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Mitsubishi Lancer Evolution 2003 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Generation: VII Model Years Covered: 2003-2005 Codes Chassis Code Prefix: CT9A 👋 Introduction Market Position Vehicle Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (though the Evo is a step above these). Key Features Manual Selling Points: Extremely comprehensive, covers all aspects of repair and maintenance, suitable for DIY enthusiasts and professional mechanics, detailed illustrations and specifications. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for all systems. Page Count Total Pages: Over 5000 Manual Type Manual Category: Factory Service Repair Manual Language Primary Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, rebuilding, performance tuning, timing belt replacement, firing orders, serpentine belt routings. Drivetrain Systems: Transmission information, U-joint and CV-joint service procedures, 4WD system. Braking Systems: Brake service and repair, including ABS diagnostics. Suspension Steering: Front end procedures, specifications, suspension component service. Electrical Electronics: Wiring diagrams, computer diagnostic codes, troubleshooting and diagnostics. Body Chassis: Sunroof service, exterior and interior component repair. Climate Control: Air conditioning service and capacities. Procedures Included Maintenance Procedures: Factory maintenance schedules and charts, oil changes, fluid replacements. Diagnostic Procedures: Trouble codes, troubleshooting, diagnostics, computer diagnostic codes. Repair Procedures: Complete repair procedures for all covered systems. Performance Tuning: Engine performance specifications and tuning advice. Technical Depth Depth Of Coverage: From basic DIY tasks to complete engine and transmission rebuilding. Torque Specifications: Complete torque specifications provided for all fasteners. Wiring Diagrams Coverage: Complete and detailed wiring diagrams for all vehicle systems. Illustrations Count: Hundreds of illustrations aiding in repair and understanding. 📊 Manual Specifications File Format PDF Features: Searchable text, zoomable diagrams, printable pages. Print Quality Illustration Detail: Hundreds of illustrations with detailed parts views. Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Media: Digital Media (PDF) Compatibility Operating Systems: Compatible with all PC and MAC computers. ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 Engine Type: 2.0L Inline-4, DOHC, 16-valve, turbocharged, intercooled Performance Horsepower Est: 271-286 hp (depending on specific market and sub-model) Torque Est: 273-280 lb-ft (depending on specific market and sub-model) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G or similar twin-scroll turbocharger Cooling System Intercooler Type: Air-to-air front-mounted intercooler Engine Management ECU Type: ECU (Engine Control Unit) with programmable parameters Technical Details Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Valve Train: DOHC, 16 Valves, timing belt driven camshafts. 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Transmission (Getrag G5M31-RR-N) Optional Transmission Type Opt: Not typically offered with automatic transmissions in this generation for performance models. Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Sport-ABS, Active Yaw Control (AYC) on some models. Ayc System: Active Yaw Control (AYC) system adjusts torque distribution to the rear wheels for improved cornering stability. Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90. Fluid Capacities Manual Transmission Capacity: Approx. 2.0-2.3 liters (refer to manual for exact figure) 📐 Dimensions Exterior Length: Approx. 4,360 mm (171.7 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Weights Curb Weight: Approx. 1,360 - 1,400 kg (2,998 - 3,086 lbs) Wheelbase: Approx. 2,600 mm (102.4 in) Track Width Front: Approx. 1,500 mm (59.1 in) Track Width Rear: Approx. 1,505 mm (59.3 in) 🛡️ Safety Features Ratings NHTSA Ratings: Specific NHTSA ratings for this generation may vary by market; generally considered safe for its class due to structural integrity and AWD. Active Features Active Safety Systems: ABS (Anti-lock Braking System), Active Center Differential (ACD), AYC (Active Yaw Control), Traction Control System (TCL). Passive Features Passive Safety Features: Driver and front passenger airbags, reinforced body structure, side-impact door beams. Chassis Enhancements Chassis Design: Monocoque chassis with MacPherson strut front suspension and multi-link rear suspension. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio, CD player, likely with limited digital connectivity for the era. Driver Assistance Driver Assistance Features: Limited by modern standards, but advanced for its time with ACD and AYC for traction and handling. Connectivity Connectivity Options: Typically no Bluetooth or advanced smartphone integration. May have power windows, mirrors, and basic climate control. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 3-6 months (severe driving conditions recommended for performance vehicles). Timing Belt Replacement Interval: Typically 60,000-80,000 miles or 5-7 years (crucial for 4G63 engine). Fluid Specifications Engine Oil Specification: Refer to manual: typically 5W-30 or 10W-30 synthetic oil meeting API SN or higher. Coolant Specification: Refer to manual: typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water. Brake Fluid Specification: DOT 3 or DOT 4 brake fluid. Known Issues Common Engine Issues: Head gasket failures (due...
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Mitsubishi Lancer Evolution 2003 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Generation:
VII
Model Years Covered:
2003-2005
Codes
Chassis Code Prefix:
CT9A
👋 Introduction
Market Position
Vehicle Segment:
Performance Compact Sedan / Rally Homologation Special
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (though the Evo is a step above these).
Key Features
Manual Selling Points:
Extremely comprehensive, covers all aspects of repair and maintenance, suitable for DIY enthusiasts and professional mechanics, detailed illustrations and specifications.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair for all systems.
