Market Segment:
Performance Compact / Rally Homologation Special
Competitors:
Subaru WRX STI, Mitsubishi Lancer Evolution (previous generations), other high-performance turbocharged sedans of the era.
Vehicle Strengths:
Legendary all-wheel-drive system (S-AWC), powerful turbocharged engine, advanced suspension and differential technology, high performance on various terrains.
Benefits For Owner:
Empowers owners with the knowledge to perform maintenance, diagnose issues, and undertake repairs themselves, saving on labor costs and ensuring proper vehicle upkeep. Essential for enthusiasts looking to modify or maintain their Evo.
Systems Covered:
Engine, Engine Lubrication, Fuel System, Engine Cooling, Intake & Exhaust, Engine & Emission Control, Clutch, Manual Transaxle, Propeller Shaft, Front Axle, Rear Axle, Wheel & Tire, Power Plant Mount, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering, Body, Exterior, Interior, Supplemental Restraint System (SRS), Chassis Electrical, HVAC, Electrical Wiring, Body Repair, and more.
Estimated Page Count:
Extensive (specific number not provided, but implies comprehensive coverage)
Manual Type:
Factory Service Repair Workshop Manual
Operating Systems:
Compatible with all versions of Windows and Mac operating systems.
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of all engine components including cylinder block, cylinder head, crankshaft, pistons, connecting rods, camshafts, valves, and timing components.
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system, emission control systems, and sensor diagnostics.
Drivetrain:
Clutch operation, manual transaxle (gearbox) disassembly and repair, propeller shaft (driveshaft) maintenance, front and rear axle servicing, differential inspection, and wheel bearing replacement.
Suspension Steering:
Front and rear suspension component inspection and replacement (struts, shock absorbers, control arms, bushings), steering system diagnostics and repair, power steering system.
Brakes:
Service brake system (hydraulic components, ABS, brake pads, rotors, calipers), parking brake system.
Body Interior:
Exterior panel removal and installation, interior trim component servicing, door mechanisms, glass replacement, seat adjustments, and SRS (Supplemental Restraint System) components.
HVAC Electrical:
Heating, ventilation, and air conditioning (HVAC) system troubleshooting and repair, chassis electrical systems, lighting, instrumentation, body control modules, and electrical wiring diagrams.
Maintenance:
Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation, step-by-step troubleshooting guides.
Repair:
Detailed repair procedures for all major mechanical and electrical systems, including engine rebuilds, transmission overhauls, suspension upgrades, and bodywork.
Diagnostics:
Comprehensive diagnostic strategies, use of diagnostic tools, sensor data analysis, and electrical system testing.
Engine Rebuild Procedures:
Detailed instructions for complete engine disassembly, inspection of components (e.g., ring gap, bearing clearance), and reassembly of the 4G63 engine.
Body Repair Guidelines:
Includes procedures for body panel alignment, dent repair, rust prevention, and structural component inspection.
Depth Of Information:
Factory-level technical information covering everything from routine maintenance to complete vehicle disassembly and reassembly. Includes detailed torque specifications, diagnostic procedures, and component tolerances.
Torque Specifications:
Includes precise torque values for all critical fasteners across various systems (engine, chassis, suspension, brakes).
Electrical Diagrams:
Comprehensive electrical wiring diagrams for all vehicle circuits, aiding in diagnosis and repair of electrical faults.
NHTSA Rating:
Not directly comparable to modern testing, but built with a robust chassis.
Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS), Active Center Differential (ACD), Super Active Yaw Control (S-AWC).
Passive Safety:
Front airbags, side airbags (optional/trim dependent), reinforced chassis, three-point seat belts with pretensioners, impact-absorbing steering column.
Oil Change Interval:
Typically every 3,750 to 5,000 miles (6,000 to 8,000 km) or 6 months, depending on driving conditions. Refer to manual for exact schedule.
Timing Belt Interval:
Refer to manual; typically around 60,000-100,000 miles, but highly dependent on engine condition and driving style. Crucial replacement item.
Engine Oil Type:
SAE 5W-30 or 0W-30, API SG, SH, or SJ, ILSAC GF-2 or GF-3 (refer to manual for precise specifications and approvals).
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent green ethylene glycol based coolant).
Transmission Fluid Type:
Gear oil for manual transmission: API GL-3 or GL-4, SAE 75W-85 or 75W-90 (specific Mitsubishi part numbers recommended).
Differential Fluid Type:
API GL-5, SAE 80W-90 (for front and rear differentials). ACD and AYC units have specific fluid requirements.
Common Wear Items:
Clutch wear, turbocharger issues (if neglected or poorly maintained), fuel pump failures, front differential wear (especially with hard use), engine seal leaks.
Performance Tuning Risks:
Improper tuning can lead to engine detonation, connecting rod failure ('bent rods'), and turbocharger damage. Manual emphasizes factory specifications.
Motorsport Roots:
Direct lineage from Mitsubishi's legendary WRC (World Rally Championship) Lancer Evolution models, renowned for their rally-bred performance and durability.
Evolution Ix Distinction:
The Evolution IX represented a significant upgrade with the introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control system) on the intake camshaft, improved turbocharger (often 'super-back' turbo for quicker spool), and revised aerodynamic enhancements.
Production Years:
2005-2006 (for the Evo IX generation)
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
