Mitsubishi Lancer Complete Workshop Service Repair Manual 2000 2001 2002 2003 2004 2005 2006 2007

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Variant: Standard, ES, LS, OZ Rally, Ralliart, Evolution (specific coverage may vary by sub-model within this range) Generation Generation: Eighth Generation (CSA) Codes Chassis Codes: CS1A, CS2A, CS3A, CS5A, CS6A, CS7A, CT9A (Evolution variants) 👋 Introduction Market Position Segment: Compact Sedan/Hatchback Target Audience: DIY mechanics, independent repair shops, and owners seeking detailed repair information. Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza Key Features Strengths: Affordability, sporty handling (especially OZ Rally and Evolution models), good reliability for the price point, available AWD on Evolution models. Evolution Variants: The Lancer Evolution (Evo) models are significantly different performance vehicles, featuring turbocharged engines, AWD, and advanced aerodynamics, all covered in this comprehensive manual. 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: 2000+ Manual Type Type: Complete Workshop Service and Repair Manual Language Language: English Format Format: Downloadable PDF File Format File Type: PDF Print Quality Resolution: High-resolution scans, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Search Function: Searchable text allows for quick access to specific information. 📖 Manual Coverage Systems Covered Engine: 2.0L 4G63 SOHC, 2.4L 4G64 SOHC, 2.0L 4G63T DOHC Turbocharged (Evolution) Transmission: 5-speed Manual, 4-speed Automatic, 6-speed Manual (Evolution) Drivetrain: Front-Wheel Drive (FWD), All-Wheel Drive (AWD - Evolution) Suspension: Front: MacPherson Struts, Rear: Multi-link independent (standard), Multi-link independent with Bilstein dampers (Evolution) Brakes: Front: Ventilated Discs, Rear: Discs (Solid or Ventilated depending on trim), ABS, EBD Steering: Power Rack and Pinion Electrical System: 12V Battery, Alternator, Starter, Lighting, Fuses, Relays, ECUs, Immobilizer Body And Chassis: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Structural Components Hvac HVAC System: Air Conditioning, Heater, Ventilation, Climate Control Fuel System Fuel System: Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Lines, Fuel Filter Cooling System Cooling System: Radiator, Water Pump, Thermostat, Coolant Hoses, Fan Exhaust System Exhaust System: Exhaust Manifold, Catalytic Converter, Muffler, Pipes Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Service, Fluid Checks and Changes, Tire Rotation, Brake Pad Replacement, Belt Inspection and Replacement Engine Repair: Engine Overhaul, Head Gasket Replacement, Piston and Connecting Rod Service, Valve Train Adjustment, Timing Belt/Chain Replacement Transmission Repair: Clutch Replacement, Transmission Rebuild (Manual & Auto), Torque Converter Service, Gearbox Inspection Brake System Repair: Brake Pad and Rotor Replacement, Caliper Service, Bleeding Procedures, ABS System Diagnostics and Repair Suspension And Steering Repair: Shock Absorber/Strut Replacement, Bushing Replacement, Ball Joint and Tie Rod End Replacement, Power Steering Pump and Rack Service Electrical Diagnostics: Troubleshooting wiring diagrams, Component testing, Sensor diagnostics, ECM/PCM diagnosis, Starter and alternator testing Bodywork And Collision Repair: Panel replacement, Door adjustment, Bumper repair, Glass replacement procedures Troubleshooting: Diagnostic charts, Symptom-based troubleshooting guides, Fault code interpretation Wiring Diagrams: Complete electrical schematics for all major systems Technical Depth Depth: Comprehensive: Covers routine maintenance, diagnostic procedures, component-level repairs, and complete system overhauls. Diagnostic Tools: Includes information on diagnostic trouble codes (DTCs) and recommended procedures using scan tools. Specifications: Torque specifications for all critical fasteners, Clearances, Fluid capacities, Electrical system parameters. ⚙️ Engine Specifications Primary Engine Engine Code 1: 4G63 SOHC Displacement 1: 2.0 Liters (1997cc) Horsepower 1: Approx. 120-135 hp (varies by market/trim) Torque 1: Approx. 130-140 lb-ft (varies by market/trim) Secondary Engine Engine Code 2: 4G64 SOHC Displacement 2: 2.4 Liters (2351cc) Horsepower 2: Approx. 160 hp (varies by market/trim) Torque 2: Approx. 160-165 lb-ft (varies by market/trim) Performance Engine Engine Code 3: 4G63T DOHC Turbocharged Displacement 3: 2.0 Liters (1997cc) Horsepower 3: Approx. 271-286 hp (depending on Evo generation covered) Torque 3: Approx. 280-290 lb-ft (depending on Evo generation covered) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded (Non-turbo), 91+ Octane Unleaded (Evolution) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic Evolution Transmission Evolution Transmission: 6-speed Manual (Getrag) Features AWD System: Active Yaw Control (AYC) and/or Super All-Wheel Control (S-AWC) on Evolution models. 📐 Dimensions Exterior Length: Approx. 177.4 - 182.1 inches (varies by body style/trim) Width: Approx. 67.7 - 70.1 inches Height: Approx. 56.7 - 58.7 inches Wheelbase Wheelbase: Approx. 102.4 inches Weights Curb Weight: Approx. 2,800 - 3,200 lbs (varies significantly by trim/engine) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (for comparable years/models) IIHS Side Impact: Good (for comparable years/models) Active Features ABS: Standard on most trims Ebd: Electronic Brake-force Distribution (Standard on most trims) Traction Control: Optional on some trims, standard on Evolution Passive Features Airbags: Front dual-stage airbags (standard), Optional side-impact airbags. Seatbelts: 3-point ELR seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Base CD player with AM/FM radio, optional Rockford Fosgate premium audio system on higher trims. Aux input availability varies by trim and year. Navigation: Rarely equipped; available as an dealer-installed option on some higher...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Model Variant:

