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Mitsubishi Lancer Evo 9 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Year: 2005 Codes Chassis Code: CT9A 👋 Introduction Market Position Positioning: Performance icon, rallying pedigree, enthusiast-focused, limited production halo car...
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Mitsubishi Lancer Evo 9 2005 Service Repair ManualMitsubishi Lancer Evo 9 2005 Service Repair ManualMitsubishi Lancer Evo 9 2005 Service Repair ManualMitsubishi Lancer Evo 9 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Year:
2005
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Positioning:
Performance icon, rallying pedigree, enthusiast-focused, limited production halo car
Competitive Analysis
Competitors:
Subaru WRX STI, Mitsubishi Lancer Evolution VIII, other high-performance AWD sedans of the era
Key Features
Performance Highlights:
Advanced Symmetrical All-Wheel Drive (AWC) with Active Yaw Control (AYC) and Active Center Differential (ACD), potent turbocharged engine, robust chassis, rally-bred heritage
Target Audience:
Enthusiasts, DIY mechanics, tuners, and owners seeking in-depth knowledge for maintenance and performance modifications
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete factory service and repair for the Mitsubishi Lancer Evolution IX (2005 model year)
Regional Variants:
Covers specifications and procedures relevant to global models, with potential variations for specific markets (e.g., JDM, USDM, European)
Page Count
Estimated Page Count:
Refer to product listing for exact count, typically comprehensive covering all systems (e.g., 1000+ pages)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) or Printed (confirm with seller)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, lubrication, cooling system, fuel system, exhaust system, engine management (ECU, sensors, actuators)
Engine Performance:
Variable Valve Timing (MIVEC), turbocharger system, intercooler, emissions control
Transmission:
Manual transmission (Getrag 6-speed), clutch system, drivetrain components (transfer case, driveshafts, differentials)
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, wheel bearings, alignment specifications
Brakes:
Front and rear brake systems (performance braking often Brembo or similar), ABS, EBD, brake fluid specifications, caliper and rotor service
Steering:
Power steering system, steering rack, tie rods, steering column, alignment
Electrical:
Wiring diagrams, battery, alternator, starter motor, ignition system, lighting, fuse box layouts, common electrical faults, diagnostic codes (OBD-II)
Body And Chassis:
Body panel removal/installation, interior trim, chassis components, structural repair basics, glass replacement
HVAC:
Heating, Ventilation, and Air Conditioning system service and repair
Driver Controls:
Pedals, steering wheel, gear shifter, dashboard controls
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, spark plug service, belt replacement
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides
Repair:
Step-by-step repair instructions for all major components and systems
Disassembly Reassembly:
Detailed instructions for dismantling and reassembling engines, transmissions, and other major assemblies
Diagnosis:
Diagnostic trouble code (DTC) interpretation, sensor testing, circuit testing
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures
📊 Manual Specifications
File Format
Digital Format:
PDF (typically high-resolution, searchable text, printable)
Print Quality
Quality:
Professionally produced, with clear text and high-quality diagrams/illustrations
Binding Type
Printed Binding:
Spiral-bound or perfect-bound for durability and ease of use (if printed)
Paper Type
Printed Paper:
Durable paper stock, resistant to shop grime (if printed)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
2.0L Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1 (typical for Evo IX)
Displacement:
1997 cc
Performance
Horsepower:
287 hp @ 6500 rpm (JDM/USDM variants)
Torque:
289 lb-ft @ 3500 rpm (JDM/USDM variants)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, premium octane recommended (91+)
Turbocharger:
Mitsubishi TD05HR-16G 8.5cm2 (or similar variant)
Engine Management
ECU Type:
ECU (Engine Control Unit) with specific programming for performance and emissions
🔧 Transmission
Standard
Type:
Getrag 6-speed manual transaxle
Optional
Type:
No automatic transmission offered for Evo IX
Features
Drivetrain:
Symmetrical All-Wheel Drive (AWC) with Active Yaw Control (AYC) and Active Center Differential (ACD)
Drivetrain Controls
Acd Modes:
Manual modes for ACD (Tarmac, Gravel, Snow) selectable by driver
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 gear oil, typically with limited-slip differential additive requirements. Example: Mitsubishi Genuine Gear Oil, Red Line GL-4, Motul Gear 300.
