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2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (Evo VII-IX) Generation: Eighth Generation (Evo VII-IX) Model Years Covered: 2003, 2004, 2005 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS Key Features Powertrain: Advanced All-Wheel Drive (AWD) system (S-AYC), turbocharged engine Performance: Renowned for rally racing heritage and exceptional handling Tuning Potential: High potential for aftermarket modification and performance tuning 📋 Manual Details Coverage Areas Engine Mechanical: Yes Engine Performance: Yes Fuel System: Yes Emission Control: Yes Transmission Manual: Yes Transmission Automatic: Yes (if applicable to specific models covered) Transfer Case: Yes Drivetrain AWD: Yes Suspension Front: Yes Suspension Rear: Yes Steering: Yes Brakes Hydraulic: Yes Brakes Parking: Yes Wheels Tires: Yes Body Exterior: Yes Body Interior: Yes HVAC Climate Control: Yes Electrical System Lighting: Yes Electrical System Instruments: Yes Electrical System Power Accessories: Yes Audio Entertainment: Yes Security Alarm Immobilizer: Yes Driver Assistance Systems: Yes Troubleshooting Diagnostics: Yes Wiring Diagrams: Yes Torque Specifications: Yes Maintenance Procedures: Yes Repair Procedures: Yes Disassembly Assembly: Yes Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered All Major Systems: Comprehensive coverage of all major vehicle systems Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Diagnostics: Systematic troubleshooting guides, fault code interpretation, diagnostic tool usage Repair: Detailed step-by-step repair instructions for all major components Rebuilds: Engine, transmission, and differential rebuild procedures Adjustment Calibration: Alignment, sensor calibration, clutch adjustment Technical Depth Depth: Factory-level detail suitable for professional technicians and advanced DIY enthusiasts Diagnostic Codes: Includes specific OBD-II diagnostic trouble codes (DTCs) and their meanings Electrical Troubleshooting: In-depth electrical troubleshooting utilizing wiring diagrams and component testing 📊 Manual Specifications File Format Searchable: Yes (typically searchable PDF) Printable: Yes Print Quality Quality: High-resolution, clear text and diagrams Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (various iterations) Engine Type: Inline-4, DOHC, 16-valve, Turbocharged & Intercooled Displacement: 2.0 Liters (1997 cc) Performance Horsepower Range: Approx. 271 hp to 286 hp (depending on specific Evo VII, VIII, IX model and market) Torque Range: Approx. 273 lb-ft to 289 lb-ft (depending on specific Evo VII, VIII, IX model and market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Port Fuel Injection (MPFI) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Turbocharger Turbo Model: Mitsubishi Heavy Industries (MHI) TD04-15G, TD05-16G, or similar, depending on variant 🔧 Transmission Standard Type: 6-Speed Manual Transmission (Getrag MSF-100) Optional Type: No Automatic Transmission option for these performance-oriented models Features Drivetrain: Advanced Symmetrical All-Wheel Drive (AWD) with Active Center Differential (ACD) Torque Vectoring: Super Active Yaw Control (S-AYC) rear differential on many models 📐 Dimensions Exterior Length: Approx. 4,490 mm (176.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight Range: Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs) Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size: Typically 17x8.0 or 18x8.5 inches 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star (for similar models of the era, specific ratings may vary by year and test) IIHS Side Impact: Good (for similar models of the era, specific ratings may vary by year and test) Active Features ABS: Yes, with EBD (Electronic Brakeforce Distribution) Traction Control: Yes (Active Traction Control - ATC) Electronic Stability Control: Yes (Active Stability Control - ASC) Passive Features Airbags Driver: Yes Airbags Passenger: Yes Seatbelts: 3-point front and rear seatbelts with pretensioners Body Structure: Reinforced body structure for enhanced impact protection 💡 Technology Features Infotainment Head Unit: Factory CD Player with AM/FM Radio, some models may have upgraded Rockford Fosgate audio systems. Navigation: Optional GPS Navigation system available on some higher trims. Driver Assistance All Wheel Drive System: Advanced AWD with ACD and S-AYC offering selectable modes (Tarmac, Gravel, Snow) Performance Controls: Driver-selectable ACD modes, ACD/AYC status indicators Connectivity Auxiliary Input: Some models may feature an auxiliary audio input jack. 🔧 Maintenance Service Intervals Oil Change: Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use) Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months Spark Plugs: Every 30,000 miles (48,000 km) (Platinum or Iridium recommended) Timing Belt: Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T) Fluid Specifications Engine Oil: API SN/SM/SL, ACEA A3/B4, Viscosity: 5W-30 or 0W-30 (check owner's manual for specific recommendations, high-performance synthetic recommended) Coolant: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix) Transmission Fluid Mt: GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil) Transfer Case Fluid: GL-4 (75W-85W...
