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2005-2006 Mitsubishi Lancer Evolution IX Workshop Repair Service Manual Best

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Model Code: CT9A Market Segment: Compact Sports Sedan / Rally Homologation Special Codes Chassis Code: CT9A 👋 Introduction Market Position...
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2005-2006 Mitsubishi Lancer Evolution IX Workshop Repair Service Manual Best
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Model Code:
CT9A
Market Segment:
Compact Sports Sedan / Rally Homologation Special
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Positioning:
The Lancer Evolution IX (Evo IX) represents the pinnacle of the Evo VII/VIII/IX generation, a revered homologation special designed for Group N rally competition.
Target Audience:
Enthusiasts, performance car owners, rally replica builders, and professional mechanics specializing in Mitsubishi performance vehicles.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (though often in a different performance bracket).
Key Features
Engine Technology:
First Lancer Evolution to feature Mitsubishi's Variable Valve Timing and Lift Electronic Control (MIVEC) on the intake camshaft for enhanced power delivery across the rev range.
Drivetrain Technology:
Advanced AYC and ACD systems provided unparalleled traction and cornering agility.
Aero:
Aggressive body kit including a revised front bumper, side skirts, rear spoiler, and a vortex generator on the roof for improved aerodynamics.
Interior Appointments:
Recaro sport seats, Momo steering wheel, and a driver-focused cockpit.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Repair Service Manual
Language:
English
Format:
Digital Download (PDF)
Coverage Years:
2005-2006
Completeness:
Comprehensive, covers all major repair and maintenance aspects
📖 Manual Coverage
Systems Covered
Engine:
4G63 MIVEC Turbocharged Inline-4, including disassembly, assembly, timing, fuel, ignition, cooling, lubrication, emissions control, and ECU diagnostics.
Transmission:
6-Speed Manual (Getrag 'MLCAS'), including clutch system, gearbox internal overhaul, transfer case, and driveline.
Drivetrain:
All-Wheel Drive (AWD) system, including Active Center Differential (ACD), Super Active Yaw Control (Super AYC), front and rear differentials, driveshafts, and hubs.
Suspension:
Front MacPherson strut, Rear multi-link, including shock absorbers, springs, control arms, anti-roll bars, bushings, and alignment procedures.
Brakes:
Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, ABS, EBD, and brake fluid service.
Steering:
Power-assisted rack and pinion, including steering column, tie rods, and power steering system.
Electrical System:
Battery, charging system, starter, ignition, lighting, power windows, central locking, ECU, sensors, and wiring diagrams.
Body And Chassis:
Exterior panels, doors, hood, trunk, interior trim, chassis structure, crashworthiness details.
HVAC:
Heating, Ventilation, and Air Conditioning system, including refrigerant, compressor, and climate controls.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides for engine performance, electrical issues, and drivability concerns.
Repair:
Detailed step-by-step instructions for component removal, installation, and adjustment for all covered systems.
Rebuild:
Complete engine rebuild procedures, transmission overhaul, differential rebuilding.
Diagnostics:
OBD-II diagnostic codes, sensor testing, ECU relearn procedures, system checks.
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Technical Depth
Depth Level:
Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.
Data Accuracy:
Precise torque specifications, clearances, fluid capacities, electrical resistance values.
Visuals:
Diagrams, schematics, illustrations, and photographic representations of procedures and components.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Resolution:
High-resolution for clear images and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T MIVEC
Configuration:
1997cc, DOHC, 16-valve, turbocharged, intercooled inline-4 cylinder
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower:
280 PS (276 hp) @ 6500 rpm (JDM/European Spec), 270 hp (US Spec)
Torque:
30.0 kg-m (294 Nm / 217 lb-ft) @ 3500 rpm (JDM/European Spec), 273 lb-ft (US Spec)
Redline:
7000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch 650cc fuel injectors (later models)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G or TD05H-18G twin-scroll turbocharger with intercooler
🔧 Transmission
Standard
Transmission Type:
6-speed manual (Getrag MLCAS)
Clutch Type:
Hydraulically actuated, single-plate dry clutch
Optional
Optional Transmission:
N/A (Only Manual Transmission offered for Evolution IX)
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and driver-selectable modes (Tarmac, Gravel, Snow).
Rear Differential:
Super Active Yaw Control (Super AYC) - electronically controlled torque-vectoring rear differential.
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 2.785, 2nd: 1.954, 3rd: 1.310, 4th: 1.030, 5th: 0.777, 6th: 0.707 - approximate, varies by spec).
Transmission Fluid Spec:
Refer to manual for specific specification (typically GL-4 or GL-5 gear oil, e.g., Mitsubishi Diaqueen Super Hypoid Gear Oil LSD 80W-90 for rear diff with LSD, manual transmission fluid for gearbox).
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Track Width Front:
1510 mm (59.4 in)
Track Width Rear:
1510 mm (59.4 in)
Weights
Curb Weight:
Approximately 1400 kg (3086 lbs), varies slightly by trim and market.
Gross Weight:
Refer to manual.