Standard, ES, LS, OZ Rally, Ralliart, Evolution (specific coverage may vary by sub-model within this range)

Generation

Generation:

Eighth Generation (CSA)

Codes

Chassis Codes:

CS1A, CS2A, CS3A, CS5A, CS6A, CS7A, CT9A (Evolution variants)

👋 Introduction

Market Position

Segment:

Compact Sedan/Hatchback

Target Audience:

DIY mechanics, independent repair shops, and owners seeking detailed repair information.

Competitive Analysis

Competitors:

Honda Civic, Toyota Corolla, Mazda3, Subaru Impreza

Key Features

Strengths:

Affordability, sporty handling (especially OZ Rally and Evolution models), good reliability for the price point, available AWD on Evolution models.

Evolution Variants:

The Lancer Evolution (Evo) models are significantly different performance vehicles, featuring turbocharged engines, AWD, and advanced aerodynamics, all covered in this comprehensive manual.

📋 Manual Details

Coverage Areas

Covered Years:

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

Page Count

Estimated Page Count:

2000+

Manual Type

Type:

Complete Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

File Format

File Type:

Print Quality

Resolution:

High-resolution scans, suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Searchability

Search Function:

Searchable text allows for quick access to specific information.

📖 Manual Coverage

Systems Covered

Engine:

2.0L 4G63 SOHC, 2.4L 4G64 SOHC, 2.0L 4G63T DOHC Turbocharged (Evolution)

Transmission:

5-speed Manual, 4-speed Automatic, 6-speed Manual (Evolution)

Drivetrain:

Front-Wheel Drive (FWD), All-Wheel Drive (AWD - Evolution)

Suspension:

Front: MacPherson Struts, Rear: Multi-link independent (standard), Multi-link independent with Bilstein dampers (Evolution)

Brakes:

Front: Ventilated Discs, Rear: Discs (Solid or Ventilated depending on trim), ABS, EBD

Steering:

Power Rack and Pinion

Electrical System:

12V Battery, Alternator, Starter, Lighting, Fuses, Relays, ECUs, Immobilizer

Body And Chassis:

Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Structural Components

HVAC System:

Air Conditioning, Heater, Ventilation, Climate Control

Fuel System

Fuel System:

Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Lines, Fuel Filter

Cooling System

Cooling System:

Radiator, Water Pump, Thermostat, Coolant Hoses, Fan

Exhaust System

Exhaust System:

Exhaust Manifold, Catalytic Converter, Muffler, Pipes

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Spark Plug Service, Fluid Checks and Changes, Tire Rotation, Brake Pad Replacement, Belt Inspection and Replacement

Engine Repair:

Engine Overhaul, Head Gasket Replacement, Piston and Connecting Rod Service, Valve Train Adjustment, Timing Belt/Chain Replacement

Transmission Repair:

Clutch Replacement, Transmission Rebuild (Manual & Auto), Torque Converter Service, Gearbox Inspection

Brake System Repair:

Brake Pad and Rotor Replacement, Caliper Service, Bleeding Procedures, ABS System Diagnostics and Repair

Suspension And Steering Repair:

Shock Absorber/Strut Replacement, Bushing Replacement, Ball Joint and Tie Rod End Replacement, Power Steering Pump and Rack Service

Electrical Diagnostics:

Troubleshooting wiring diagrams, Component testing, Sensor diagnostics, ECM/PCM diagnosis, Starter and alternator testing

Bodywork And Collision Repair:

Panel replacement, Door adjustment, Bumper repair, Glass replacement procedures

Troubleshooting:

Diagnostic charts, Symptom-based troubleshooting guides, Fault code interpretation

Wiring Diagrams:

Complete electrical schematics for all major systems

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, diagnostic procedures, component-level repairs, and complete system overhauls.

Diagnostic Tools:

Includes information on diagnostic trouble codes (DTCs) and recommended procedures using scan tools.

