2003-2005 Mitsubishi Lancer Evolution Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: CT9A Model Years Covered: 2003, 2004, 2005 👋 Introduction Market Position Positioning: Performance rally-bred homologation special, competitor to Subaru WRX...

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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

Generation:

Model Years Covered:

2003, 2004, 2005

👋 Introduction

Market Position

Positioning:

Performance rally-bred homologation special, competitor to Subaru WRX STI

Target Audience:

Enthusiasts, tuners, owners seeking to maintain or repair their Evolution

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer (standard variants)

Key Features

Driving Dynamics:

Advanced all-wheel-drive system (Super All-Wheel Control - S-AWC), sophisticated suspension, powerful turbocharged engine

Performance Focus:

Designed for high-performance driving, rally heritage

Manual Utility:

Provides essential information for DIY maintenance and repair, crucial for owning a complex performance vehicle

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive A-Z repair procedures

Specific Models Covered:

Lancer Evolution (GSR, MR, RS variants likely included)

Page Count

Estimated Page Count:

High volume, likely 1000+ pages (typical for full workshop manuals)

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63T (2.0L DOHC MIVEC Turbocharged I4), including diagnostics, rebuild, tuning

Engine Management:

ECU diagnostics, sensors, actuators, emissions control systems

Fuel System:

Fuel injection, fuel pump, injectors, fuel pressure regulator, tank and lines

Cooling System:

Radiator, water pump, thermostat, hoses, fan assembly

Lubrication System:

Oil pump, oil filter, oil cooler, lubrication passages

Transmission:

6-speed manual (Getrag Type), including clutch, gearbox, transfer case, driveline

Drivetrain:

Front differential, rear differential (Active YAW Control - AYC system for higher trims)

Suspension:

Front struts, rear shocks, control arms, anti-roll bars, bushings, springs

Steering:

Power steering system, steering rack, steering column

Brakes:

Front Brembo calipers (standard on many models), rear calipers, ABS system, brake lines, parking brake

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays

Lighting:

Headlights, taillights, interior lighting, bulb specifications

HVAC:

Air conditioning system, heater, blower motor, climate control unit

Body And Frame:

Body panels, doors, hoods, fenders, chassis, rust prevention

Interior:

Seats, dashboard, trim panels, airbags

Safety Systems:

Airbag system, seat belt mechanisms, structural safety analysis

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, timing belt inspection/replacement (if applicable to 4G63T variant)

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, error code interpretation

Component Replacement:

Engine, transmission, brakes, suspension components, turbocharger, intercooler

Rebuilding Procedures:

Engine rebuild, transmission rebuild, differential rebuild

Alignment And Balancing:

Wheel alignment specifications, tire balancing

Electrical Diagnostics:

Wiring harness repair, connector diagnostics, component testing

Body Repair:

Panel replacement, dent repair, frame straightening procedures

Technical Depth

Depth:

Detailed, from basic fluid changes to complete engine and transmission overhauls

Diagnostic Tools:

Information on using OBD-II scanners and specific Mitsubishi diagnostic tools

Torque Specifications:

Comprehensive torque values for all fasteners

Clearances And Tolerances:

Engine component clearances, bearing tolerances, etc.

Wiring Diagrams:

Full electrical schematics for all systems

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable PDF

Print Quality

Image Quality:

High Quality Photos, Illustrations And Diagrams (as per description)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

2.0L Inline 4-cylinder, DOHC, 16-valve, Turbocharged, Intercooled

Mivec:

Yes (Mitsubishi Innovative Valve timing Electronic Control)

Performance

Horsepower:

Approximately 270-280 HP (depending on market and specific trim)

Torque:

Approximately 280-290 lb-ft (depending on market and specific trim)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Management

ECU Type:

Engine Control Unit (ECU) with integrated boost control

Forced Induction

Turbocharger:

Mitsubishi TD05HRA-15G or similar (specific model may vary)

Intercooler:

