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2005 Mitsubishi Lancer Evolution Service Repair Manual Downl

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 2005 Codes Chassis Code: CT9A Platform: JDM/Global 8th Generation Lancer (CY/CZ series) 👋 Introduction Market Position Positioning: The 2005 Mitsubishi Lancer Evolution (CT9A, commonly known as the Evo VIII MR or FQ variants for specific markets) represents the pinnacle of rally-inspired performance in its segment during the mid-2000s. It competed directly with vehicles like the Subaru Impreza WRX STI, offering a potent blend of turbocharged power, advanced all-wheel-drive systems, and precise handling. Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS, Honda Civic Type R (though typically FWD). Key Features Performance Highlights: Iconic 4G63T engine, advanced electronically controlled Active Center Differential (ACD) and Active Yaw Control (AYC) or Super Active Yaw Control (Super AYC), Bilstein suspension, Recaro seating, aggressive aerodynamic styling, and potent braking system. 📋 Manual Details Coverage Areas Systems Covered: Engine mechanical, engine fuel & emissions, engine electrical, ignition, lubrication, cooling, exhaust, intake, transmission (manual & automatic), drivetrain, front & rear suspension, steering, brakes (hydraulic & parking), chassis electrical, body & frame, interior & exterior trim, climate control, safety systems (SRS, ABS), diagnostics, troubleshooting, maintenance schedules, wiring diagrams, specifications, component locations. Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Detailed coverage of the 4G63T engine, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing belt, turbocharger system (including MHI TD05H-16G or similar twin-scroll turbocharger), intercooler, fuel injection, ignition, emissions control (including ACD, AYC, Super AYC systems), lubrication, cooling, and exhaust. Procedures Included Repair Procedures: Step-by-step instructions for engine rebuilding, turbocharger maintenance and replacement, clutch replacement, transmission overhaul, differential service, brake caliper and rotor replacement, suspension component replacement (bushings, ball joints, struts), steering rack repair, electrical component diagnosis and repair, body panel alignment and repair, HVAC system servicing, SRS system troubleshooting, and more. Technical Depth Depth: Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Includes detailed diagnostic procedures, torque specifications, electrical schematics, troubleshooting flowcharts, and component data. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for quick information retrieval. Print Quality Print Readability: High-resolution scans suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Performance Horsepower Hp: Approximately 270-280 hp (JDM/Euro) / 271 hp (USDM) Torque Lb Ft: Approximately 270-285 lb-ft (JDM/Euro) / 273 lb-ft (USDM) Compression Ratio: 8.8:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential multi-port injection Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Turbocharger Turbo Model: Mitsubishi Heavy Industries (MHI) TD05H-16G twin-scroll (or similar variations across markets) Intercooler Type: Air-to-air front-mounted intercooler 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission (Getrag-built) Optional Transmission Type: N/A for Evolution VIII MR/FQ variants; some earlier Evo VIII models may have offered a 5-speed auto, but not typically specified for this performance tier. Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC. Drivetrain Specs Acd Modes: Tarmac, Gravel, Snow 📐 Dimensions Exterior Length: Approx. 4490 mm (176.8 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1415 mm (55.7 in) Wheelbase: Approx. 2600 mm (102.4 in) Track Width Front: Approx. 1500 mm (59.1 in) Track Width Rear: Approx. 1505 mm (59.3 in) Weights Curb Weight: Approx. 1400-1450 kg (3086-3197 lbs) Gross Vehicle Weight Rating: Approx. 1780 kg (3924 lbs) Cargo Trunk Capacity: Approx. 10.5 cu ft (can vary slightly by market) 🛡️ Safety Features Ratings NHTSA Front Crash Test: Not directly rated by NHTSA for this specific model year; however, the Lancer platform generally performed well for its era. Focus on structural integrity and driver aids. Active Features Traction Control: Standard (integrated with ACD/AYC/Super AYC systems) Anti-Lock Brakes: Standard ABS with EBD (Electronic Brakeforce Distribution) Electronic Stability Control: Not a standard feature on all 2005 models; often integrated within the ACD/AYC system's broader traction management. Check specific market variants. Passive Features Airbags Front: Driver and Front Passenger airbags standard. Airbags Side: Optional side-impact airbags available on some trims/markets. Seatbelts: 3-point front seatbelts with pretensioners and load limiters, 3-point rear seatbelts. Body Structure: Reinforced safety cell, front and rear crumple zones. 💡 Technology Features Infotainment Audio System: Factory CD player with AM/FM radio, often with premium speaker options (e.g., Rockford Fosgate) on higher trims. Aux input or USB ports are generally not standard. Navigation: Optional factory navigation system on some models, typically a more basic unit compared to modern systems. Driver Assistance Active Center Differential: Key technological feature for enhanced traction and...