Specifications:

Torque specifications for all critical fasteners, Clearances, Fluid capacities, Electrical system parameters.

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

4G63 SOHC

Displacement 1:

2.0 Liters (1997cc)

Horsepower 1:

Approx. 120-135 hp (varies by market/trim)

Torque 1:

Approx. 130-140 lb-ft (varies by market/trim)

Secondary Engine

Engine Code 2:

4G64 SOHC

Displacement 2:

2.4 Liters (2351cc)

Horsepower 2:

Approx. 160 hp (varies by market/trim)

Torque 2:

Approx. 160-165 lb-ft (varies by market/trim)

Performance Engine

Engine Code 3:

4G63T DOHC Turbocharged

Displacement 3:

2.0 Liters (1997cc)

Horsepower 3:

Approx. 271-286 hp (depending on Evo generation covered)

Torque 3:

Approx. 280-290 lb-ft (depending on Evo generation covered)

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded (Non-turbo), 91+ Octane Unleaded (Evolution)

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual

Optional

Optional Transmission:

4-speed Automatic

Evolution Transmission

Evolution Transmission:

6-speed Manual (Getrag)

Features

AWD System:

Active Yaw Control (AYC) and/or Super All-Wheel Control (S-AWC) on Evolution models.

📐 Dimensions

Exterior

Length:

Approx. 177.4 - 182.1 inches (varies by body style/trim)

Width:

Approx. 67.7 - 70.1 inches

Height:

Approx. 56.7 - 58.7 inches

Wheelbase

Wheelbase:

Approx. 102.4 inches

Weights

Curb Weight:

Approx. 2,800 - 3,200 lbs (varies significantly by trim/engine)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 Stars (for comparable years/models)

IIHS Side Impact:

Good (for comparable years/models)

Active Features

Standard on most trims

Electronic Brake-force Distribution (Standard on most trims)

Traction Control:

Optional on some trims, standard on Evolution

Passive Features

Airbags:

Front dual-stage airbags (standard), Optional side-impact airbags.

Seatbelts:

3-point ELR seatbelts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Base CD player with AM/FM radio, optional Rockford Fosgate premium audio system on higher trims. Aux input availability varies by trim and year.

Navigation:

Rarely equipped; available as an dealer-installed option on some higher trims.

Driver Assistance

Cruise Control:

Standard on most trims

Stability Control:

Not typically available on non-Evolution models of this generation.

Connectivity

Bluetooth:

Not standard; available as a dealer-installed accessory on later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil type (consult manual for specifics).

Engine Coolant Replacement:

Every 30,000 - 60,000 miles or 2-4 years (using appropriate coolant).

Spark Plug Replacement:

Every 60,000 - 100,000 miles for platinum/iridium plugs (check specific type).

Transmission Fluid Change:

Every 30,000 - 60,000 miles (manual & auto, consult manual for specific intervals and fluid types).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 5W-40 (API SJ or higher, consult manual for exact specification).

Engine Oil Capacity:

Approx. 4.5 - 5.0 quarts (4.3 - 4.7 liters) with filter change (for 2.0L/2.4L engines).

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent silicate-free, ethylene glycol-based coolant.

Transmission Fluid Type Manual:

API GL-4 SAE 75W-90 (for standard manual), specific Mitsubishi fluid for 6-speed.

Transmission Fluid Type Automatic:

Mitsubishi DiaQueen ATF-J2 or equivalent Dexron III/VI compatible fluid.

Known Issues

Engine Common Issues:

Minor oil leaks from valve cover gasket, potential for carbon buildup in intake manifold on higher mileage units, timing belt replacement interval is critical for non-interference engines (check manual).

Transmission Common Issues:

Clutch wear on manual transmissions, occasional hard shifting in automatic transmissions.

Suspension Common Issues:

Worn sway bar links, strut mounts, and ball joints can cause noise and affect handling.

Electrical Common Issues:

Window regulator failures, intermittent power to accessories, dashboard warning light issues.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Mitsubishi Motors is a Japanese multinational automotive manufacturer known for its diverse range of vehicles and motorsports heritage, particularly with the Lancer Evolution.

Model Evolution

Lancer History:

The Lancer nameplate has been used by Mitsubishi since 1973. This specific generation (2000-2007) saw significant styling updates and the introduction of the high-performance Evolution models in many markets.

Production

Production Years:

2000-2007 (for this specific generation)

Production Locations

Manufacturing Plants:

Primarily Japan, also other global assembly plants.

🏆 Awards & Recognition

Recognitions

Motorsports Legacy:

The Lancer platform is most famous for its dominant rally heritage with the Lancer Evolution, which has won numerous World Rally Championship titles.

Performance Awards:

The Lancer Evolution models consistently received high marks in automotive reviews for their performance, handling, and technology, often being compared to sports cars from premium manufacturers.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and powertrain. Generally average to above average for the standard models, while the Evolution models are praised for performance but require more rigorous maintenance.