2005 Mitsubishi Lancer Evolution Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 2005 Codes Chassis Code: CT9A (This manual is likely for this specific generation of Lancer Evolution, often referred to as the Evolution VIII or IX, depending on specific market variations. The CT9A chassis code is representative of this era.) 👋 Introduction Market Position Vehicle Positioning: The 2005 Mitsubishi Lancer Evolution (often referred to as Evo VIII or early Evo IX) is a high-performance, rally-bred compact sports sedan, positioned as a competitor to cars like the Subaru Impreza WRX STI. It's renowned for its advanced all-wheel-drive system, potent turbocharged engine, and exceptional handling capabilities. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Mazda Mazdaspeed3, Ford Focus RS (in some markets). Key Features Performance Focus: The manual provides in-depth information critical for maintaining and repairing the high-performance aspects of the Evolution, including its sophisticated AWD and turbocharged powertrain. Target Audience: Enthusiasts, performance drivers, and technicians who need accurate and detailed information for service and repair. It empowers owners to perform maintenance and repairs themselves or to ensure they are not misled by repair shops. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, and Maintenance for the 2005 Mitsubishi Lancer Evolution. Page Count Estimated Page Count: Approximately 2000+ pages (typical for comprehensive service manuals of this era and vehicle complexity). Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English (based on product description context) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, internal components (pistons, rings, bearings, valves, camshafts), cylinder head, block, crankshaft, lubrication system, cooling system. Engine Performance: Turbocharger system, intercooler, exhaust system, ignition system, fuel injection system (including ECU diagnostics), emission controls. Transmission: Manual transmission (likely the Getrag 6-speed for many Evolution models), clutch system, differential (front and rear), transfer case, Super Active Yaw Control (S-AYC) system (if applicable to the specific 2005 model variant). Includes disassembly, assembly, and adjustment procedures. Drivetrain: Driveshafts, CV joints, propeller shaft, wheel bearings, hub assemblies. Suspension: Front and rear suspension components (struts, shock absorbers, control arms, sway bars, bushings), alignment specifications, diagnosis and repair of suspension noise and handling issues. Brakes: Front and rear brake systems (disc brakes), caliper overhaul, brake pad replacement, rotor replacement, hydraulic system bleeding, ABS system components and diagnostics. Steering: Power steering system, steering rack, tie rods, steering column, diagnosis and repair of steering issues. Body And Chassis: Body panel removal and installation, structural components, glass replacement, door mechanisms, interior trim, exterior trim, rust repair considerations. Electrical System: Wiring diagrams, component locations, fuses, relays, battery system, charging system (alternator), starting system (starter motor), lighting system, instrument panel, power windows, power locks, audio system, ECU and sensor diagnostics, immobilizer system. HVAC: Heating system, ventilation, air conditioning (AC) system, refrigerant handling, compressor, condenser, evaporator, cabin filter replacement, diagnosis and repair of HVAC faults. Fuel And Emissions: Fuel system components (pump, filter, injectors), evaporative emissions control (EVAP), catalytic converter, exhaust gas recirculation (EGR) if applicable, oxygen sensors, and diagnostic procedures related to emissions. Steering System Details: Power steering pump, fluid reservoir, steering rack, tie rod ends, steering column components, alignment procedures and specifications. Brake System Details: Front and rear brake system layout, master cylinder, brake booster, ABS unit, hydraulic lines, brake pad and rotor replacement, caliper service, brake fluid bleeding procedures. Procedures Included Maintenance Tasks: Scheduled maintenance (oil changes, filter replacements, spark plug replacement, fluid flushes), belt inspection and replacement, brake inspection, tire rotation. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, on-board diagnostics (OBD-II) functionality. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. Torque Specifications: Detailed torque specifications for critical fasteners across all vehicle systems, crucial for proper assembly and safety. Special Tools: Identification and usage instructions for specialized tools required for specific repair and maintenance procedures. Troubleshooting Guides: Structured troubleshooting charts based on symptoms to help diagnose issues systematically. Technical Depth Depth: Comprehensive coverage suitable for professional technicians and advanced DIY enthusiasts. Includes detailed explanations of system operation, diagnostic strategies, and complete overhaul procedures. Diagnostic Codes: Explanation of diagnostic trouble codes (DTCs) and procedures for accessing and clearing them using an OBD-II scanner. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically, digital service manuals include searchable text for quick information retrieval. Print Quality Printability: High-resolution, printable pages. Users can print only the sections they need. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (This iconic turbocharged 2.0-liter inline-4 engine is standard for the Evolution VIII and early Evolution IX models. Later Evo IX models might feature the 4G63T MIVEC variant.) Performance Horsepower: Approximately 271 hp @ 6500 rpm (Varies slightly by market and specific model year designation within 2005, e.g., MR variants). Torque:...