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2005 Mitsubishi Lancer Evolution Service Repair Manual Downl
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Year:
2005
Codes
Chassis Code:
CT9A
Platform:
JDM/Global 8th Generation Lancer (CY/CZ series)
👋 Introduction
Market Position
Positioning:
The 2005 Mitsubishi Lancer Evolution (CT9A, commonly known as the Evo VIII MR or FQ variants for specific markets) represents the pinnacle of rally-inspired performance in its segment during the mid-2000s. It competed directly with vehicles like the Subaru Impreza WRX STI, offering a potent blend of turbocharged power, advanced all-wheel-drive systems, and precise handling.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS, Honda Civic Type R (though typically FWD).
Key Features
Performance Highlights:
Iconic 4G63T engine, advanced electronically controlled Active Center Differential (ACD) and Active Yaw Control (AYC) or Super Active Yaw Control (Super AYC), Bilstein suspension, Recaro seating, aggressive aerodynamic styling, and potent braking system.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine mechanical, engine fuel & emissions, engine electrical, ignition, lubrication, cooling, exhaust, intake, transmission (manual & automatic), drivetrain, front & rear suspension, steering, brakes (hydraulic & parking), chassis electrical, body & frame, interior & exterior trim, climate control, safety systems (SRS, ABS), diagnostics, troubleshooting, maintenance schedules, wiring diagrams, specifications, component locations.
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Detailed coverage of the 4G63T engine, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing belt, turbocharger system (including MHI TD05H-16G or similar twin-scroll turbocharger), intercooler, fuel injection, ignition, emissions control (including ACD, AYC, Super AYC systems), lubrication, cooling, and exhaust.
Procedures Included
Repair Procedures:
Step-by-step instructions for engine rebuilding, turbocharger maintenance and replacement, clutch replacement, transmission overhaul, differential service, brake caliper and rotor replacement, suspension component replacement (bushings, ball joints, struts), steering rack repair, electrical component diagnosis and repair, body panel alignment and repair, HVAC system servicing, SRS system troubleshooting, and more.
Technical Depth
Depth:
Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Includes detailed diagnostic procedures, torque specifications, electrical schematics, troubleshooting flowcharts, and component data.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality
Print Readability:
High-resolution scans suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Performance
Horsepower Hp:
Approximately 270-280 hp (JDM/Euro) / 271 hp (USDM)
Torque Lb Ft:
Approximately 270-285 lb-ft (JDM/Euro) / 273 lb-ft (USDM)
Compression Ratio:
8.8:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential multi-port injection
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Turbocharger
Turbo Model:
Mitsubishi Heavy Industries (MHI) TD05H-16G twin-scroll (or similar variations across markets)
Intercooler
Type:
Air-to-air front-mounted intercooler
🔧 Transmission
Standard
Transmission Type:
6-speed Manual Transmission (Getrag-built)
Optional
Transmission Type:
N/A for Evolution VIII MR/FQ variants; some earlier Evo VIII models may have offered a 5-speed auto, but not typically specified for this performance tier.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC.
Drivetrain Specs
Acd Modes:
Tarmac, Gravel, Snow
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Track Width Front:
Approx. 1500 mm (59.1 in)
Track Width Rear:
Approx. 1505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1400-1450 kg (3086-3197 lbs)
Gross Vehicle Weight Rating:
Approx. 1780 kg (3924 lbs)
Cargo
Trunk Capacity:
Approx. 10.5 cu ft (can vary slightly by market)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Not directly rated by NHTSA for this specific model year; however, the Lancer platform generally performed well for its era. Focus on structural integrity and driver aids.
