Rear), Clutch system
Suspension Steering:
Front suspension (MacPherson strut), Rear suspension (Multi-link), Power steering system, Wheel alignment, Suspension components
Braking Systems:
Front and Rear Disc Brakes (Brembo option), ABS (Anti-lock Braking System), Brake hydraulics, Parking brake system
Electrical Systems:
Power distribution, Starting and charging systems, Lighting, Instruments, Wiper/Washer systems, Audio system, ECU (Engine Control Unit) and related sensors, Immobilizer, SRS (Supplemental Restraint System)
Body Chassis:
Body structure, Exterior panels, Doors, Windows, Hood, Trunk, Interior trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning)
Procedures Included
Routine Maintenance:
Oil change, Filter replacement, Spark plug replacement, Belt inspection/replacement, Fluid checks and top-offs, Brake pad inspection
Engine Repair:
Engine overhaul, Piston/ring replacement, Cylinder head service, Timing belt/chain replacement, Turbocharger rebuild/replacement, MIVEC system diagnostics and repair
Drivetrain Repair:
Transmission removal/installation, Clutch replacement, Differential service, ACD/AYC system troubleshooting and repair, Driveshaft and U-joint service
Suspension Steering Repair:
Shock absorber/strut replacement, Bushing replacement, Ball joint replacement, Tie rod end replacement, Steering rack service
Brake Repair:
Brake pad/rotor replacement, Caliper service, Brake bleeding, ABS sensor replacement, ABS module troubleshooting
Electrical Diagnostics:
Wiring diagrams, Fuse and relay identification, Component testing, Diagnostic trouble code (DTC) interpretation, Sensor testing
Bodywork Repair:
Panel replacement, Dent repair, Door alignment, Glass replacement, Interior trim installation
Troubleshooting:
System-specific diagnostic flowcharts, Symptom-based troubleshooting guides
Technical Depth
Depth Of Information:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
Detail Level:
Detailed step-by-step instructions with torque specifications, clearances, and component tolerances.
Illustrations:
Tons of detailed pictures and diagrams
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Print Quality
Printability:
All pages are printable
Image Quality:
High-resolution images and diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged with MIVEC
Engine Displacement:
2.0 Liters (1997cc)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Turbocharger Spec:
Mitsubishi TD05HR-16G6-10.5T (or similar, depending on market/spec)
Performance
Horsepower Ps Usdm:
286 PS (approx. 282 hp) @ 6500 rpm
Torque Nm Usdm:
392 Nm (approx. 289 lb-ft) @ 3500 rpm
Horsepower Ps Jdm:
280 PS (approx. 276 hp) @ 6500 rpm (often underestimated)
Torque Nm Jdm:
392 Nm (approx. 289 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded Gasoline (premium recommended)
Fuel System Components:
High-flow fuel injectors, electric fuel pump, Bosch ECU
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission
Transmission Gear Ratios Primary:
Refer to manual for specific ratios (e.g., 1st: 2.750, 2nd: 1.944, 3rd: 1.370, 4th: 1.030, 5th: 0.864, 6th: 0.760)
Optional
Optional Transmission:
N/A (Manual transmission was standard for Evo IX)
Features
Drivetrain Features:
Symmetrical All-Wheel Drive with Active Center Differential (ACD) and Active Yaw Control (AYC).
Clutch Type:
Hydraulically operated, single dry plate clutch
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2630 mm (103.5 in)
Front Track:
1515 mm (59.6 in)
Rear Track:
1515 mm (59.6 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Curb Weight Kg:
1400-1450 kg (approx. 3086-3197 lbs), varies by trim
Gross Vehicle Weight Rating Kg:
Refer to vehicle VIN plate
Cargo
Trunk Volume Liters:
350 L (approx. 12.4 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star (as per available records for similar models/years)
IIHS Front Impact:
Good (as per available records for similar models/years)
Active Features
Active Safety:
ABS (Anti-lock Braking System), Active Center Differential (ACD), Active Yaw Control (AYC)
Passive Features
Passive Safety:
Driver and front passenger airbags, Side curtain airbags (optional/market dependent), Reinforced chassis, Seatbelt pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Basic aftermarket or factory radio systems, typically single-DIN or double-DIN units with CD player and AM/FM radio. Bluetooth and navigation were not standard factory features on most models.
Driver Assistance
Driver Assistance Features:
ABS, ACD, AYC. No electronic stability control (ESC) as standard on most markets/trims, though some later JDM models might have had it.
Connectivity
Connectivity Options:
Limited to factory radio connectivity (e.g., CD changer port), often upgraded with aftermarket head units for modern smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Every 5,000-7,500 km (3,000-4,500 miles) or 6 months, depending on driving conditions.
Timing Belt Replacement Km:
Every 96,000 km (60,000 miles) or 7 years, whichever comes first.
Spark Plug Replacement Km:
Every 48,000 km (30,000 miles) - Iridium plugs.
Fluid Specifications
Engine Oil Type:
Fully Synthetic 5W-30 or 0W-30 (API SN/SP or ILSAC GF-5/GF-6)
Engine Oil Capacity Liters:
4.5 Liters (with filter change)
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent HOAT coolant
Transmission Fluid Type:
DiaQueen LSD Gear Oil 75W-85 GL-5 or equivalent (for manual transmission)
Transfer Case Fluid Type:
DiaQueen LSD Gear Oil 75W-85 GL-5 or equivalent
Rear Differential Fluid Type:
DiaQueen LSD Gear Oil 75W-85 GL-5 or equivalent (for AYC-equipped vehicles, specific LSD fluid is critical)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear, turbocharger seal leaks, ACD pump failure, suspension bushings, wheel bearings, exhaust manifold cracks (under high stress).
Engine Specific Concerns:
Valve stem seals, PCV system clogging, oil slinger issues (if poorly maintained). MIVEC solenoid issues can arise with age/lack of maintenance.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation, known for its rally heritage and performance-oriented vehicles.
Model Evolution
Evolution Lineage:
Part of the Lancer Evolution series, which originated as a homologation special for World Rally Championship (WRC).
Ninth Generation:
The Evo IX represents the final iteration of the CT9A platform, refining the technology and performance of its predecessors.
Production
Production Years:
2005-2007
Manufacturing Locations:
Japan
Key Trims:
GSR (Grand Sport Racing), RS (Rally Sport - more stripped down, often RHD only).
🏆 Awards & Recognition
Recognitions
Automotive Press Acclaim:
Consistently praised by automotive media for its handling, performance, and rally-bred capabilities. Frequently featured in 'best performance car' lists and comparison tests.
Ratings
Enthusiast Ratings:
Highly regarded by enthusiasts and tuners for its robust powertrain, effective AWD system, and significant aftermarket support.
Certifications
Homologation:
Rally homologation for the World Rally Championship (WRC).
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