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2001-2005 Mitsubishi Lancer EVO Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: VII Years Covered: 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution (VII generation) was positioned as a high-performance, rally-bred sports sedan, a halo model for the Lancer lineup, competing against formidable rivals like the Subaru WRX STI and other performance-oriented compact cars. Competitive Analysis Competitors: Subaru Impreza WRX STI, Audi S3, Ford Focus RS, BMW M3 (in broader performance sedan context). Key Features Performance Features: Advanced All-Wheel Drive (AWD) system (Super Active Yaw Control - SYAWC), turbocharged intercooled engine, close-ratio manual transmission, performance-tuned suspension, large brakes, aerodynamic enhancements. Manual Advantage Format Benefit: Consolidates multiple paper manuals into a single, easily searchable digital format, protecting original manuals from wear and tear, offering convenience and cost savings compared to antique paper manuals. 📋 Manual Details Coverage Areas Regions Covered: Global (specific variations may apply based on OEM publication) Page Count Estimated Page Count: Comprehensive (exact count varies by specific OEM edition, often thousands of pages across multiple volumes for a full factory set) Manual Type Type: Factory Service and Repair Manual Language Language: English (as indicated by product description for this sale) Format Format: CD-ROM (digitized factory documentation) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (Cylinder Head, Cylinder Block, Oil Pump, Water Pump, etc.), Engine Control System, Fuel System (Fuel Pump, Injectors, Throttle Body), Cooling System, Exhaust System, Ignition System, Transmission (Manual Transaxle, Automatic Transaxle), Drive Shafts, Differential Case. Chassis: Suspension Systems (Front, Rear), Steering System, Brake System (ABS, Brake Booster, Master Cylinder), Wheel and Tire System, Drivetrain Components (Axle Hubs, Driveshafts). Electrical: Lighting System, Starting System, Charging System, Supplemental Restraint System (SRS/Airbags), Power Window Control, Power Door Lock Control, Audio & Visual System, Combination Meter, Instrument Panel, Wiring Diagrams, Wire Harness Repair, Sensors (Yaw Rate, Skid Control, Camshaft, etc.). Body: Body Repair, Exterior Components (Bumpers, Hood, Doors, Glass), Interior Components (Seats, Headlining, Instrument Panel), Sun Roof System, Wiper and Washer System, Exterior and Interior Trim. Procedures Included Maintenance: Routine maintenance checks, fluid changes, lubrication, filter replacements, belt inspections and replacement, spark plug replacement. Diagnostics: Troubleshooting charts, fault code diagnosis (OBD-II), symptom-based diagnostics, component testing procedures, electrical system diagnostics. Repair: Detailed step-by-step repair instructions for all major mechanical, electrical, and body components, including engine rebuilds, transmission overhaul, brake system repairs, suspension component replacement, body panel repair and replacement. Specifications: Torque specifications for all fasteners, clearances, measurements, diagnostic values, fluid capacities, and component tolerances. Technical Depth Depth: Comprehensive factory-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete vehicle overhauls and complex diagnostic procedures. 📊 Manual Specifications File Format Digital Format: CD-ROM containing digitized manual content, viewable on PC with Windows operating systems. Print Quality Printable Pages: Yes, users can print individual pages or sections as needed. Binding Type Physical Binding: Not Applicable (digital format on CD-ROM) Paper Type Physical Paper Type: Not Applicable (digital format on CD-ROM) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (internally known as 'Big Turbo' variant for Evo VII/VIII) Configuration: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Displacement: 1997 cc (2.0 Liters) Performance Horsepower: Approximately 280 PS (276 hp) at 6500 RPM (official figures often conservative due to 'gentleman's agreement' in Japan) Torque: Approximately 373 Nm (275 lb-ft) at 3000 RPM (official figures often conservative) Fuel System Induction: Electronic Fuel Injection (EFI) with multi-point injection, Turbocharged with intercooler Fuel Type: Premium Unleaded Gasoline (95 RON or higher) Cooling System Coolant Capacity: Approximately 6.0 Liters (12.7 US Quarts) Lubrication System Oil Capacity: Approximately 4.5 Liters (4.8 US Quarts) with filter change Recommended Oil: API SG or higher, SAE 10W-30 (check manual for specific viscosity based on climate) Emission Control Systems: Catalytic converter, secondary air injection (specifics vary by market). 🔧 Transmission Standard Type: 6-speed Manual Transaxle Optional Type: Not Applicable (Evo VII was predominantly manual) Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) and ACD (Active Center Differential) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (check manual for specific type) Clutch Type: Hydraulically operated, multi-plate wet clutch (for AYC/ACD system components) 📐 Dimensions Exterior Length: Approx. 4,415 mm (173.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,600 mm (102.4 in) Weights Curb Weight: Approx. 1,400 kg (3,086 lbs) - Varies by specification Gross Vehicle Weight Rating: Check vehicle placard (typically around 1,800 kg) Cargo Trunk Capacity: Approx. 0.30 m³ (10.6 cu ft) - Varies by specification 🛡️ Safety Features Ratings NHTSA Ratings: Not consistently rated by NHTSA for this generation and market positioning; generally considered a performance-focused vehicle. Passive Features Airbags: Driver and passenger front airbags, optional side airbags and curtain airbags. Seat Belts: 3-point front and rear seat belts, pretensioners, load limiters. Body Structure: Reinforced safety cage, crumple...
