Mitsubishi Lancer Evolution 9 EVO IX 2005-2007 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Model Nickname: EVO IX Codes Chassis Code: CT9A Engine Code Primary: 4G63T MIVEC 👋 Introduction Market Position Segment: Performance Sedan, Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Honda Civic Type R (later generations), Ford Focus RS, Volkswagen Golf R Key Features Performance Focus: Legendary turbocharged performance, advanced all-wheel-drive system, rally-bred handling. Tuning Potential: Highly regarded for its robust powertrain and chassis, making it a popular platform for aftermarket tuning and motorsport. Manual Value Proposition Benefit To Owner: Empowers owners with the knowledge to perform maintenance, diagnostics, and repairs, saving time and money, and maintaining optimal performance. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007 Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, timing belt/chain, piston/ring inspection, cylinder head service, valve train, crankshaft, camshafts, oil pump, water pump, lubrication system Engine Performance: Turbocharger system, intercooler, fuel injection, ignition system, emissions control, exhaust system, cooling system Transmission: Manual transmission (Getrag 6-speed), clutch system, transfer case, driveshafts, differentials (front, center, rear AYC/ACD) Drivetrain: All-Wheel Control (AWC), Active Center Differential (ACD), Active Yaw Control (AYC), Super Active Yaw Control (S-AYC) Brakes: Front/rear disc brakes, ABS, EBD, brake fluid, caliper service, rotor replacement, parking brake Suspension: MacPherson strut front, multi-link rear, shock absorbers, springs, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, wheel alignment Electrical System: Battery, charging system (alternator), starter, lighting, ignition system, ECU, wiring diagrams, fuses, relays, sensors Body And Interior: Body panels, doors, windows, seats, dashboard, HVAC, interior trim, sound deadening Body Electrical: Power windows, power locks, mirrors, wipers, horn, audio system, alarm system Diagnostics: OBD-II diagnostics, fault codes, troubleshooting procedures, sensor testing Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes Repair Major Engine: Engine rebuild, head gasket replacement, turbocharger overhaul, fuel injector replacement Repair Transmission: Transmission rebuild, clutch replacement, differential service Repair Brakes: Brake caliper rebuild, brake line replacement, ABS module diagnosis Repair Suspension: Strut/shock absorber replacement, bushing replacement, alignment procedures Repair Electrical: Wiring harness repair, component testing, ECU programming, sensor replacement Troubleshooting: Step-by-step troubleshooting guides for common and complex issues, diagnostic flowcharts Body Repair: Body panel replacement, door alignment, bumper repair Technical Depth Depth: Comprehensive: from basic maintenance to complete engine/transmission overhauls, electrical diagnostics, and bodywork. Diagnostics Level: Advanced diagnostic procedures and troubleshooting for all major systems. Wiring Diagrams: Detailed, color-coded wiring diagrams for all electrical systems. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically) Print Quality Quality: High-resolution scans of original factory documentation. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Completeness: Full factory service manual coverage, no exclusions. ⚙️ Engine Specifications Primary Engine Engine Type: 2.0L Inline 4-Cylinder DOHC Turbocharged MIVEC Performance Horsepower Ps: 280 PS (approx. 276 hp) at 6500 rpm Torque Nm: 392 Nm (approx. 289 lb-ft) at 3500 rpm Bore X Stroke: 86.0 mm x 86.0 mm Compression Ratio: 8.8:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Port Injection Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Turbocharger Turbo Model: Mitsubishi TD05H-15G (Twin-Scroll) Cooling System Intercooler Type: Air-to-Air Front-Mount 🔧 Transmission Standard Type: 6-Speed Manual (Getrag Type) Optional Type: N/A (Manual Transmission Exclusive) Features Drivetrain Layout: All-Wheel Drive (AWD) with AYC/ACD Transfer Case: Center Differential with ACD Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (refer to manual for exact specifications) Transfer Case Fluid: Refer to manual for specific type and capacity Rear Differential Fluid: Refer to manual for specific type and capacity 📐 Dimensions Exterior Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2625 mm (103.3 in) Weights Curb Weight: Approx. 1450-1500 kg (3197-3307 lbs), depending on trim Gross Vehicle Weight Rating: Refer to vehicle placard Wheels Tires Wheel Size: 17 x 8.5 inches (standard) Tire Size: 235/45R17 (standard) Bolt Pattern: 5x114.3 mm 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating: 4-Star (Driver), 4-Star (Passenger) - Based on typical Lancer platform ratings for the era Active Features Active Safety: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), All-Wheel Control (AWC) Passive Features Airbags: Front dual-stage airbags, optional side-impact airbags Seatbelts: 3-point front and rear seatbelts with pretensioners and load limiters Body Structure: Reinforced safety cell construction 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional Rockford Fosgate premium audio system. Navigation: Optional factory navigation system on some trims. Driver Assistance Traction Control: Traction Control System (TCS) integrated with AWC. Awc Modes: Driver-selectable modes for ACD (Tarmac, Gravel, Snow) affecting center differential lock-up. Connectivity Connectivity Features: Limited by modern standards; primarily focused on audio system connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every...
Traction Control System (TCS) integrated with AWC.
Awc Modes:
Driver-selectable modes for ACD (Tarmac, Gravel, Snow) affecting center differential lock-up.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on audio system connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use), 7,500 miles (12,000 km) or 12 months (normal use) - Consult manual for definitive intervals.
Engine Oil Filter:
Replace with every oil change.
Air Filter:
Inspect every 7,500 miles (12,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace approximately every 30,000-45,000 miles (48,000-72,000 km), depending on plug type (refer to manual).
Timing Belt:
NOT APPLICABLE (4G63T uses a timing chain)
Fluid Specifications
Engine Oil:
SAE 5W-30 Synthetic (API SN or higher, ILSAC GF-5 or higher recommended). Refer to manual for specific OEM recommendations. Capacity: Approx. 4.7 Liters (5.0 US Quarts) with filter.
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent HOAT), 50/50 mix with distilled water. Capacity: Approx. 7.5 Liters (7.9 US Quarts).
Brake Fluid:
DOT 3 or DOT 4 High-Temperature Brake Fluid.
Power Steering Fluid:
Refer to manual for specific type (typically ATF Dexron III or equivalent).
Known Issues
Engine Common Problems:
Head gasket failures (especially when modified or poorly maintained), turbocharger wear, oil consumption, clutch wear due to aggressive driving.
Drivetrain Common Problems:
AYC/ACD pump failure, differential wear under high stress.
Electrical Common Problems:
Worn wiring insulation, sensor failures, blower motor resistor issues.
Chassis Common Problems:
Subframe rust, suspension bushing wear, exhaust system corrosion.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Direct lineage from Mitsubishi's successful World Rally Championship (WRC) vehicles.
Model Evolution
Evo Generation:
Ninth Generation (CT9A)
Key Evo Ix Updates:
Introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control) to the 4G63 engine, updated turbocharger, revised ACD and AYC systems, Bilstein suspension, larger Enkei wheels.
Production
Production Years:
2005-2007
Manufacturing Location:
Mizushima, Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently praised by automotive publications for its handling, braking, and all-wheel-drive capabilities. Often ranked highly in enthusiast polls for affordable sports cars.
Ratings
Enthusiast Ratings:
Highly regarded by car enthusiasts and tuners globally for its performance potential and rally heritage.
Certifications
Homologation:
Built as a homologation special for the FIA Group N rally regulations.
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