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2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual (2003 2004 2005)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (Evo VII, VIII, IX chassis basis) Covered Years: 2003, 2004, 2005 Codes Chassis Codes: CT9A (for models covered by this manual, referring to the Evolution VIII and early Evolution IX variants) 👋 Introduction Market Position Segment: Performance Compact Sedan (rally homologation special) Positioning: The Lancer Evolution (Evo) occupied a unique niche as a highly capable, all-wheel-drive, turbocharged performance car derived from a standard production sedan. It was renowned for its sophisticated electronically controlled all-wheel-drive system (AWC), advanced differentials, and potent turbocharged engine, making it a formidable competitor in its segment and a popular choice for enthusiasts and motorsport participants. Competitive Analysis Key Competitors: Subaru WRX STI, Ford Focus RS, Audi S3, Volkswagen Golf R (in various generations and markets). Key Features Performance Focus: Built for speed, handling, and driver engagement, emphasizing technological integration for optimal traction and agility. Rally Heritage: Direct lineage from Mitsubishi's successful World Rally Championship (WRC) vehicles, translating performance technology to the street. Ease Of Use Note Manual Usability: The manual is presented with 'easy to read type' and aims to provide 'all the information needed to do the procedure correctly,' indicating a focus on clarity and completeness for a broad user base. 📋 Manual Details Coverage Areas Vehicle Scope: Mitsubishi Lancer Evolution 2003 TM, 2003 BM, 2004, 2005 Market Scope: Likely includes North American and potentially global specifications for the respective model years, reflecting the Evolution's international presence. Page Count Estimated Page Count: Not specified, but typical factory service manuals for this era and complexity often range from 1500-3000+ pages. Manual Type Type: Factory Service Repair Manual Intended User: Amateur owners to professional technicians Language Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Reader Requirement: Adobe PDF Reader 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63T variants), Intake/Exhaust, Cooling, Fuel System, Lube System, Ignition, Starting, Charging, Manual Transmission, Automatic Transmission (less common for Evo), Transfer Case, Drive Shafts, Differentials, Axles. Chassis: Suspension (front and rear), Steering (column, power steering), Brakes (control system, conventional, parking brake), Wheels & Tires. Electrical Electronics: Control Systems (engine management, various vehicle controls), Multiplex/CAN Communication, Supplemental Restraint System (Airbags), Seat Belts, Engine Immobilizer, Cruise Control, Meter/Audio/Visual, Horn, Wipers & Washers, Door Locks, Instrument Panel. Body Interior Exterior: Air Conditioning, Windshield/Glass/Mirrors, Exterior/Interior Trim, Seats, Engine Hood/Doors. Procedures Included Maintenance: Routine inspections, fluid changes, filter replacements, belt adjustments, spark plug replacement, brake pad/rotor replacement. Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings, system checks, component testing. Repair Rebuild: Detailed step-by-step instructions for major component removal, disassembly, inspection, repair, and reassembly (e.g., engine internal components, transmission overhaul, suspension component replacement). Electrical Troubleshooting: Wiring diagrams, circuit testing procedures, component diagnostics. Technical Data Specifications: Torque specifications, fluid capacities and types, clearances, pressures, electrical resistance values, engine timing specifications, emission control information. Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance and fluid checks to advanced engine and transmission rebuilding, complex electrical system diagnostics, and chassis component overhaul. 📊 Manual Specifications File Format Quality: PDF format, typically offering high clarity for text and diagrams. Searchable text is a common feature of well-produced PDF manuals. Print Quality Printability: Designed to be printable, allowing users to create physical copies of specific sections or the entire manual for workshop use. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (2.0L DOHC Turbocharged Inline-4 MIVEC in later versions) Performance Horsepower Range: Approx. 270-280 hp (SAE net) for Japanese/European models, with North American models often around 271 hp. Specific output can vary slightly by year and market regulations (e.g., OE or JDM spec). Torque Range: Approx. 273-284 lb-ft (SAE net). Specific torque figures may differ slightly by market and tune. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Electronic Throttle Control (ETC) on some models. Turbocharger: Garrett or MHI (Mitsubishi Heavy Industries) turbocharger with intercooler. Evolution VIII MR and later typically featured a twin-scroll turbocharger. Engine Features Cylinder Head: 16-valve DOHC (Double Overhead Camshaft) Engine Management: ECU (Electronic Control Unit) with sophisticated tuning for performance and emissions. The manual would detail diagnostic procedures for the ECU and associated sensors. 🔧 Transmission Standard Type: 6-speed Manual Transmission (Getrag or Mitsubishi-sourced, depending on specific model variant and year) Optional Type: Fewer models offered an automatic transmission, typically a 5-speed INVECS-II Sportronic. However, the 6-speed manual is the iconic and dominant transmission for performance models of this era. Features AWD System: Advanced All-Wheel Control (AWC) system, including Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) on rear differential (on many models). The manual would detail the operation, maintenance, and troubleshooting of these systems. 📐 Dimensions Exterior Length: Approx. 4490 mm (176.8 in) for Evolution VIII/IX chassis Width: Approx....
