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Mitsubishi Lancer 2003-2005 Factory Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Years Covered: 2003, 2004, 2005 Chassis Codes: CS_A (Sedan), CS_Z (Hatchback - likely referencing the Lancer Cedia platform, though specific chassis...
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Mitsubishi Lancer 2003-2005 Factory Service Repair Manual Pdf
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Model Years Covered:
2003, 2004, 2005
Chassis Codes:
CS_A (Sedan), CS_Z (Hatchback - likely referencing the Lancer Cedia platform, though specific chassis codes might vary by region)
👋 Introduction
Market Position
Segment:
Compact Sedan/Hatchback
Target Audience:
Budget-conscious buyers, first-time car owners, value-oriented commuters
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Nissan Sentra
Key Features Vehicle
Value Proposition:
Affordable pricing, reliable mechanicals, decent fuel economy, sportier styling than some rivals
Key Features Manual
Value Proposition:
Authoritative, dealer-level repair information, comprehensive coverage for all major vehicle systems, essential for accurate diagnostics and repairs.
📋 Manual Details
Coverage Areas
Primary Coverage:
North American Market (implied by dealer reference, though content may be global)
Page Count
Estimated Page Count:
Over 2000 pages (typical for a full factory service manual)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel & Emissions, Exhaust, Cooling, Lubrication, Ignition, Turbocharging (if applicable to specific trims)
Drivetrain:
Transmission (Manual & Automatic), Drivetrain Components (Driveshafts, Differentials)
Chassis:
Suspension (Front & Rear), Steering System, Brake System, Wheels & Tires
Electrical:
Body Electrical, Powertrain Control Module (PCM), Lighting, Instrumentation, Audio System, HVAC Controls, Power Accessories, SRS (Airbag) System
Body And Trim:
Exterior Body Panels, Interior Trim, Doors, Glass, Bumpers, Seals
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Checks and Changes, Filter Replacements, Belt Inspections
Repair And Rebuild:
Engine Overhaul, Transmission Rebuild, Brake Component Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Electrical Circuit Diagrams, Component Testing Procedures
Specifications And Data:
Torque Specifications, Clearances, Tolerances, Wiring Diagrams, Component Locations
Technical Depth
Depth:
Comprehensive (Factory Level - Suitable for Professional Technicians and Advanced DIYers)
📊 Manual Specifications
File Format
File Type:
Digital (PDF)
Searchability:
Searchable Text (assuming OCR or native digital text)
Print Quality
Print Quality:
High-Resolution (suitable for printing sections or entire manual)
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine Options
Engine Code 1:
4G13 SOHC (likely 1.3L)
Engine Code 2:
4G15 SOHC (likely 1.5L)
Engine Code 3:
4G18 SOHC (likely 1.6L)
Engine Code 4:
4G94 SOHC/DOHC (likely 2.0L - common in North America for ES/LS trims)
Engine Code 5:
4G63 SOHC/DOHC (2.0L - potentially for performance variants like GTS or non-turbo Eclipse-derived engines)
Engine Code 6:
4G64 SOHC (2.4L - less common for Lancer, more for Outlander/Galant of same era)
Performance
Horsepower Range:
Approx. 90 hp (1.3L) to 160 hp (2.0L DOHC non-turbo, e.g., GTS)
Torque Range:
Approx. 85 lb-ft to 135 lb-ft (depending on engine)
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI) / Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Engine Control Unit (ECU) / Powertrain Control Module (PCM)
🔧 Transmission
Standard Transmission
Type:
5-Speed Manual
Optional Transmission
Type:
4-Speed Automatic (INVECS-II or similar)
Features
Drive Type:
Front-Wheel Drive (FWD) - All-Wheel Drive (AWD) variants were less common for this generation Lancer in North America, but possible in global markets or specific performance trims not detailed.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-3 SAE 75W-90 or 75W-85 (Specifics detailed in manual)
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF SP-II M or SP-III equivalent (Specifics detailed in manual)
📐 Dimensions
Exterior Length
Sedan Approximate:
174.0 - 175.0 inches
Exterior Width
Approximate:
67.3 - 67.7 inches
Exterior Height
Approximate:
55.5 - 57.3 inches
Wheelbase
Approximate:
102.4 inches
Weights
Curb Weight Range:
Approx. 2500 - 2800 lbs (depending on engine and transmission)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver), 4 Stars (Passenger) - For 2003 Model
IIHS Front Offset:
Good (for models equipped with side airbags, varies by year and configuration)
Active Features
ABS:
Available/Standard depending on trim level
Traction Control:
Available on higher trims or as an option
Passive Features
Airbags:
Driver and Front Passenger Airbags standard; Optional Side Curtain Airbags and/or Side Impact Airbags available on some trims.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM CD player or cassette with 4-6 speakers. Optional premium audio available on higher trims. Auxiliary input likely not standard.
Navigation:
Not typically available on this generation Lancer.
Driver Assistance
Cruise Control:
Available on ES, LS, GTS trims, often part of an option package.
Power Features:
Power windows, power door locks, and power mirrors were available, standard on higher trims.
Connectivity
Bluetooth:
Not standard or available for this model year.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 miles or 6 months (whichever comes first), consult manual for exact interval based on driving conditions.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 60,000 miles depending on spark plug type (standard vs. platinum/iridium).
Timing Belt Replacement:
Critical item for engines with timing belts (likely 4G1x, 4G9x engines). Typically every 60,000 - 100,000 miles or 5-7 years. The manual will specify belt type and interval.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.7 - 4.5 Quarts (4.0 - 4.2 Liters) depending on engine size. Check manual for precise capacity.
Engine Oil Viscosity:
SAE 5W-30 or 5W-20 is common, but consult manual for specific engine/climate recommendations. API SL or SM service classification.
Coolant:
Ethylene Glycol-based, Asian Red/Pink or Green type. 50/50 mix with distilled water. Capacity approx. 5-6 Quarts.
Known Issues
Engine Performance:
Occasional rough idle or misfires due to fouled spark plugs, vacuum leaks, or EGR valve issues.
Electrical:
Alternator failures, power window motor issues, and occasional parasitic battery drain reported.
Suspension And Steering:
Worn tie rod ends, ball joints, and strut mounts can lead to steering looseness and clunking noises.
Transmission:
Automatic transmissions can sometimes exhibit delayed engagement or rough shifting, often requiring fluid and filter service. Manual clutches have typical wear life.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation (Japan)
Model Evolution
Generation Code:
This generation corresponds to the JDM Mitsubishi Lancer Cedia platform (CS_A/CS_W), which was widely exported and adapted for various global markets.
Design Philosophy:
Continuation of a long-standing nameplate, focusing on affordability, practicality, and evolving towards more modern styling and safety features compared to previous generations.
Production
Manufacturing Locations:
Primarily Japan, also potentially other global assembly plants based on market.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While not a consistent award-winner, the Lancer often received positive mentions for its value, styling, and available sporty trims within the compact car segment. Specific awards vary by automotive publication and region.
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