Active Features
Traction Control:
Standard (integrated with ACD/AYC/Super AYC systems)
Anti-Lock Brakes:
Standard ABS with EBD (Electronic Brakeforce Distribution)
Electronic Stability Control:
Not a standard feature on all 2005 models; often integrated within the ACD/AYC system's broader traction management. Check specific market variants.
Passive Features
Airbags Front:
Driver and Front Passenger airbags standard.
Airbags Side:
Optional side-impact airbags available on some trims/markets.
Seatbelts:
3-point front seatbelts with pretensioners and load limiters, 3-point rear seatbelts.
Body Structure:
Reinforced safety cell, front and rear crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory CD player with AM/FM radio, often with premium speaker options (e.g., Rockford Fosgate) on higher trims. Aux input or USB ports are generally not standard.
Navigation:
Optional factory navigation system on some models, typically a more basic unit compared to modern systems.
Driver Assistance
Active Center Differential:
Key technological feature for enhanced traction and handling. Allows variable torque distribution between front and rear axles.
Active Yaw Control:
Electronically controlled torque vectoring to improve cornering stability and reduce understeer by differentially braking or applying torque to the rear wheels. Super AYC offered enhanced electronic control.
Connectivity
Bluetooth:
Not a standard feature.
Cruise Control:
Standard on most models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first, under severe driving conditions (frequent spirited driving, track use, short trips). Standard interval typically 7,500 miles (12,000 km) or 6 months.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 4-5 years, whichever comes first. Crucial due to interference engine design.
Spark Plug Replacement:
Typically at 30,000 miles (48,000 km) for iridium plugs, or as specified by manufacturer for other types.
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Fluid Specifications
Engine Oil Type:
Synthetic API SL or higher, SAE 5W-30 or 10W-30 (depending on climate and driving conditions). Refer to manual for specific viscosity recommendations.
Engine Oil Capacity:
Approx. 4.7 Liters (5.0 US Quarts) with filter change.
Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil for manual transmission.
Transfer Case Fluid Type:
API GL-5, SAE 75W-90.
Rear Differential Fluid Type:
API GL-5, SAE 75W-90.
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).
Known Issues
Engine Gaskets:
Head gasket failures can occur, especially in modified or aggressively driven vehicles due to high cylinder pressures. Lifter tick or noise can also be present.
Turbocharger:
Oil starvation or heat soak can lead to premature turbo failure. Regular oil changes and proper cool-down procedures are critical.
Clutch Wear:
Due to the performance nature, clutches can wear faster than in standard vehicles, especially with aggressive driving or launching.
Acd Pump Failure:
The ACD hydraulic pump can fail over time, leading to the ACD warning light and potential loss of AWD function. Regular flushing of ACD fluid is recommended.
Suspension Bushings:
Rubber suspension bushings can degrade over time, leading to vague handling and noise. Performance upgrades often involve polyurethane bushings.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi has a storied history in motorsport, particularly in the World Rally Championship (WRC). The Lancer Evolution lineage directly stems from this rally-bred technology, making it a homologation special designed for competition.
Model Evolution
Evolution Series:
The 2005 model year represents the later stages of the 8th Generation Lancer Evolution (CT9A). It followed the Evo VII and preceded the 9th Generation (CT9A/CZ4A). Key advancements in the VIII generation included the introduction of the Active Center Differential (ACD) and Active Yaw Control (AYC), significantly improving handling dynamics.
Evolution Viii Mr:
The 'MR' designation (Mitsubishi Racing) for the 2005 model typically signifies specific enhancements like revised suspension tuning, lighter Enkei wheels, a different turbocharger specification, and often a color-keyed roof panel and front lip spoiler. The 'FQ' variants (e.g., FQ300, FQ330) were primarily UK market performance upgrades by Mitsubishi Motors UK.
Production
Production Period:
8th Generation Lancer Evolution: 2001-2007
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently lauded by automotive journalists and enthusiasts for its exceptional performance, handling, and rally-inspired driving experience. Often appeared on 'best handling car' lists and performance vehicle benchmarks of its era.
Motorsport Success:
The Lancer Evolution platform, including the 8th generation, has a strong heritage of success in professional rallying, which directly influenced its design and marketing.
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