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2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Code:
CT9A (Evo VII-IX)
Generation:
Eighth Generation (Evo VII-IX)
Model Years Covered:
2003, 2004, 2005
👋 Introduction
Market Position
Segment:
Performance Compact Sedan / Rally Homologation Special
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS
Key Features
Powertrain:
Advanced All-Wheel Drive (AWD) system (S-AYC), turbocharged engine
Performance:
Renowned for rally racing heritage and exceptional handling
Tuning Potential:
High potential for aftermarket modification and performance tuning
📋 Manual Details
Coverage Areas
Engine Mechanical:
Yes
Engine Performance:
Yes
Fuel System:
Yes
Emission Control:
Yes
Transmission Manual:
Yes
Transmission Automatic:
Yes (if applicable to specific models covered)
Transfer Case:
Yes
Drivetrain AWD:
Yes
Suspension Front:
Yes
Suspension Rear:
Yes
Steering:
Yes
Brakes Hydraulic:
Yes
Brakes Parking:
Yes
Wheels Tires:
Yes
Body Exterior:
Yes
Body Interior:
Yes
HVAC Climate Control:
Yes
Electrical System Lighting:
Yes
Electrical System Instruments:
Yes
Electrical System Power Accessories:
Yes
Audio Entertainment:
Yes
Security Alarm Immobilizer:
Yes
Driver Assistance Systems:
Yes
Troubleshooting Diagnostics:
Yes
Wiring Diagrams:
Yes
Torque Specifications:
Yes
Maintenance Procedures:
Yes
Repair Procedures:
Yes
Disassembly Assembly:
Yes
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Repair Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
All Major Systems:
Comprehensive coverage of all major vehicle systems
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Diagnostics:
Systematic troubleshooting guides, fault code interpretation, diagnostic tool usage
Repair:
Detailed step-by-step repair instructions for all major components
Rebuilds:
Engine, transmission, and differential rebuild procedures
Adjustment Calibration:
Alignment, sensor calibration, clutch adjustment
Technical Depth
Depth:
Factory-level detail suitable for professional technicians and advanced DIY enthusiasts
Diagnostic Codes:
Includes specific OBD-II diagnostic trouble codes (DTCs) and their meanings
Electrical Troubleshooting:
In-depth electrical troubleshooting utilizing wiring diagrams and component testing
📊 Manual Specifications
File Format
Searchable:
Yes (typically searchable PDF)
Printable:
Yes
Print Quality
Quality:
High-resolution, clear text and diagrams
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (various iterations)
Engine Type:
Inline-4, DOHC, 16-valve, Turbocharged & Intercooled
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Range:
Approx. 271 hp to 286 hp (depending on specific Evo VII, VIII, IX model and market)
Torque Range:
Approx. 273 lb-ft to 289 lb-ft (depending on specific Evo VII, VIII, IX model and market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Multi-Port Fuel Injection (MPFI)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Turbocharger
Turbo Model:
Mitsubishi Heavy Industries (MHI) TD04-15G, TD05-16G, or similar, depending on variant
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission (Getrag MSF-100)
Optional
Type:
No Automatic Transmission option for these performance-oriented models
Features
Drivetrain:
Advanced Symmetrical All-Wheel Drive (AWD) with Active Center Differential (ACD)
Torque Vectoring:
Super Active Yaw Control (S-AYC) rear differential on many models
📐 Dimensions
Exterior
Length:
Approx. 4,490 mm (176.8 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,630 mm (103.5 in)
Weights
Curb Weight Range:
Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs)
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size:
Typically 17x8.0 or 18x8.5 inches
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star (for similar models of the era, specific ratings may vary by year and test)
IIHS Side Impact:
Good (for similar models of the era, specific ratings may vary by year and test)
Active Features
ABS:
Yes, with EBD (Electronic Brakeforce Distribution)
Traction Control:
Yes (Active Traction Control - ATC)
Electronic Stability Control:
Yes (Active Stability Control - ASC)
Passive Features
Airbags Driver:
Yes
Airbags Passenger:
Yes
Seatbelts:
3-point front and rear seatbelts with pretensioners
Body Structure:
Reinforced body structure for enhanced impact protection
💡 Technology Features
Infotainment
Head Unit:
Factory CD Player with AM/FM Radio, some models may have upgraded Rockford Fosgate audio systems.
Navigation:
Optional GPS Navigation system available on some higher trims.
Driver Assistance
All Wheel Drive System:
Advanced AWD with ACD and S-AYC offering selectable modes (Tarmac, Gravel, Snow)
Performance Controls:
Driver-selectable ACD modes, ACD/AYC status indicators
Connectivity
Auxiliary Input:
Some models may feature an auxiliary audio input jack.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use)
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plugs:
Every 30,000 miles (48,000 km) (Platinum or Iridium recommended)
Timing Belt:
Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T)
Fluid Specifications
Engine Oil:
API SN/SM/SL, ACEA A3/B4, Viscosity: 5W-30 or 0W-30 (check owner's manual for specific recommendations, high-performance synthetic recommended)
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix)
Transmission Fluid Mt:
GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)
Transfer Case Fluid:
GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)
Rear Differential Fluid Lsd:
GL-5 (75W-90 or 80W-90) API GL-5 compliant with LSD additive (e.g., DiaQueen LSD Gear Oil)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
4G63T engine generally robust, but can suffer from rod bearing failure under high load/poor maintenance. Turbocharger lifespan can be affected by oil quality and heat cycling.
Drivetrain Wear:
S-AYC system can develop issues; ACD pump can fail. Clutch wear is normal for spirited driving.
Rust Corrosion:
Can be prone to rust, especially around wheel wells and sills, if not properly maintained or living in corrosive environments.
Suspension Components:
Bushings and ball joints can wear over time, leading to imprecise handling.
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Direct lineage from Mitsubishi's successful WRC (World Rally Championship) program
Model Evolution
Eighth Generation:
Built on the Lancer Cedia platform, significantly re-engineered for performance
Evo Vii:
Introduction of Active Center Differential (ACD) and Active Yaw Control (AYC) integration
Evo Viii:
Improved turbocharger, stronger engine internals, revised suspension geometry, option of 'SSL' package
Evo Ix:
Introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system for improved power and efficiency, updated turbocharger (IX MR featured twin-scroll turbo)
Production
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Years:
2001-2007 (Evo VII: 2001-2003, Evo VIII: 2003-2005, Evo IX: 2005-2007)
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
Eighth generation Lancer Evolution models were frequently recognized on Car and Driver's '10Best' lists.
Enthusiast Following:
Cult following among automotive enthusiasts for its performance and rally heritage.
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