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2001-2005 Mitsubishi Lancer EVO Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Generation:
VII
Years Covered:
2001, 2002, 2003, 2004, 2005
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution (VII generation) was positioned as a high-performance, rally-bred sports sedan, a halo model for the Lancer lineup, competing against formidable rivals like the Subaru WRX STI and other performance-oriented compact cars.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Audi S3, Ford Focus RS, BMW M3 (in broader performance sedan context).
Key Features
Performance Features:
Advanced All-Wheel Drive (AWD) system (Super Active Yaw Control - SYAWC), turbocharged intercooled engine, close-ratio manual transmission, performance-tuned suspension, large brakes, aerodynamic enhancements.
Manual Advantage
Format Benefit:
Consolidates multiple paper manuals into a single, easily searchable digital format, protecting original manuals from wear and tear, offering convenience and cost savings compared to antique paper manuals.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specific variations may apply based on OEM publication)
Page Count
Estimated Page Count:
Comprehensive (exact count varies by specific OEM edition, often thousands of pages across multiple volumes for a full factory set)
Manual Type
Type:
Factory Service and Repair Manual
Language
Language:
English (as indicated by product description for this sale)
Format
Format:
CD-ROM (digitized factory documentation)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (Cylinder Head, Cylinder Block, Oil Pump, Water Pump, etc.), Engine Control System, Fuel System (Fuel Pump, Injectors, Throttle Body), Cooling System, Exhaust System, Ignition System, Transmission (Manual Transaxle, Automatic Transaxle), Drive Shafts, Differential Case.
Chassis:
Suspension Systems (Front, Rear), Steering System, Brake System (ABS, Brake Booster, Master Cylinder), Wheel and Tire System, Drivetrain Components (Axle Hubs, Driveshafts).
Electrical:
Lighting System, Starting System, Charging System, Supplemental Restraint System (SRS/Airbags), Power Window Control, Power Door Lock Control, Audio & Visual System, Combination Meter, Instrument Panel, Wiring Diagrams, Wire Harness Repair, Sensors (Yaw Rate, Skid Control, Camshaft, etc.).
Body:
Body Repair, Exterior Components (Bumpers, Hood, Doors, Glass), Interior Components (Seats, Headlining, Instrument Panel), Sun Roof System, Wiper and Washer System, Exterior and Interior Trim.
Procedures Included
Maintenance:
Routine maintenance checks, fluid changes, lubrication, filter replacements, belt inspections and replacement, spark plug replacement.
Diagnostics:
Troubleshooting charts, fault code diagnosis (OBD-II), symptom-based diagnostics, component testing procedures, electrical system diagnostics.
Repair:
Detailed step-by-step repair instructions for all major mechanical, electrical, and body components, including engine rebuilds, transmission overhaul, brake system repairs, suspension component replacement, body panel repair and replacement.
Specifications:
Torque specifications for all fasteners, clearances, measurements, diagnostic values, fluid capacities, and component tolerances.
Technical Depth
Depth:
Comprehensive factory-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete vehicle overhauls and complex diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format:
CD-ROM containing digitized manual content, viewable on PC with Windows operating systems.
Print Quality
Printable Pages:
Yes, users can print individual pages or sections as needed.