Front-mounted air-to-air intercooler

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Transmission Model:

Getrag Type (F5M51 or similar robust variant)

Optional

Optional Transmission:

N/A (Manual transmission was standard for Evolution models)

Features

Driveline Layout:

All-Wheel Drive (AWD)

Active Yaw Control:

Included on GSR and MR trims, enhancing cornering stability and torque vectoring

Fluid Specifications

Manual Transmission Fluid:

Refer to manual for specific API GL-4/GL-5 gear oil, typically 75W-90 or 75W-85

Transfer Case Fluid:

Refer to manual for specific type (likely same as transmission fluid or a dedicated AWD fluid)

Rear Differential Fluid:

Refer to manual for specific type (e.g., API GL-5 75W-90)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2625 mm (103.3 inches)

Length:

Approx. 4490 mm (176.8 inches)

Width:

Approx. 1770 mm (69.7 inches)

Height:

Approx. 1415 mm (55.7 inches)

Weights

Curb Weight:

Approx. 1450-1500 kg (3197-3307 lbs) depending on trim

Gross Vehicle Weight Rating:

Refer to vehicle placard

Wheels Tires

Standard Wheel Size:

17x8 inches

Standard Tire Size:

235/45R17

Bolt Pattern:

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

🛡️ Safety Features

Ratings

NHTSA Ratings:

Variable by year/test; generally good frontal and side impact protection for its era

Active Features

Yes, Anti-lock Braking System

Yes, S-AWC (Super All-Wheel Control) with Active Yaw Control (AYC)

Traction Control:

Yes, Active Traction Control (TCL)

Electronic Stability Control:

Yes, Active Stability Control (ASC)

Passive Features

Airbags:

Frontal airbags, side airbags (standard on some trims)

Seatbelts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts

Body Structure:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, premium audio options may exist (e.g., Rockford Fosgate)

Driver Assistance

Active Safety Systems:

S-AWC, AYC, ASC, TCL contribute significantly to driver confidence and safety

Connectivity

Connectivity Options:

Limited by era; typically only basic audio input (e.g., auxiliary jack might be present on later models)

Performance Monitoring

Gauge Cluster:

Includes boost gauge, G-meter (on some trims), and essential performance readouts

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-7,500 miles or 6 months, whichever comes first (severe use may require shorter intervals)

Timing Belt Interval:

Refer to manual, usually around 60,000-100,000 miles or 5-7 years. Crucial for the 4G63T engine.

Spark Plug Interval:

Typically 60,000 miles for iridium plugs

Fluid Specifications

Engine Oil Type:

5W-30 or 10W-30 Synthetic (refer to manual for specific API and ACEA classifications)

Engine Oil Capacity:

Approx. 4.5-5.0 Liters (with filter)

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent G12/G12+ rated coolant)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine Wear:

Ringland failure on early 4G63T engines under extreme stress, rod bearing wear

Turbocharger:

Turbo seal leaks leading to oil consumption, wastegate actuator issues

Clutch Wear:

High-performance clutch can wear faster with aggressive driving

Ayc Pump:

AYC pump failure or leaks on AYC-equipped models

Electronics:

Occasional issues with ABS sensors, SRS warning lights

📚 Vehicle History

Brand Heritage

Heritage:

Mitsubishi's strong motorsport heritage, particularly in World Rally Championship (WRC)

Model Evolution

Evolution Series:

Part of the legendary Lancer Evolution lineage, known for its rally-inspired technology and performance

Eighth Generation:

This generation (CT9A) marked significant aerodynamic and chassis improvements over the previous VII generation

Production

Production Period:

2003-2007 for CT9A chassis (with minor updates between years)

Production Location

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Automotive Press Acclaim:

Consistently praised by automotive journalists for its handling, performance, and rally-bred capabilities

Ratings

Handling Scores:

Top marks for grip, steering feedback, and track performance in its class

Certifications

Homologation:

Developed to meet WRC homologation requirements, influencing its design and performance tuning