Fluid Capacities
Manual Transmission Capacity:
Refer to manual, approximately 2.2 - 2.5 liters
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2635 mm (103.7 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs), depending on trim and options
Gross Vehicle Weight Rating:
Refer to vehicle placard
🛡️ Safety Features
Ratings
NHTSA Rating:
Not consistently rated by NHTSA for early models; later models generally perform well but specific ratings may vary by market and test year.
Active Features
ABS:
Anti-lock Braking System (ABS)
Ebd:
Electronic Brakeforce Distribution (EBD)
Traction Control:
Traction Control System (TCS)
Passive Features
Airbags:
Driver and passenger front airbags, often side airbags depending on market and trim
Seatbelts:
Three-point seatbelts with pretensioners
Chassis Structure:
Reinforced chassis and body structure for occupant protection
💡 Technology Features
Infotainment
Audio System:
Typically a factory AM/FM/CD stereo system with basic speaker configuration. Aftermarket upgrades are common.
Dashboard Display:
Analog gauges for speed, tachometer, fuel, and temperature. Includes warning lights and basic driver information.
Driver Assistance
AWD System:
Advanced Symmetrical All-Wheel Drive with ACD and AYC is the primary driver assistance/performance technology.
Connectivity
Connectivity Features:
Limited by modern standards. Basic power outlets for charging devices. No integrated Bluetooth or navigation typically from factory.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000 miles or 6 months, whichever comes first (refer to manual for specific recommendations based on driving conditions)
Spark Plugs:
Typically around 60,000 miles for performance spark plugs (refer to manual for correct type and gap)
Timing Belt:
The 4G63T uses a timing belt, replacement typically around 90,000 - 105,000 miles. Crucial to maintain for engine integrity.
Fluid Specifications
Engine Oil:
Refer to manual. Typically 5W-30 or 10W-30 synthetic oil. Example: Mobil 1 5W-30, Castrol Edge 5W-30.
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent (50/50 mix with distilled water)
Fluid Capacities
Engine Oil Capacity:
Approx. 4.5 - 5.0 liters (with filter)
Coolant Capacity:
Approx. 6.5 - 7.0 liters
Known Issues
Engine Oil Consumption:
Some 4G63T engines can consume oil, especially when driven hard or if maintenance is neglected. Regular checks are vital.
Turbo Failure:
Can occur due to oil starvation, heat soak, or improper shutdown procedures. Regular oil changes and cool-down periods are recommended.
Clutch Wear:
As with any performance vehicle, clutch wear can be accelerated with aggressive driving. The manual will detail clutch inspection and replacement.
Acd Pump Failure:
The ACD pump and its associated sensors can sometimes fail, leading to loss of AWD functionality or incorrect behavior. The manual covers diagnostics.
Rod Knock:
A potential catastrophic failure in high-mileage or heavily modified engines. Proper lubrication and avoidance of over-revving are key. The manual outlines engine assembly and tolerances.
📚 Vehicle History
Brand Heritage
Rally Connection:
Direct lineage from Mitsubishi's successful World Rally Championship (WRC) cars
Model Evolution
Evo Ix Introduction:
Introduced in 2005 as an update to the Evolution VIII, featuring an aluminum cylinder head, MIVEC variable valve timing, and a larger turbocharger for increased power and efficiency.
Production
Production Period:
2005-2007 (Lancer Evolution IX generation)
Production Locations
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Rally Dominance:
The Lancer Evolution series, including the Evo IX, is renowned for its dominance in motorsport, particularly WRC.
Enthusiast Appreciation:
Consistently ranked among the best performance cars of its era by automotive publications and enthusiasts for its handling, acceleration, and driver engagement.
Tuning Platform:
Highly regarded as a platform for tuning and performance modification, with a vast aftermarket support ecosystem.
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