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Mitsubishi Lancer Evolution 2003 2004 2005 lancer x Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Generation: VIII (CT9A) Model Year: 2003, 2004, 2005 Codes Chassis Code: CT9A 👋 Introduction Market Position Segment: High-performance compact sedan...
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Mitsubishi Lancer Evolution 2003 2004 2005 lancer x Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Generation:
VIII (CT9A)
Model Year:
2003, 2004, 2005
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Segment:
High-performance compact sedan / rally homologation special.
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Subaru Impreza WRX.
Key Features
Powertrain:
Iconic 4G63T engine, advanced Super All-Wheel Control (S-AWC) system, robust 6-speed manual transmission.
Performance:
Renowned for its rally-bred performance, exceptional handling, and powerful acceleration.
Target Audience
User Base:
Enthusiasts, performance drivers, tuners, and owners seeking detailed technical knowledge.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service and repair for Mitsubishi Lancer Evolution VIII models 2003-2005.
Page Count
Pages:
Likely over 1000 pages (typical for full service manuals of this era).
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
4G63T (2.0L MIVEC Turbocharged Inline-4), including maintenance, diagnostics, disassembly, assembly, and troubleshooting.
Transmission:
6-speed Manual (Getrag 450), including clutch, drivetrain, transfer case, and differential maintenance and repair.
Suspension:
MacPherson strut front, multi-link rear, including geometry, component replacement, and alignment procedures.
Brakes:
Front Brembo 4-piston, Rear Brembo 2-piston, ABS, EBD, including hydraulic system, pad/rotor replacement, and bleeding.
Electrical:
Wiring diagrams, ECU, sensors, lighting, ignition, charging system, starter, and body electrical components.
Fuel System:
Fuel injection, fuel pump, injectors, fuel pressure regulation, and emissions control systems.
Cooling System:
Radiator, water pump, thermostat, cooling fan operation, and coolant specifications.
Exhaust System:
Turbocharger system, catalytic converter, mufflers, and related components.
Body And Chassis:
Structural components, body panels, doors, glass, interior trim, and collision repair information.
HVAC:
Air conditioning system, heater, and ventilation diagnostics and repair.
Driver Control:
Steering system, pedals, shifter, and interior controls.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, spark plug service, belt inspection/replacement.
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), sensor testing, and electrical system diagnostics.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including torque specifications.
Disassembly Assembly:
Complete breakdown and reassembly instructions for engine, transmission, drivetrain, suspension, and brake components.
Calibration Adjustment:
Procedures for wheel alignment, throttle body cleaning/adjustment, and electronic system calibration.
Technical Depth
Depth:
Full factory-level technical information suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid checks to complete engine rebuilds.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchable:
Likely searchable text for efficient information retrieval.
Print Quality
Printability:
Printable for physical reference.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) DOHC MIVEC Turbocharged Inline-4
Performance
Horsepower Hp:
276 hp @ 6500 rpm (JDM/European spec), 271 hp (US spec)
Torque Lbft:
289 lb-ft @ 3500 rpm (JDM/European spec), 273 lb-ft (US spec)
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger
Turbo Model:
Mitsubishi TD05HR-16G 8cm^2 (often upgraded in aftermarket tuning)
Cooling System
Cooling Capacity Liters:
~7.4 liters (coolant)
🔧 Transmission
Standard
Type:
6-speed Manual (Getrag 450)
Gear Ratios 1St:
3.143
Gear Ratios 2Nd:
2.143
Gear Ratios 3Rd:
1.565
Gear Ratios 4Th:
1.161
Gear Ratios 5Th:
0.943
Gear Ratios 6Th:
0.762
Final Drive Ratio:
4.059
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (SAYC).
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, viscosity SAE 75W-90 (check manual for specific OEM recommendations)
📐 Dimensions
Exterior
Length Mm:
4415 mm
Width Mm:
1770 mm
Height Mm:
1415 mm
Wheelbase Mm:
2625 mm
Weights
Curb Weight Kg:
~1450 kg
Gross Vehicle Weight Rating Kg:
~1850 kg
Tires Wheels
Tire Size Front:
235/45R17 (standard)
Tire Size Rear:
235/45R17 (standard)
Wheel Bolt Pattern:
5x114.3
Wheel Offset:
+38 mm (standard)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (for 2004 model year)
NHTSA Side Impact:
4/5 Stars (for 2004 model year)
IIHS Moderate Overlap Front:
Good (for 2004 model year)
Active Features
ABS:
Anti-lock Braking System with Electronic Brakeforce Distribution (EBD)
Traction Control:
Active Traction Control (ATC) and Active Stability Control (ASC)
Passive Features
Airbags:
Driver, Passenger, Side Curtain Airbags (model dependent)
Seatbelts:
3-point front and rear seatbelts with pre-tensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player with optional Rockford Fosgate premium audio system (8 speakers).
Display:
Digital odometer, trip computer, and basic climate control display.
Driver Assistance
S Awc:
Super All-Wheel Control (S-AWC) integrates ACD and AYC (Active Yaw Control) for enhanced traction and cornering.
Cruise Control:
Standard cruise control system.
Connectivity
Oem Integration:
Limited OEM connectivity by modern standards; primarily analog systems with basic electronic controls.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed.
Spark Plugs:
Replace at 30,000 miles (48,000 km) for standard plugs, or at higher intervals for platinum/iridium plugs (consult manual for specifics).
Timing Belt:
Replace at 60,000 miles (96,000 km) or 5 years, whichever comes first (critical maintenance item for 4G63).
Fluid Specifications
Engine Oil:
SAE 0W-30 or 0W-40 synthetic oil meeting API SM or ACEA A3/B4 specifications (refer to manual for precise OEM grade).
Coolant:
Mitsubishi Long Life Coolant (DIA QUEEN SUPER LONG LIFE COOLANT) or equivalent ethylene glycol-based antifreeze with demineralized water (50/50 mix).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Engine Lifters:
Potential for lifter tick or noise, especially on older or poorly maintained engines. Can be related to oil viscosity or wear.
Clutch Wear:
Due to the performance nature, clutch wear can be accelerated with aggressive driving.
Turbo Charger:
Risk of turbo seal failure or bearing wear if oil changes are neglected or if the engine is repeatedly run very hard without proper cool-down periods.
Rust:
Common issue in older vehicles, particularly on rear quarter panels, rocker panels, and around wheel wells, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Rally Roots:
Directly derived from Mitsubishi's WRC (World Rally Championship) winning Lancer Evolution platform.
Model Evolution
Generation Viii:
The Evo VIII introduced the iconic 6-speed manual transmission and further refined the S-AWC system. It was a significant evolution, especially for the US market where it was first officially imported in this generation.
Production
Production Years Viii:
2003-2005
Manufacturing Location:
Japan
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