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Mitsubishi Lancer EVO 9 Workshop Manual

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๐Ÿท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Model Code: CT9A Codes Engine Code Primary: 4G63 Engine Code Variant: 4G63-MIVEC ๐Ÿ‘‹ 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. ๐Ÿ“‹ 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) ๐Ÿ“– 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 ๐Ÿ“Š 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) โš™๏ธ 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 ๐Ÿ”ง 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 ๐Ÿ“ 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) ๐Ÿ›ก๏ธ 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 ๐Ÿ’ก Technology...
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Mitsubishi Lancer EVO 9 Workshop Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Model Code:
CT9A
Codes
Engine Code Primary:
4G63
Engine Code Variant:
4G63-MIVEC
๐Ÿ‘‹ 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.
๐Ÿ“‹ 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)
๐Ÿ“– 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
๐Ÿ“Š 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)
โš™๏ธ 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
๐Ÿ”ง 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
๐Ÿ“ 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)
๐Ÿ›ก๏ธ 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
๐Ÿ’ก 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.
๐Ÿ”ง 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.
๐Ÿ“š 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).
๐Ÿ† 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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