CT9A (This manual is likely for this specific generation of Lancer Evolution, often referred to as the Evolution VIII or IX, depending on specific market variations. The CT9A chassis code is representative of this era.)
👋 Introduction
Market Position
Vehicle Positioning:
The 2005 Mitsubishi Lancer Evolution (often referred to as Evo VIII or early Evo IX) is a high-performance, rally-bred compact sports sedan, positioned as a competitor to cars like the Subaru Impreza WRX STI. It's renowned for its advanced all-wheel-drive system, potent turbocharged engine, and exceptional handling capabilities.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Mazda Mazdaspeed3, Ford Focus RS (in some markets).
Key Features
Performance Focus:
The manual provides in-depth information critical for maintaining and repairing the high-performance aspects of the Evolution, including its sophisticated AWD and turbocharged powertrain.
Target Audience:
Enthusiasts, performance drivers, and technicians who need accurate and detailed information for service and repair. It empowers owners to perform maintenance and repairs themselves or to ensure they are not misled by repair shops.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service, Repair, and Maintenance for the 2005 Mitsubishi Lancer Evolution.
Page Count
Estimated Page Count:
Approximately 2000+ pages (typical for comprehensive service manuals of this era and vehicle complexity).
Manual transmission (likely the Getrag 6-speed for many Evolution models), clutch system, differential (front and rear), transfer case, Super Active Yaw Control (S-AYC) system (if applicable to the specific 2005 model variant). Includes disassembly, assembly, and adjustment procedures.
Front and rear suspension components (struts, shock absorbers, control arms, sway bars, bushings), alignment specifications, diagnosis and repair of suspension noise and handling issues.
Brakes:
Front and rear brake systems (disc brakes), caliper overhaul, brake pad replacement, rotor replacement, hydraulic system bleeding, ABS system components and diagnostics.
Steering:
Power steering system, steering rack, tie rods, steering column, diagnosis and repair of steering issues.
Body And Chassis:
Body panel removal and installation, structural components, glass replacement, door mechanisms, interior trim, exterior trim, rust repair considerations.
Electrical System:
Wiring diagrams, component locations, fuses, relays, battery system, charging system (alternator), starting system (starter motor), lighting system, instrument panel, power windows, power locks, audio system, ECU and sensor diagnostics, immobilizer system.
HVAC:
Heating system, ventilation, air conditioning (AC) system, refrigerant handling, compressor, condenser, evaporator, cabin filter replacement, diagnosis and repair of HVAC faults.
Fuel And Emissions:
Fuel system components (pump, filter, injectors), evaporative emissions control (EVAP), catalytic converter, exhaust gas recirculation (EGR) if applicable, oxygen sensors, and diagnostic procedures related to emissions.
Steering System Details:
Power steering pump, fluid reservoir, steering rack, tie rod ends, steering column components, alignment procedures and specifications.
Brake System Details:
Front and rear brake system layout, master cylinder, brake booster, ABS unit, hydraulic lines, brake pad and rotor replacement, caliper service, brake fluid bleeding procedures.
Procedures Included
Maintenance Tasks:
Scheduled maintenance (oil changes, filter replacements, spark plug replacement, fluid flushes), belt inspection and replacement, brake inspection, tire rotation.
Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.
Torque Specifications:
Detailed torque specifications for critical fasteners across all vehicle systems, crucial for proper assembly and safety.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair and maintenance procedures.
Troubleshooting Guides:
Structured troubleshooting charts based on symptoms to help diagnose issues systematically.
Technical Depth
Depth:
Comprehensive coverage suitable for professional technicians and advanced DIY enthusiasts. Includes detailed explanations of system operation, diagnostic strategies, and complete overhaul procedures.
Diagnostic Codes:
Explanation of diagnostic trouble codes (DTCs) and procedures for accessing and clearing them using an OBD-II scanner.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Typically, digital service manuals include searchable text for quick information retrieval.
Print Quality
Printability:
High-resolution, printable pages. Users can print only the sections they need.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63 (This iconic turbocharged 2.0-liter inline-4 engine is standard for the Evolution VIII and early Evolution IX models. Later Evo IX models might feature the 4G63T MIVEC variant.)