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2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual (2003 2004 2005)
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Code:
CT9A (Evo VII, VIII, IX chassis basis)
Covered Years:
2003, 2004, 2005
Codes
Chassis Codes:
CT9A (for models covered by this manual, referring to the Evolution VIII and early Evolution IX variants)
👋 Introduction
Market Position
Segment:
Performance Compact Sedan (rally homologation special)
Positioning:
The Lancer Evolution (Evo) occupied a unique niche as a highly capable, all-wheel-drive, turbocharged performance car derived from a standard production sedan. It was renowned for its sophisticated electronically controlled all-wheel-drive system (AWC), advanced differentials, and potent turbocharged engine, making it a formidable competitor in its segment and a popular choice for enthusiasts and motorsport participants.
Competitive Analysis
Key Competitors:
Subaru WRX STI, Ford Focus RS, Audi S3, Volkswagen Golf R (in various generations and markets).
Key Features
Performance Focus:
Built for speed, handling, and driver engagement, emphasizing technological integration for optimal traction and agility.
Rally Heritage:
Direct lineage from Mitsubishi's successful World Rally Championship (WRC) vehicles, translating performance technology to the street.
Ease Of Use Note
Manual Usability:
The manual is presented with 'easy to read type' and aims to provide 'all the information needed to do the procedure correctly,' indicating a focus on clarity and completeness for a broad user base.
📋 Manual Details
Coverage Areas
Vehicle Scope:
Mitsubishi Lancer Evolution 2003 TM, 2003 BM, 2004, 2005
Market Scope:
Likely includes North American and potentially global specifications for the respective model years, reflecting the Evolution's international presence.
Page Count
Estimated Page Count:
Not specified, but typical factory service manuals for this era and complexity often range from 1500-3000+ pages.
Manual Type
Type:
Factory Service Repair Manual
Intended User:
Amateur owners to professional technicians
Language
Language:
English
Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac
Reader Requirement:
Adobe PDF Reader
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63T variants), Intake/Exhaust, Cooling, Fuel System, Lube System, Ignition, Starting, Charging, Manual Transmission, Automatic Transmission (less common for Evo), Transfer Case, Drive Shafts, Differentials, Axles.
Chassis:
Suspension (front and rear), Steering (column, power steering), Brakes (control system, conventional, parking brake), Wheels & Tires.
Electrical Electronics:
Control Systems (engine management, various vehicle controls), Multiplex/CAN Communication, Supplemental Restraint System (Airbags), Seat Belts, Engine Immobilizer, Cruise Control, Meter/Audio/Visual, Horn, Wipers & Washers, Door Locks, Instrument Panel.
Body Interior Exterior:
Air Conditioning, Windshield/Glass/Mirrors, Exterior/Interior Trim, Seats, Engine Hood/Doors.
Procedures Included
Maintenance:
Routine inspections, fluid changes, filter replacements, belt adjustments, spark plug replacement, brake pad/rotor replacement.
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings, system checks, component testing.
Repair Rebuild:
Detailed step-by-step instructions for major component removal, disassembly, inspection, repair, and reassembly (e.g., engine internal components, transmission overhaul, suspension component replacement).
Electrical Troubleshooting:
Wiring diagrams, circuit testing procedures, component diagnostics.
Technical Data Specifications:
Torque specifications, fluid capacities and types, clearances, pressures, electrical resistance values, engine timing specifications, emission control information.
Technical Depth
Depth:
Comprehensive, covering everything from basic preventative maintenance and fluid checks to advanced engine and transmission rebuilding, complex electrical system diagnostics, and chassis component overhaul.
📊 Manual Specifications
File Format
Quality:
PDF format, typically offering high clarity for text and diagrams. Searchable text is a common feature of well-produced PDF manuals.
Print Quality
Printability:
Designed to be printable, allowing users to create physical copies of specific sections or the entire manual for workshop use.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (2.0L DOHC Turbocharged Inline-4 MIVEC in later versions)
Performance
Horsepower Range:
Approx. 270-280 hp (SAE net) for Japanese/European models, with North American models often around 271 hp. Specific output can vary slightly by year and market regulations (e.g., OE or JDM spec).
Torque Range:
Approx. 273-284 lb-ft (SAE net). Specific torque figures may differ slightly by market and tune.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Throttle Control (ETC) on some models.
Turbocharger:
Garrett or MHI (Mitsubishi Heavy Industries) turbocharger with intercooler. Evolution VIII MR and later typically featured a twin-scroll turbocharger.
Engine Features
Cylinder Head:
16-valve DOHC (Double Overhead Camshaft)
Engine Management:
ECU (Electronic Control Unit) with sophisticated tuning for performance and emissions. The manual would detail diagnostic procedures for the ECU and associated sensors.
