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Mitsubishi Lancer Evolution 7 2001-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VII Model Code: CT9A Model Variant: Evolution VII Codes Platform Chassis Code: JDM CT9A 👋 Introduction Market Position Segment: Performance Sedan...
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Mitsubishi Lancer Evolution 7 2001-2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VII
Model Code:
CT9A
Model Variant:
Evolution VII
Codes
Platform Chassis Code:
JDM CT9A
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, tuners, and owners seeking in-depth knowledge for maintenance and performance upgrades.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Renault Clio V6 Sport.
Key Features
Performance Focus:
Built for rally racing homologation, emphasizing advanced AWD, turbocharged power, and precise handling.
Technological Advancements:
Introduction of Active Yaw Control (AYC) significantly enhanced cornering stability and driver feedback.
📋 Manual Details
Coverage Areas
Engine:
4G63 (2.0L Turbocharged Inline-4)
Transmission:
5-Speed Manual
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Suspension:
Front: MacPherson Struts, Rear: Multi-link
Brakes:
Front: Ventilated Discs, Rear: Ventilated Discs (Brembo option)
Electrical:
Complete Wiring Diagrams, ECU Functions, Sensors
Bodywork:
Body Panels, Interior Trim, Exterior Components
HVAC:
Heating, Ventilation, Air Conditioning System
Chassis:
Frame, Steering, Wheel Alignment
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, component specifications, timing belt replacement, turbocharger service.
Engine Management:
ECU pinouts, sensor testing, fuel injection system diagnostics, ignition system operation.
Transmission Gearbox:
Clutch system, gearbox overhaul, gear selection mechanism, specific procedures for the 5-speed gearbox.
All Wheel Drive System:
Active Yaw Control (AYC) operation and diagnostics, ACD (Active Center Differential) system, propeller shaft and rear differential service.
Suspension Steering:
Front and rear suspension component replacement, steering rack diagnostics and repair, wheel alignment specifications.
Braking System:
Brake fluid replacement, caliper and rotor service, ABS system diagnostics, Brembo brake system specifics (if applicable).
Fuel System:
Fuel pump and filter replacement, fuel pressure testing, injector service.
Cooling System:
Radiator, thermostat, water pump replacement, coolant specifications and flush procedures.
Exhaust System:
Exhaust component replacement, catalytic converter information.
Electrical System:
Battery, alternator, starter motor service, lighting system, power windows, central locking.
Body Interior:
Door panel removal, seat adjustment, dashboard components, exterior trim replacement.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement intervals and procedures.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults.
Repair Overhaul:
Comprehensive instructions for engine rebuilds, transmission overhauls, and component replacements.
Diagnostics Testing:
Testing procedures for all major electrical and mechanical components.
Wiring Diagrams:
Detailed, system-specific wiring schematics for easy troubleshooting.
Torque Specifications:
Precise torque values for all critical fasteners.
Fluid Capacities Types:
Exact fluid types and quantities for engine oil, transmission fluid, brake fluid, coolant, etc.
Specifications Measurements:
All necessary technical data, tolerances, and measurements for proper repair.
Technical Depth
Depth:
Factory-level detail suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text within the PDF for quick information retrieval.
Print Quality
Print Recommendation:
High-resolution pages suitable for printing key sections or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (DOHC, 16-valve, Inline-4)
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Turbocharger:
Mitsubishi TD05HR-16G (Twin-Scroll)
Intercooler:
Air-to-air, top-mounted
Performance
Horsepower:
280 PS (276 bhp / 206 kW) @ 6500 rpm (JDM Spec)
Torque:
370 Nm (273 lb-ft) @ 3000 rpm (JDM Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Premium (98 RON recommended)
Fuel Pump Part Number:
MD347037 (Example, verify with VIN)
Fuel Filter Part Number:
MD071013 (Example, verify with VIN)
Fluid Specifications
Engine Oil Capacity:
4.5 Liters (with filter)
Engine Oil Type:
SAE 10W-30 or 10W-40 (API SG/SH/SJ or ILSAC GF-2/GF-3)
🔧 Transmission
Standard
Type:
5-Speed Manual
Features
Drivetrain:
Full-time All-Wheel Drive (AWD)
Center Differential:
Active Center Differential (ACD)
Rear Differential:
Active Yaw Control (AYC) Rear Differential
Fluid Specifications
Gearbox Oil Capacity:
2.1 Liters
Gearbox Oil Type:
API GL-4, SAE 75W-90
Transfer Case Oil Capacity:
0.6 Liters
Transfer Case Oil Type:
API GL-3, SAE 80W-90
Rear Differential Oil Capacity:
1.1 Liters
Rear Differential Oil Type:
API GL-5, SAE 80W-90 (Limited Slip Differential compatible)
📐 Dimensions
Exterior
Length:
4435 mm (174.6 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Front Track:
1515 mm (59.6 in)
Rear Track:
1510 mm (59.4 in)
Weights
Curb Weight:
1460 kg (3219 lbs) (Approx.)