Performance
Horsepower:
Approximately 271 hp @ 6500 rpm (Varies slightly by market and specific model year designation within 2005, e.g., MR variants).
Torque:
Approximately 273 lb-ft @ 3500 rpm (Varies slightly by market and specific model year designation).
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) with a turbocharged, intercooled induction system.
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended).
Engine Layout
Configuration:
Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged.
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent (typically a P-HOAT type, pink or orange in color).
Lubrication System
Oil Type:
Synthetic SAE 5W-30 is commonly recommended. Consult manual for specific viscosity grades and API service classifications.
Engine Mechanical
Bore X Stroke:
85.0 mm x 88.0 mm
Displacement:
1997 cc
Compression Ratio:
8.8:1
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission (Getrag MR983396 is a common part number for the gearbox itself).
Optional
Transmission Type:
None for the performance-oriented Evolution models of this era.
Features
All Wheel Drive:
Advanced Symmetrical All-Wheel Drive with Active Yaw Control (AYC) and/or Active Center Differential (ACD), depending on the specific 2005 model variant (e.g., Evo VIII MR, Evo IX).
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific gear oil specifications. Typically a GL-4 or GL-5 gear oil in a suitable viscosity grade (e.g., 75W-90). ACD and AYC units may require specific fluid types.
📐 Dimensions
Exterior
Length:
Approximately 4490 mm (176.8 inches)
Width:
Approximately 1770 mm (69.7 inches)
Height:
Approximately 1450 mm (57.1 inches)
Wheelbase:
Approximately 2625 mm (103.3 inches)
Weights
Curb Weight:
Approximately 1450 - 1500 kg (3197 - 3307 lbs), depending on trim and options.
🛡️ Safety Features
Ratings
NHTSA Rating:
NHTSA ratings for this specific year and model are generally not as readily available or as comprehensive as modern vehicles. Early Lancer Evolution models were not extensively crash-tested by NHTSA in the US market as a distinct model. The focus was more on performance and rally homologation.
Active Features
AWD System:
Sophisticated All-Wheel Drive (AYC/ACD) significantly enhances traction and stability.
ABS:
Anti-lock Braking System (ABS) with EBD (Electronic Brakeforce Distribution).
Passive Features
Airbags:
Front airbags for driver and passenger. Side airbags may be optional on some trims.
Body Structure:
Reinforced unibody construction designed for rally-derived rigidity and safety.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player. Upgraded Rockford Fosgate audio systems were often an option on higher trims (e.g., MR).
Driver Assistance
Performance Aids:
The primary 'technology' here is the advanced mechanical and electronic integration of the drivetrain (ACD/AYC) and suspension for optimal performance and handling.
Connectivity
Connectivity Features:
Limited by modern standards. Primarily basic audio connectivity. No integrated Bluetooth or USB ports typically found on 2005 models unless aftermarket.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles or 6 months, especially under spirited driving conditions. Consult the manual for specific recommendations.
Spark Plugs:
Platinum or Iridium spark plugs, usually with a service interval of 60,000-100,000 miles, depending on plug type. The manual will specify the correct part number and interval.
Timing Belt:
The 4G63 engine uses a timing belt. Replacement interval is typically around 60,000 to 90,000 miles or 7-10 years. This is a critical maintenance item due to the interference design of the engine.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Refer to manual for exact specification and bleeding procedures.
Power Steering Fluid:
Refer to manual for specific power steering fluid type. Often a Dexron III ATF or specific power steering fluid.
Known Issues
Engine Reliability:
While robust, the 4G63 engine can be prone to turbocharger wear with age and high mileage, head gasket issues under extreme stress, and clutch wear due to the performance nature of the vehicle. Proper maintenance is key.
Suspension Wear:
Bushings and ball joints can wear over time, leading to clunks and handling degradation, especially in vehicles that have seen track or aggressive street use.
Ayc Acd Reliability:
These advanced differential systems can be complex. Sensor failures or fluid leaks in these units can lead to operational issues. Regular fluid changes are important.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
The Lancer Evolution's lineage is deeply rooted in World Rally Championship (WRC) racing, where it achieved significant success and homologation specials.
Model Evolution
Generation:
The 2005 model year falls within the eighth generation (CT9A chassis code) of the Lancer Evolution, which was produced from 2003 to 2005. This generation saw significant updates over the previous generation, including a revised chassis, suspension, and the introduction of the ACD and AYC systems.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Press:
The Lancer Evolution consistently received praise from automotive journalists and publications for its performance, handling, and value as a rally-bred sports car. Often lauded as one of the best driver's cars in its segment.