Page Count
Total Pages:
Over 5000
Manual Type
Manual Category:
Factory Service Repair Manual
Language
Primary Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, rebuilding, performance tuning, timing belt replacement, firing orders, serpentine belt routings.
Drivetrain Systems:
Transmission information, U-joint and CV-joint service procedures, 4WD system.
Braking Systems:
Brake service and repair, including ABS diagnostics.
Suspension Steering:
Front end procedures, specifications, suspension component service.
Electrical Electronics:
Wiring diagrams, computer diagnostic codes, troubleshooting and diagnostics.
Body Chassis:
Sunroof service, exterior and interior component repair.
Climate Control:
Air conditioning service and capacities.
Procedures Included
Maintenance Procedures:
Factory maintenance schedules and charts, oil changes, fluid replacements.
Diagnostic Procedures:
Trouble codes, troubleshooting, diagnostics, computer diagnostic codes.
Repair Procedures:
Complete repair procedures for all covered systems.
Performance Tuning:
Engine performance specifications and tuning advice.
Technical Depth
Depth Of Coverage:
From basic DIY tasks to complete engine and transmission rebuilding.
Torque Specifications:
Complete torque specifications provided for all fasteners.
Wiring Diagrams Coverage:
Complete and detailed wiring diagrams for all vehicle systems.
Illustrations Count:
Hundreds of illustrations aiding in repair and understanding.
📊 Manual Specifications
File Format
PDF Features:
Searchable text, zoomable diagrams, printable pages.
Print Quality
Illustration Detail:
Hundreds of illustrations with detailed parts views.
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Media:
Digital Media (PDF)
Compatibility
Operating Systems:
Compatible with all PC and MAC computers.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63
Engine Type:
2.0L Inline-4, DOHC, 16-valve, turbocharged, intercooled
Performance
Horsepower Est:
271-286 hp (depending on specific market and sub-model)
Torque Est:
273-280 lb-ft (depending on specific market and sub-model)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPI)
Turbocharger:
Mitsubishi TD05HR-16G or similar twin-scroll turbocharger
Cooling System
Intercooler Type:
Air-to-air front-mounted intercooler
Engine Management
ECU Type:
ECU (Engine Control Unit) with programmable parameters
Technical Details
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Valve Train:
DOHC, 16 Valves, timing belt driven camshafts.
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual Transmission (Getrag G5M31-RR-N)
Optional
Transmission Type Opt:
Not typically offered with automatic transmissions in this generation for performance models.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Sport-ABS, Active Yaw Control (AYC) on some models.
Ayc System:
Active Yaw Control (AYC) system adjusts torque distribution to the rear wheels for improved cornering stability.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.
Fluid Capacities
Manual Transmission Capacity:
Approx. 2.0-2.3 liters (refer to manual for exact figure)
📐 Dimensions
Exterior
Length:
Approx. 4,360 mm (171.7 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Weights
Curb Weight:
Approx. 1,360 - 1,400 kg (2,998 - 3,086 lbs)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Track Width Front:
Approx. 1,500 mm (59.1 in)
Track Width Rear:
Approx. 1,505 mm (59.3 in)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings for this generation may vary by market; generally considered safe for its class due to structural integrity and AWD.
Active Features
Active Safety Systems:
ABS (Anti-lock Braking System), Active Center Differential (ACD), AYC (Active Yaw Control), Traction Control System (TCL).
Passive Features
Passive Safety Features:
Driver and front passenger airbags, reinforced body structure, side-impact door beams.
Chassis Enhancements
Chassis Design:
Monocoque chassis with MacPherson strut front suspension and multi-link rear suspension.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio, CD player, likely with limited digital connectivity for the era.
Driver Assistance
Driver Assistance Features:
Limited by modern standards, but advanced for its time with ACD and AYC for traction and handling.
Connectivity
Connectivity Options:
Typically no Bluetooth or advanced smartphone integration. May have power windows, mirrors, and basic climate control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (severe driving conditions recommended for performance vehicles).
Timing Belt Replacement Interval:
Typically 60,000-80,000 miles or 5-7 years (crucial for 4G63 engine).
Fluid Specifications
Engine Oil Specification:
Refer to manual: typically 5W-30 or 10W-30 synthetic oil meeting API SN or higher.
Coolant Specification:
Refer to manual: typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Engine Issues:
Head gasket failures (due to high stress), turbocharger wear, piston ring wear, valve seal issues.
Common Drivetrain Issues:
Clutch wear, AYC pump failures, differential issues under heavy abuse.
Common Suspension Issues:
Wear in bushings and ball joints, strut wear, especially with aggressive driving.
Technical Specifications
Spark Plug Gap:
Refer to manual: typically 0.039-0.043 inches (1.0-1.1 mm).
Idle Speed:
Refer to manual: approximately 750-850 RPM.
📚 Vehicle History
Brand Heritage
Mitsubishi Motorsport Legacy:
Built on the success of Mitsubishi's rally heritage, particularly in the World Rally Championship (WRC).
Model Evolution
Evolution Development:
Developed as a homologation special for Group A touring car racing, evolving from the standard Lancer sedan.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Years Specific:
2001-2003 (for the VII generation)
🏆 Awards & Recognition
Recognitions
Automotive Journal Accolades:
Consistently praised by automotive journalists for its handling, performance, and rally-bred capabilities. Often cited as a benchmark for performance sedans.
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