Towing Capacity:
Not specified/recommended.
Cargo
Trunk Volume:
Approximately 10.3 cu ft (0.29 m³)
Wheels Tires
Wheel Size:
17x8 inches (standard)
Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Tire Size:
235/45R17 (standard)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Refer to NHTSA data for specific model year; generally performed well for its class and era.
IIHS Crash Test:
Refer to IIHS data for specific model year.
Active Features
Traction Control:
Active electronically controlled traction control system.
Stability Control:
Active Stability Control (ASC) - available on some trims.
ABS:
4-wheel Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD).
Brake Bias Control:
Adjustable brake bias control on some models.
Passive Features
Airbags:
Driver and front passenger airbags; side airbags optional or standard on some trims.
Seatbelts:
3-point front seatbelts with pre-tensioners and force limiters, 3-point rear seatbelts.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
Body Structure:
Reinforced body structure with a safety cage for occupant protection.
💡 Technology Features
Infotainment
Head Unit:
Factory fitted Clarion or Mitsubishi CD/radio head unit with optional CD changer. Aftermarket upgrades are common.
Speakers:
Standard speaker system; Rockford Fosgate premium audio optional on some trims.
Driver Assistance
ABS:
Standard 4-channel ABS.
Traction Control:
Standard electronically controlled traction control.
Stability Control:
Optional Active Stability Control (ASC).
Performance Modes:
Driver-selectable modes for ACD (Tarmac, Gravel, Snow) influence the differential's locking effect.
Connectivity
Bluetooth:
Not factory equipped. Requires aftermarket installation.
Usb:
Not factory equipped. Requires aftermarket installation.
Powertrain Control
ECU:
ECU (Engine Control Unit) with sophisticated mapping for the MIVEC and turbocharging systems. Highly tunable.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 miles or 6 months, whichever comes first (severe driving conditions may require more frequent changes).
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 30,000-60,000 miles, depending on plug type (refer to manual for specific recommendation, often Iridium type).
Timing Belt Replacement:
Every 60,000-70,000 miles or 5 years. Crucial to follow this interval due to interference engine design.
Coolant Flush:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil:
Refer to manual for exact viscosity (e.g., 5W-30, 10W-30, 10W-40 depending on climate). Mitsubishi recommends Diaqueen SS 5W-30 or equivalent API SN/ILSAC GF-5 compliant oil.
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change.
Transmission Fluid:
Refer to manual for specific specification (e.g., Mitsubishi Diaqueen Gear Oil GL-4 75W-85 or equivalent for gearbox; Diaqueen Super Hypoid Gear Oil LSD 80W-90 for rear differential with AYC).
Coolant:
Mitsubishi Diaqueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze (typically pink or red).
Brake Fluid:
DOT 3 or DOT 4 compatible brake fluid.
Known Issues
Engine:
Weak connecting rods on early 4G63 engines (less prevalent on Evo IX's later revisions but still a consideration for high-power builds), turbo oil feed line failures leading to turbo seizure, valve stem seal degradation, spark plug blow-out due to weak threads in cylinder head (especially if plugs are overtightened or frequently removed).
Drivetrain:
AYC pump failure or leaks, clutch wear, differential whine or failure if fluids are neglected.
Suspension:
Worn ball joints, bushings, and wheel bearings; shock absorber degradation.
Electrical:
ECU failure (especially early models), alternator issues, wiring harness degradation in high-heat areas.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's extensive success in the World Rally Championship (WRC) with Tommi Mäkinen securing four consecutive drivers' titles from 1996-1999 formed the bedrock for the Lancer Evolution lineage.
Model Evolution
Generations:
The Evolution IX is the final iteration of the CT9A platform, succeeding the Evolution VIII. It built upon the established formula with significant mechanical and styling updates.
Key Updates From Evo Viii:
Introduction of MIVEC engine, updated turbocharger, revised ACD and AYC systems, 6-speed manual transmission, and revised bodywork/aero.
Trim Levels:
Commonly available in GSR (more luxury-oriented) and RS (lighter, more basic, homologation-focused) variants, with specific market variations like MR (Mitsubishi Racing) offering higher specifications.
Production
Production Period:
2005-2007 (model years 2005-2006)
Manufacturing Location:
Mizushima Plant, Okayama Prefecture, Japan
Global Availability:
Primarily sold in Japan, North America (limited), Europe, Australia, and other select markets.
🏆 Awards & Recognition
Recognitions
Performance Car Of The Year:
Consistently ranked highly in performance car reviews and 'car of the year' awards by automotive publications globally for its handling and performance.
Rally Homologation:
Built to homologate the Lancer Evolution for Group N and Group A rally racing, which has cemented its iconic status among motorsport enthusiasts.
Enthusiast Following:
Holds a legendary status in the enthusiast community, often lauded for its raw driving experience and tunable platform.
Ratings
Handling Dynamics:
Universally praised for its exceptional handling, grip, and responsiveness, a direct result of its AWD system, sophisticated differentials, and balanced chassis.
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