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Mitsubishi Lancer Evolution 2003-2005 Service Repair Workshop Manual (2003 2004 2005)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A Model Generation: Seventh Generation (CT9A) Codes Chassis Code: CT9A Engine Code Primary: 4G63 (2.0L Turbocharged) 👋 Introduction Market...
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Sku: 307938
Mitsubishi Lancer Evolution 2003-2005 Service Repair Workshop Manual (2003 2004 2005)
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Code:
CT9A
Model Generation:
Seventh Generation (CT9A)
Codes
Chassis Code:
CT9A
Engine Code Primary:
4G63 (2.0L Turbocharged)
👋 Introduction
Market Position
Positioning:
The Lancer Evolution (Evo) of this era established itself as a dominant force in rally-inspired performance sedans, blending potent turbocharged power with advanced all-wheel-drive technology.
Target Audience:
Enthusiasts, tuners, and owners seeking in-depth knowledge for maintenance, repair, and modification of their Lancer Evolution.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (lower spec), performance variants of other compact sedans (e.g., BMW 3 Series, Audi A4)
Key Features Vehicle
Performance Focus:
Legendary turbocharged engine, sophisticated AWD systems, and agile handling.
Key Features Manual
Completeness:
Provides the definitive factory-level repair information required for professional servicing and DIY enthusiasts alike.
Diagrams:
Features high-quality, detailed diagrams that illustrate complex procedures and component locations.
📋 Manual Details
Coverage Areas
Years Covered:
2003, 2004, 2005
Regions Covered:
Global (primarily focused on JDM/USDM specifications for the applicable years)
Trim Levels Covered:
GSR, RS, MR (where applicable to the CT9A platform)
Page Count
Approximate Pages:
1000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63 MIVEC), Transmission (Manual and SST - where applicable), Drivetrain (AYC, ACD, DCCD), Fuel System, Exhaust System
Chassis:
Suspension (Front/Rear), Steering, Brakes (ABS, Brembo), Wheels and Tires
Body:
Body Exterior, Interior Trim, Doors, Hood, Trunk, Bumpers, Glass
Electrical:
Wiring Diagrams, Lighting, Instruments, Audio, HVAC Control, Power Accessories, ECUs (Engine Control Unit, Transmission Control Unit, ABS Control Unit, etc.)
Comfort And Convenience:
HVAC System, Power Windows, Power Locks, Cruise Control, Keyless Entry
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Diagnostics:
Troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation, symptom-based diagnostics
Repair:
Component removal and installation, assembly and disassembly procedures, torque specifications
Overhaul:
Engine overhaul, transmission rebuild, differential servicing
Alignment:
Wheel alignment specifications and procedures
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typically OCR'd for easy searching)
Print Quality
Image Resolution:
High (clear diagrams and photos)
Text Clarity:
Excellent
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
4G63T (2.0L Inline-4 DOHC 16-valve)
Engine Displacement:
1997 cc (2.0 Liters)
Engine Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
Aspiration:
Turbocharged and Intercooled
Valve Train:
DOHC (Double Overhead Camshafts), MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on later models/specific tunes.
Performance
Horsepower Est Jdm:
280 PS (approx. 276 bhp)
Torque Est Jdm:
343 Nm (approx. 253 lb-ft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane recommended)
Fuel Pump Type:
In-tank electric fuel pump
Technical Details
Ignition System:
Electronic Ignition (Coil-on-Plug)
Cooling System:
Pressurized liquid cooling system with thermostat and electric fan.
🔧 Transmission
Standard
Type:
Getrag KM-132N 5-Speed Manual Transmission
Optional
Type:
Not typically offered on this generation, but later Evolutions had SST (Sports Shift Transmission).
Features
Gear Ratios Manual:
Refer to manual for specific ratios (varies by model/region, e.g., 1st: 3.083, 2nd: 2.056, 3rd: 1.545, 4th: 1.133, 5th: 0.914)
Clutch Type:
Hydraulically operated, single-plate, dry-type clutch
Fluid Specifications
Manual Transmission Fluid:
GL-4 SAE 75W-90 (Mitsubishi Genuine Gear Oil or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 inches)
Width:
Approx. 1770 mm (69.7 inches)
Height:
Approx. 1415 mm (55.7 inches)
Wheelbase:
Approx. 2630 mm (103.5 inches)
Weights
Curb Weight Est:
Approx. 1450-1500 kg (3197-3307 lbs) depending on trim
Gross Vehicle Weight Rating Est:
Refer to vehicle placard
🛡️ Safety Features
Ratings
NHTSA Rating Est:
Not consistently rated for this specific period and model variant globally. Often based on individual market testing.
IIHS Rating Est:
Not consistently rated for this specific period and model variant globally.
Active Features
AWD System:
Super Active Yaw Control (S-AYC), Active Center Differential (ACD), optional electronically controlled all-wheel-drive (DCCD - Driver Controlled Center Coupling on some trims).
Braking System:
Four-wheel Anti-lock Braking System (ABS), front and rear ventilated discs (often Brembo on performance trims).
Passive Features
Airbags:
Front airbags (driver and passenger), optional side airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners and load limiters.
Body Structure:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player, often with premium audio options (e.g., Rockford Fosgate).
Climate Control:
Manual or Automatic Climate Control depending on trim.
Driver Assistance
Traction Control:
Standard traction control system (TCL) in conjunction with AWD.
Stability Control:
Not commonly featured on this specific generation, focus was on mechanical grip and AWD sophistication.
Connectivity
Cruise Control:
Standard on most models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions. Refer to manual for exact recommendation.
Spark Plug Replacement Interval:
Around 60,000 miles (100,000 km) for iridium plugs, earlier for other types. Consult manual.
Timing Belt Replacement Interval:
Approximately 60,000-100,000 miles (100,000-160,000 km) or based on time. Crucial for the 4G63 engine.
Fluid Specifications
Engine Oil Type:
API SG or SH, ACEA A2 or A3, SAE 10W-30 or 10W-40 (or 5W-30 for cold climates). Refer to manual for exact specification.
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent (typically ethylene glycol-based, pink/red color).
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
ATF DEXRON II or III (consult manual for specific type)
Transfer Case Fluid Type:
Gear Oil API GL-5 SAE 75W-90
Rear Differential Fluid Type:
Gear Oil API GL-5 SAE 80W-90 (or 75W-90)
Known Issues
Engine:
Timing belt failure (if not replaced on schedule), turbocharger wear, piston ring issues (especially with high mileage or aggressive tuning), spark plug blow-out on early models with non-recessed plugs.
Drivetrain:
AYC/ACD pump failure, differential wear (especially with abuse), manual transmission synchro wear.
Suspension:
Worn bushings, strut mounts, ball joints due to performance driving.
Electrical:
Fuel pump relay issues, occasional ECU sensor failures.
📚 Vehicle History
Brand Heritage
Rally Roots:
Mitsubishi's extensive and successful history in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution.
Model Evolution
Ct9A Introduction:
The CT9A platform, introduced in 2001 for the Japanese market, represented a significant evolution in chassis rigidity and aerodynamic refinement.
Evo Vii To Viii Transition:
The 2003 model year marked the transition from the Lancer Evolution VII to the Lancer Evolution VIII, with key updates to the drivetrain and styling.
Production
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Years For Ct9A:
2001-2007 (with various updates and sub-models within this period)
🏆 Awards & Recognition
Recognitions
Motorsport Success:
Numerous rally victories and championships, a testament to its engineering.
Automotive Press Awards:
Consistently praised by automotive journalists for its performance, handling, and value proposition in the sports sedan segment.
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