Binding Type
Physical Binding:
Not Applicable (digital format on CD-ROM)
Paper Type
Physical Paper Type:
Not Applicable (digital format on CD-ROM)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63 (internally known as 'Big Turbo' variant for Evo VII/VIII)
Configuration:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower:
Approximately 280 PS (276 hp) at 6500 RPM (official figures often conservative due to 'gentleman's agreement' in Japan)
Torque:
Approximately 373 Nm (275 lb-ft) at 3000 RPM (official figures often conservative)
Fuel System
Induction:
Electronic Fuel Injection (EFI) with multi-point injection, Turbocharged with intercooler
Fuel Type:
Premium Unleaded Gasoline (95 RON or higher)
Cooling System
Coolant Capacity:
Approximately 6.0 Liters (12.7 US Quarts)
Lubrication System
Oil Capacity:
Approximately 4.5 Liters (4.8 US Quarts) with filter change
Recommended Oil:
API SG or higher, SAE 10W-30 (check manual for specific viscosity based on climate)
Emission Control
Systems:
Catalytic converter, secondary air injection (specifics vary by market).
🔧 Transmission
Standard
Type:
6-speed Manual Transaxle
Optional
Type:
Not Applicable (Evo VII was predominantly manual)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) and ACD (Active Center Differential)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (check manual for specific type)
Clutch
Type:
Hydraulically operated, multi-plate wet clutch (for AYC/ACD system components)
📐 Dimensions
Exterior
Length:
Approx. 4,415 mm (173.8 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,400 kg (3,086 lbs) - Varies by specification
Gross Vehicle Weight Rating:
Check vehicle placard (typically around 1,800 kg)
Cargo
Trunk Capacity:
Approx. 0.30 m³ (10.6 cu ft) - Varies by specification
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not consistently rated by NHTSA for this generation and market positioning; generally considered a performance-focused vehicle.
Passive Features
Airbags:
Driver and passenger front airbags, optional side airbags and curtain airbags.
Seat Belts:
3-point front and rear seat belts, pretensioners, load limiters.
Body Structure:
Reinforced safety cage, crumple zones.
Active Features
ABS:
Anti-lock Braking System (ABS)
Traction Control:
Active Traction Control (ATC)
Stability Control:
Active Yaw Control (AYC), Active Center Differential (ACD)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player, potentially with cassette; premium audio options might include more speakers and amplifier.
Display:
Basic LCD display for audio and climate controls, analog gauges for engine and vehicle speed.
Driver Assistance
Performance Enhancements:
Active Yaw Control (AYC) and Active Center Differential (ACD) are key technological features, dynamically managing torque distribution for optimal traction and handling.
Connectivity
Connectivity Features:
Limited by era; primarily focused on audio input. No modern Bluetooth or USB connectivity natively.
Engine Management
ECU:
Engine Control Unit (ECU) with sophisticated programming for managing fuel, ignition, turbo boost, and AWD systems. Often tunable for performance.
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions; severe conditions may require shorter intervals).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum-tipped plugs; check manual for specific type and interval.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years (critical component for the 4G63 engine; failure can cause severe damage).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4, Low Viscosity (LV) (refer to manual for precise specification)
Power Steering Fluid:
Dexron III ATF or equivalent power steering fluid (check manual)
Coolant:
Long-life ethylene glycol coolant, 50/50 mix with distilled water.
Known Issues
Engine Issues:
Cracked cylinder heads (especially on heavily modified engines), turbocharger wear, connecting rod bearing failures if oil starvation occurs.
Drivetrain Issues:
AYC/ACD pump failures, clutch wear (especially in hard-driven vehicles), differential issues.
Electrical Issues:
Wiring harness issues in high-stress areas, sensor failures.
Maintenance Schedule Highlight
Critical Items:
Timing belt replacement is paramount. Regular oil changes with high-quality oil are essential to protect the turbocharged engine. Inspection of the AWD system components (AYC/ACD) is recommended.
📚 Vehicle History
Brand Heritage
Motorsport Link:
Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) Lancer Evolutions, providing a homologation special for rallying.
Model Evolution
Evo Series:
The Evo VII followed the Evo VI, introducing significant chassis and drivetrain updates, including the advanced AYC and ACD systems, and a wider body.
Production
Production Period:
Evo VII: 2001-2003, Evo VIII: 2003-2005 (Overlap and evolution of technologies).
Production Locations
Assembly Plant:
Mizushima Plant, Kurashiki, Okayama, Japan.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists for its exceptional handling, braking, and performance, often lauded as one of the greatest rally-bred road cars.
Ratings
Performance Metrics:
Zero to 60 mph times typically in the low 5-second range. Track performance is exceptionally high for its class and era.
Certifications
Homologation:
Built as a homologation special for FIA Group A/WRC regulations, though specific Evo VII configurations may differ from strict rally homologation. The manual covers the road-going production version.
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