2003-2005 Mitsubishi Lancer Evolution Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (Evo VII-IX) Generation: Eighth Generation (Evo VII-IX) Model Years Covered: 2003, 2004, 2005 👋 Introduction Market Position Segment:...

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标签: 2003 2004 2005 Car Cars Lancer Evolution Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Model Code:

CT9A (Evo VII-IX)

Generation:

Eighth Generation (Evo VII-IX)

Model Years Covered:

2003, 2004, 2005

👋 Introduction

Market Position

Segment:

Performance Compact Sedan / Rally Homologation Special

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS

Key Features

Powertrain:

Advanced All-Wheel Drive (AWD) system (S-AYC), turbocharged engine

Performance:

Renowned for rally racing heritage and exceptional handling

Tuning Potential:

High potential for aftermarket modification and performance tuning

📋 Manual Details

Coverage Areas

Engine Mechanical:

Engine Performance:

Fuel System:

Emission Control:

Transmission Manual:

Transmission Automatic:

Yes (if applicable to specific models covered)

Transfer Case:

Drivetrain AWD:

Suspension Front:

Suspension Rear:

Steering:

Brakes Hydraulic:

Brakes Parking:

Wheels Tires:

Body Exterior:

Body Interior:

HVAC Climate Control:

Electrical System Lighting:

Electrical System Instruments:

Electrical System Power Accessories:

Audio Entertainment:

Security Alarm Immobilizer:

Driver Assistance Systems:

Troubleshooting Diagnostics:

Wiring Diagrams:

Torque Specifications:

Maintenance Procedures:

Repair Procedures:

Disassembly Assembly:

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Repair Manual (FSM)

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

All Major Systems:

Comprehensive coverage of all major vehicle systems

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, tune-ups

Diagnostics:

Systematic troubleshooting guides, fault code interpretation, diagnostic tool usage

Repair:

Detailed step-by-step repair instructions for all major components

Rebuilds:

Engine, transmission, and differential rebuild procedures

Adjustment Calibration:

Alignment, sensor calibration, clutch adjustment

Technical Depth

Depth:

Factory-level detail suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Codes:

Includes specific OBD-II diagnostic trouble codes (DTCs) and their meanings

Electrical Troubleshooting:

In-depth electrical troubleshooting utilizing wiring diagrams and component testing

📊 Manual Specifications

File Format

Searchable:

Yes (typically searchable PDF)

Printable:

Print Quality

Quality:

High-resolution, clear text and diagrams

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T (various iterations)

Engine Type:

Inline-4, DOHC, 16-valve, Turbocharged & Intercooled

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Range:

Approx. 271 hp to 286 hp (depending on specific Evo VII, VIII, IX model and market)

Torque Range:

Approx. 273 lb-ft to 289 lb-ft (depending on specific Evo VII, VIII, IX model and market)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Multi-Port Fuel Injection (MPFI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Turbocharger

Turbo Model:

Mitsubishi Heavy Industries (MHI) TD04-15G, TD05-16G, or similar, depending on variant

🔧 Transmission

Standard

Type:

6-Speed Manual Transmission (Getrag MSF-100)

Optional

Type:

No Automatic Transmission option for these performance-oriented models

Features

Drivetrain:

Advanced Symmetrical All-Wheel Drive (AWD) with Active Center Differential (ACD)

Torque Vectoring:

Super Active Yaw Control (S-AYC) rear differential on many models

📐 Dimensions

Exterior

Length:

Approx. 4,490 mm (176.8 in)

Width:

Approx. 1,770 mm (69.7 in)

Height:

Approx. 1,415 mm (55.7 in)

Wheelbase:

Approx. 2,630 mm (103.5 in)

Weights

Curb Weight Range:

Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Wheel Size:

Typically 17x8.0 or 18x8.5 inches

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-Star (for similar models of the era, specific ratings may vary by year and test)

IIHS Side Impact:

Good (for similar models of the era, specific ratings may vary by year and test)

Active Features

Yes, with EBD (Electronic Brakeforce Distribution)

Traction Control:

Yes (Active Traction Control - ATC)

Electronic Stability Control:

Yes (Active Stability Control - ASC)

Passive Features

Airbags Driver:

Airbags Passenger:

Seatbelts:

3-point front and rear seatbelts with pretensioners

Body Structure:

Reinforced body structure for enhanced impact protection

💡 Technology Features

Infotainment

Head Unit:

Factory CD Player with AM/FM Radio, some models may have upgraded Rockford Fosgate audio systems.

Navigation:

Optional GPS Navigation system available on some higher trims.

Driver Assistance

All Wheel Drive System:

Advanced AWD with ACD and S-AYC offering selectable modes (Tarmac, Gravel, Snow)

Performance Controls:

Driver-selectable ACD modes, ACD/AYC status indicators

Connectivity

Auxiliary Input:

Some models may feature an auxiliary audio input jack.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe use)

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Spark Plugs:

Every 30,000 miles (48,000 km) (Platinum or Iridium recommended)

Timing Belt:

Every 60,000 miles (96,000 km) or 5 years (CRITICAL for 4G63T)

Fluid Specifications

Engine Oil:

API SN/SM/SL, ACEA A3/B4, Viscosity: 5W-30 or 0W-30 (check owner's manual for specific recommendations, high-performance synthetic recommended)

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix)

Transmission Fluid Mt:

GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)

Transfer Case Fluid:

GL-4 (75W-85W or 75W-90) API SG or higher (e.g., DiaQueen LSD Gear Oil)

Rear Differential Fluid Lsd:

GL-5 (75W-90 or 80W-90) API GL-5 compliant with LSD additive (e.g., DiaQueen LSD Gear Oil)

Brake Fluid:

DOT 3 or DOT 4

Known Issues

Engine Reliability:

4G63T engine generally robust, but can suffer from rod bearing failure under high load/poor maintenance. Turbocharger lifespan can be affected by oil quality and heat cycling.

Drivetrain Wear:

S-AYC system can develop issues; ACD pump can fail. Clutch wear is normal for spirited driving.

Rust Corrosion:

Can be prone to rust, especially around wheel wells and sills, if not properly maintained or living in corrosive environments.

Suspension Components:

Bushings and ball joints can wear over time, leading to imprecise handling.

📚 Vehicle History

Brand Heritage

Motorsport Roots:

Direct lineage from Mitsubishi's successful WRC (World Rally Championship) program

Model Evolution

Eighth Generation:

Built on the Lancer Cedia platform, significantly re-engineered for performance

Evo Vii:

Introduction of Active Center Differential (ACD) and Active Yaw Control (AYC) integration

Evo Viii:

Improved turbocharger, stronger engine internals, revised suspension geometry, option of 'SSL' package

Evo Ix:

Introduction of MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system for improved power and efficiency, updated turbocharger (IX MR featured twin-scroll turbo)

Production

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Years:

2001-2007 (Evo VII: 2001-2003, Evo VIII: 2003-2005, Evo IX: 2005-2007)

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

Eighth generation Lancer Evolution models were frequently recognized on Car and Driver's '10Best' lists.

Enthusiast Following:

Cult following among automotive enthusiasts for its performance and rally heritage.