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Mitsubishi Lancer Evolution 2003-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Generation: VII Model Code: CT9A Year Range: 2003-2005 👋 Introduction Market Position Vehicle Segment: Performance Compact Sedan / Rally Homologation...
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类型: Car
厂商:
Mitsubishi
斯库: 363303
标签: 2003 2004 2005 Car Cars Lancer Evolution Misc Mitsubishi
Mitsubishi Lancer Evolution 2003-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Model Generation:
VII
Model Code:
CT9A
Year Range:
2003-2005
👋 Introduction
Market Position
Vehicle Segment:
Performance Compact Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, performance drivers, mechanics specializing in Japanese performance vehicles
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Honda Civic Type R (equivalent generations), Ford Focus RS (later generations)
Key Features
Legendary Engine:
4G63T - renowned for durability and tuning potential
Advanced AWD:
Super-Active Center Differential (S-AYC) and Active Center Differential (ACD) for superior traction and handling
Rally Heritage:
Directly derived from Mitsubishi's WRC-winning lineage
📋 Manual Details
Coverage Areas
Documentation Type:
Factory Service Manual
Market Focus:
North America (primarily, with global applicability for core systems)
Specific Models Covered:
Lancer Evolution VII GSR, RS (and related variants relevant to the 2003-2005 model years)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Repair and Service Manual
Manual Purpose:
Factory Authorized Repair and Service
Language
Language:
English
Format
Format:
Digital (PDF)
File Format:
PDF
Searchability:
Searchable text
Printability:
Printable pages
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63T), transmission, drivetrain (AWD systems, ACD, AYC)
Chassis:
Suspension, steering, brakes, wheels, tires
Electrical:
Wiring diagrams, ECU, sensors, lighting, accessories, audio systems
Body And Interior:
Body panels, interior trim, seats, HVAC, safety restraints
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Component removal/installation, overhaul procedures, diagnostics and troubleshooting
Diagnostics:
OBD-II codes, troubleshooting charts, electrical system diagnostics
Technical Depth
Depth Of Information:
Comprehensive: From basic fluid checks to complete engine and transmission rebuilds
Special Procedures:
ACD/AYC system calibration, differential maintenance, turbocharger service
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
DOHC Inline-4, 16-valve, Turbocharged, Intercooled
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower:
271 hp @ 6500 rpm (JDM/European spec; US spec slightly lower)
Torque:
273 lb-ft @ 3500 rpm (JDM/European spec; US spec slightly lower)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC)
Fuel Type:
Unleaded Premium (91 octane or higher recommended)
Engine Components
Turbocharger Type:
Mitsubishi TD05HR-16G6-10.5T (Twin-Scroll)
🔧 Transmission
Standard
Transmission Type:
6-speed Manual
Optional
Optional Transmission:
None (Manual was standard for Evolution models)
Features
Drivetrain:
All-Wheel Drive (AWD)
AWD System:
Active Center Differential (ACD) and Super Active Yaw Control (S-AYC)
Fluid Specifications
Manual Transmission Fluid Spec:
API GL-3 or GL-4 (specific viscosity like 75W-85 or 75W-90, check manual for exact spec)
Fluid Capacity
Manual Transmission Fluid Capacity:
~2.1 Liters
📐 Dimensions
Exterior
Length:
4400 mm
Width:
1770 mm
Height:
1415 mm
Wheelbase:
2625 mm
Weights
Curb Weight:
1400-1450 kg (depending on trim and options)
Gross Vehicle Weight:
Approximately 1840 kg
Wheels Tires
Standard Wheel Size:
17x8.0 inch
Standard Tire Size:
235/45R17
Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Center Bore:
67.1 mm
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not officially rated in all categories due to homologation nature; generally considered robust for its class.
Active Features
Active Safety Systems:
ACD, AYC, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Passive Features
Airbags:
Front driver and passenger airbags
Body Structure:
Reinforced body structure for rigidity and crash protection
Seat Belts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium audio system (e.g., Rockford Fosgate on some trims)
Display:
Basic LCD display for climate control and audio information.
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Connectivity Features:
Limited by era; primarily focused on audio input. No modern Bluetooth or USB connectivity standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750-5,000 miles or 6 months, whichever comes first (depending on driving conditions; severe use requires more frequent changes).
Major Tune Up:
Refer to manual for specific mileage intervals for spark plugs, timing belt (if applicable to this specific variant/year), and other major service items.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 or 5W-40 Synthetic (API SG, SH, SJ, SL, SM or ILSAC GF-2, GF-3, GF-4 rated) - Consult manual for exact recommendation based on climate.
Engine Oil Capacity:
~4.5 Liters (with filter change)
Coolant Spec:
Mitsubishi Super Long Life Coolant (or equivalent long-life ethylene glycol-based antifreeze/coolant)
Brake Fluid Spec:
DOT 3 or DOT 4
Power Steering Fluid Spec:
Dexron III ATF or equivalent power steering fluid
Known Issues
Common Issues:
Head gasket failures (especially on modified engines), turbocharger wear, ACD/AYC pump failures, clutch wear, rust on chassis components.
Maintenance Importance:
Crucial to follow strict maintenance schedules, particularly for oil and coolant, given the high-performance nature of the 4G63T engine.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a deep-rooted history in the World Rally Championship (WRC), with the Lancer Evolution being a dominant force for many years.
Model Evolution
Evolution Series:
The Evolution VII (CT9A) followed the highly successful Evolution VI, incorporating a new chassis and updated electronics, but retaining the iconic 4G63T engine.
Production
Production Period:
2001-2003 (for Evolution VII)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Journalism Acclaim:
Consistently praised by automotive journalists for its exceptional handling, potent powertrain, and rally-bred performance.
Iconic Status:
Recognized as a JDM icon and a benchmark for performance sedans of its era.
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