Mitsubishi Lancer Evolution 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 2005 Codes Chassis Code: CT9A Engine Code: 4G63 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Target...

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Sku: 344557

Tags: 2005 Car Cars Lancer Evolution Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Year:

Codes

Chassis Code:

Engine Code:

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, tuners, and owners seeking in-depth knowledge for maintenance and performance modifications.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (lower trim).

Key Features

Performance Focus:

Designed for high-performance driving, rally-bred technology.

AWD System:

Iconic Active Yaw Control (AYC) and Active Center Differential (ACD) system for advanced traction.

Engine Powerplant:

Legendary turbocharged 4G63 engine, a favorite for tuning and performance.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete service and repair for all systems and components.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, valve train.

Engine Fuel System:

Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, fuel filter replacement.

Engine Ignition System:

Ignition coils, spark plugs, crank angle sensor, camshaft position sensor, ignition timing.

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan system, troubleshooting overheating.

Engine Lubrication System:

Oil pump, oil filter, oil pan, oil pressure monitoring, oil cooler (if equipped).

Forced Induction:

Turbocharger (TD05H-16G), intercooler, boost control system, wastegate, blow-off valve.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, exhaust sensors (O2).

Transmission Manual:

5-speed and 6-speed (RS models) manual transmission, clutch system, gearbox overhaul, gear ratios.

Transmission AWD:

Advanced All-Wheel Control (AWC) system, Active Center Differential (ACD), electronically controlled viscous coupling (VCU), rear differential.

Suspension Front:

MacPherson strut, control arms, anti-roll bar, steering knuckle, wheel bearing replacement.

Suspension Rear:

Multi-link independent suspension, trailing arms, shock absorbers, springs, alignment specifications.

Brakes Front:

Brembo 4-piston calipers, vented rotors, brake pad replacement, caliper service.

Brakes Rear:

Brembo 2-piston calipers, vented rotors, brake pad replacement, caliper service.

Steering System:

Power steering system, steering rack, tie rod ends, steering column, alignment procedures.

Electrical System:

Battery, charging system (alternator), starter motor, lighting system, wiring diagrams.

ECU Tuning Diagnostics:

Engine Control Unit (ECU) diagnostics, sensor data interpretation, fault codes (DTCs) and troubleshooting charts.

Body Exterior:

Body panels, doors, hood, trunk, bumpers, trim, glass replacement.

Body Interior:

Seats, dashboard, center console, door panels, headliner, carpet replacement.

Climate Control:

HVAC system, air conditioning (A/C) compressor, refrigerant, heater core, blower motor, climate control module.

Safety Systems:

Airbag system, SRS (Supplemental Restraint System) components and diagnostics, seat belts.

Procedures Included

Routine Maintenance:

Oil and filter change, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush, brake fluid flush.

Troubleshooting:

Diagnostic procedures for all major systems, fault code interpretation, step-by-step troubleshooting flowcharts.

Major Repairs:

Engine rebuilds, transmission overhauls, turbocharger replacement, suspension component replacement, brake system service.

Component Replacement:

Detailed instructions for replacing individual parts and assemblies across all vehicle systems.

Electrical Diagnostics:

Wiring diagrams for all circuits, troubleshooting electrical faults, component testing.

Suspension Alignment:

Front and rear wheel alignment specifications and adjustment procedures.

A C Service:

Refrigerant handling, leak detection, component replacement, system evacuation and charging.

Body Work:

Panel removal and installation, door adjustment, glass replacement.

Technical Depth

Depth Level:

Comprehensive - covers everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Tools:

Information on diagnostic trouble codes (DTCs) and sensor readings, implying use of scan tools.

Torque Specifications:

Detailed torque values for all fasteners and critical components.

Clearances Tolerances:

Specific engine and mechanical clearances and tolerances for assembly.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable text and clear diagrams.

Printable:

Yes, pages are printable.

Print Quality

Diagram Clarity:

Crisp, clear, and easily understandable technical drawings and schematics.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 16-valve DOHC Turbocharged

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Peak:

276 HP (206 kW) @ 6500 RPM (JDM/Euro Spec)

Torque Peak:

289 lb-ft (392 Nm) @ 3500 RPM (JDM/Euro Spec)

Redline:

7500 RPM

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

91 Octane (Premium Unleaded)

Turbocharger

Turbo Model:

Mitsubishi TD05H-16G

🔧 Transmission

Standard

Transmission Type:

6-speed Manual (RS Model)

Optional

Transmission Type:

5-speed Manual (GSR Model)

Features

AWD System:

Mitsubishi Active Yaw Control (AYC) and Active Center Differential (ACD)

Clutch Type:

Hydraulically actuated, multi-plate dry clutch

📐 Dimensions

Exterior

Length:

4420 mm (174.0 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2625 mm (103.3 in)

Weights

Curb Weight:

1450 kg (3197 lbs) - Approx.

🛡️ Safety Features

Ratings

NHTSA Rating:

Not Specifically Rated (Vehicle Class/Era)

Active Features

Yes, Anti-lock Braking System

Traction Control:

Yes, Active Traction Control (ATC)

Passive Features

Airbags:

Driver and Passenger Airbags

Seatbelts:

3-point Seatbelts with Pretensioners

💡 Technology Features

Infotainment

Head Unit:

Factory AM/FM/CD player with optional premium sound system.

Display:

Basic LCD display for clock and radio information.

Driver Assistance

Active Aero:

Active Center Differential (ACD) and Active Yaw Control (AYC) are key electronic performance aids.

Connectivity

Connectivity Options:

Limited by modern standards; primarily focused on audio playback.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months, whichever comes first (severe use).

Spark Plug Replacement:

60,000 miles

Timing Belt Replacement:

60,000 miles (or per manual recommendation, critical component)

Fluid Specifications

Engine Oil:

API SG or SH, SAE 5W-30 or 10W-30 (check manual for specific viscosity based on temperature)

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant.

Brake Fluid:

DOT 3 or DOT 4

Transmission Fluid Manual:

API GL-4, SAE 75W-85 or 75W-90 (specific Mitsubishi specs).

Transfer Case Fluid:

API GL-5, SAE 75W-90 (specific Mitsubishi specs).

Rear Differential Fluid:

API GL-5, SAE 75W-90 (specific Mitsubishi specs).

Known Issues

Engine Oil Consumption:

Some models can exhibit increased oil consumption, particularly if driven hard or poorly maintained. Monitor oil levels diligently.

Clutch Wear:

Performance driving can lead to premature clutch wear. Regular inspection and maintenance are key.

Ayc Pump Failure:

The AYC pump can fail over time, affecting the active yaw control system. Proper fluid maintenance is important.

Turbocharger Maintenance:

Requires proper warm-up and cool-down cycles to prevent premature turbo failure. Regular oil changes are critical.

📚 Vehicle History

Brand Heritage

Motorsport Roots:

Direct lineage from Mitsubishi's WRC (World Rally Championship) heritage.

Model Evolution

Evolution Series:

Eighth generation Lancer Evolution (CZ/DA chassis, CT9A platform for this model).

Previous Generation:

Lancer Evolution VII (CT9A platform introduced)

Subsequent Generation:

Lancer Evolution IX (further refinements on CT9A)

Production

Production Years:

2003-2005

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Consistently lauded by automotive publications for its handling, acceleration, and rally-inspired performance.

Enthusiast Following:

Cult following among performance car enthusiasts worldwide.

Certifications

Homologation:

Built to homologate the Lancer for WRC competition.