Gross Vehicle Weight Rating:
1800 kg (Approx.)
Towing Capacity:
Not Recommended
Wheel Tire
Wheel Size:
17 x 8.0 inches
Wheel Bolt Pattern:
5x114.3
Tire Size:
235/45R17
🛡️ Safety Features
Ratings
Crash Test Results:
NHTSA and IIHS ratings vary by market and are generally not as comprehensive for this era of performance vehicles as modern standards.
Active Features
ABS:
Anti-lock Braking System (4-channel, 4-sensor)
Ayc:
Active Yaw Control (AYC) – Electronically controlled torque distribution to rear wheels.
Acd:
Active Center Differential (ACD) – Electronically controlled torque split between front and rear axles.
Passive Features
Airbags:
Driver and Front Passenger Airbags
Seatbelts:
Three-point front and rear seatbelts with pretensioners and force limiters.
Body Structure:
Reinforced chassis and safety cell design.
💡 Technology Features
Infotainment
Head Unit:
Factory original audio system (typically AM/FM/CD player, market-dependent).
Speakers:
Standard speaker configuration, often with door-mounted units and tweeters.
Driver Assistance
Ayc System:
Active Yaw Control is a sophisticated torque-vectoring system that enhances cornering dynamics.
Acd System:
Active Center Differential allows for adjustable torque distribution between front and rear axles, often with driver-selectable modes (Tarmac, Gravel, Snow).
Connectivity
Bluetooth:
Not equipped with factory Bluetooth connectivity.
Usb:
Not equipped with factory USB ports.
Instrumentation
Gauge Cluster:
Includes tachometer, speedometer, boost gauge, and auxiliary gauges for oil pressure and voltage.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first, under normal use. Shorter intervals recommended for spirited driving.
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000-30,000 km (9,000-18,000 miles).
Spark Plug Replacement:
Every 60,000-100,000 km (37,000-60,000 miles), depending on plug type (platinum/iridium recommended).
Timing Belt Replacement:
Every 90,000-100,000 km (56,000-62,000 miles) or 7 years, whichever comes first. Critically important for the 4G63 engine.
Coolant Replacement:
Every 2 years or 40,000 km (24,000 miles).
Brake Fluid Replacement:
Every 2 years or 40,000 km (24,000 miles).
Fluid Specifications
Coolant Type:
Mitsubishi Super Long Life Coolant (LLC) or equivalent ethylene glycol-based coolant.
Known Issues
Engine Mounts:
Can degrade over time, leading to increased vibration and harsher engine feel. Replacement recommended with stiffer aftermarket options for performance use.
Oil Sludge:
The 4G63 can be prone to oil sludge if maintenance intervals are neglected, particularly with aggressive driving. Regular oil changes are crucial.
Ayc Pump:
The AYC hydraulic pump can fail over time, leading to the illumination of the AYC warning light and loss of its functionality. Diagnosis and potential pump replacement or bypass may be required.
Clutch Wear:
Performance driving can accelerate clutch wear. Regular inspection and adjustment are advised.
Susceptibility To Corrosion:
Older vehicles, particularly those in humid or salted environments, may exhibit rust on body panels, subframes, and exhaust components.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) Lancer models.
Model Evolution
Seventh Generation:
The Evo VII marked a significant evolution, inheriting the stronger chassis from the standard Lancer Cedia platform, enabling higher power output and improved handling characteristics over its predecessors.
Key Upgrades From Evo Vi:
Stronger chassis, revised suspension geometry, larger turbocharger (TD05HR-16G), inclusion of Active Center Differential (ACD) and Active Yaw Control (AYC) as standard.
Production
Production Years:
2001 - 2002
Manufacturing Location:
Japan
Market Availability:
Primarily Japan (JDM), with limited grey market imports to other regions.
🏆 Awards & Recognition
Recognitions
Rally Success:
The Lancer Evolution platform is globally renowned for its motorsport pedigree, consistently winning championships in WRC.
Automotive Journalism:
Praised by automotive media for its exhilarating performance, advanced AWD technology, and raw driving experience.
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