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (Getrag or Mitsubishi-sourced, depending on specific model variant and year)
Optional
Type:
Fewer models offered an automatic transmission, typically a 5-speed INVECS-II Sportronic. However, the 6-speed manual is the iconic and dominant transmission for performance models of this era.
Features
AWD System:
Advanced All-Wheel Control (AWC) system, including Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) on rear differential (on many models). The manual would detail the operation, maintenance, and troubleshooting of these systems.
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in) for Evolution VIII/IX chassis
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1450 mm (57.1 in)
Weights
Curb Weight:
Approx. 1450 - 1500 kg (3197 - 3307 lbs), depending on specific trim and options.
Wheelbase
Wheelbase:
Approx. 2625 mm (103.3 in)
Track Width
Front Track:
Approx. 1500 mm (59.1 in)
Rear Track:
Approx. 1505 mm (59.3 in)
🛡️ Safety Features
Ratings
NHTSA Crash Test:
Not directly applicable to all global markets or specific Evo trims of this era, but standard Lancer safety features would have been present. Specific Evo crash data is less commonly cited than its performance metrics.
Active Features
Braking System:
Four-wheel disc brakes, typically with Brembo calipers on front (4-piston) and rear (2-piston) for many performance variants. Anti-lock Braking System (ABS) is standard.
Traction Control:
Active Traction Control (ATC) and Active Stability Control (ASC) are usually standard, working in conjunction with the AWC system.
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags and curtain airbags might have been optional or standard on certain higher trims/markets.
Seatbelts:
Three-point seatbelts with pretensioners for front seats. Rear seatbelts as standard.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM CD player with speaker system. Higher trims might have premium audio. Manual covers system operation and basic troubleshooting.
Driver Assistance
Traction Stability Control:
Advanced AWC, ACD, and ASC systems are key technological features that the manual extensively covers in terms of operation and maintenance.
Connectivity
Multiplex Communication:
The manual details the Multiplex/CAN (Controller Area Network) communication system, essential for understanding how various ECUs communicate and for diagnosing network-related faults.
Comfort Features
Climate Control:
Manual or automatic climate control systems are detailed, including servicing of the air conditioning system.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, especially under spirited driving conditions. Refer to manual for specific severe/normal service recommendations.
Air Filter Replacement:
Inspect every 7,500 miles (12,000 km), replace as needed or every 15,000 miles (24,000 km).
Spark Plug Replacement:
Typically every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., standard, iridium). Manual will specify exact type and interval.
Timing Belt Replacement:
Crucial for the 4G63T engine. Typically every 60,000-90,000 miles (96,000-144,000 km). The manual will provide precise intervals and related component (tensioner, idler pulleys, water pump) replacement recommendations.
Fluid Specifications
Engine Oil:
API Service SL or higher, Viscosity SAE 0W-30, 5W-30, or 5W-40, often synthetic. Specific OEM recommendations should be followed. Refer to manual for exact grades.
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Transmission Fluid:
Manual: Hypoid gear oil SAE 75W-90 GL-4 or GL-5 (check manual for specific recommendation). Automatic: ATF SP-III or equivalent.
Differential Fluid:
Hypoid gear oil SAE 75W-90 GL-5 for front and rear differentials. ACD requires specific ACD fluid. The manual will detail these critical specifications.
Known Issues
Engine:
Head gasket failures (especially on heavily modified engines), turbocharger wear, connecting rod issues (less common on stock engines but a concern for high-mileage or tuned cars).
Powertrain:
ACD pump failures, clutch wear (especially with aggressive driving), AYC pump and system issues.
Suspension Chassis:
Bushings wear over time leading to vague handling. Wheel bearing failures are also a possibility.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a storied history in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution achieved significant success throughout the 1990s and early 2000s. This racing pedigree heavily influenced the development and marketing of the production Evolution models.
Model Evolution
Evolution Series:
The 2003-2005 models typically encompass the Evolution VIII and early Evolution IX generations (e.g., CT9A chassis). The Evo VIII (introduced 2003) featured significant updates over the Evo VII, including a revised front fascia, Bilstein suspension components, and a strengthened body. The Evo IX (introduced 2005) further refined the formula, most notably with the introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control) variable valve timing to the 4G63T engine, boosting power and efficiency.
Production
Manufacturing Location:
Japan (primarily Mizushima Plant, Kurashiki, Okayama Prefecture).
Sales Focus:
Initially conceived as a homologation special for rally racing, the Evolution gained a significant global following and was officially imported to markets like North America starting with the Evo VIII.
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently praised by automotive journalists and enthusiasts for its exceptional handling, braking, and all-wheel-drive performance. Often featured on 'best performance car' lists during its production run. The manual facilitates the maintenance of these high-performance attributes.
Certifications
Homologation Status:
Developed for FIA WRC homologation, underscoring its performance engineering focus and pedigree.
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