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Mitsubishi Evolution IX 2005-2008 Service Repair Manual

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The Mitsubishi Lancer Evolution IX, chassis code CT9A, represents a pinnacle of performance engineering, produced from 2005 to 2007. This iconic model, a homologation special with deep rallying roots, is...
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Mitsubishi Evolution IX 2005-2008 Service Repair ManualMitsubishi Evolution IX 2005-2008 Service Repair ManualMitsubishi Evolution IX 2005-2008 Service Repair ManualMitsubishi Evolution IX 2005-2008 Service Repair Manual
The Mitsubishi Lancer Evolution IX, chassis code CT9A, represents a pinnacle of performance engineering, produced from 2005 to 2007. This iconic model, a homologation special with deep rallying roots, is renowned for its potent 4G63T 2.0-liter turbocharged inline-4 engine featuring MIVEC technology, coupled with an advanced All-Wheel Control (AWC) system that includes Active Center Differential (ACD) and Super Active Yaw Control (Super AYC). Its reinforced chassis, performance-tuned suspension, and aggressive aerodynamic enhancements, often complemented by Brembo brakes, deliver exceptional handling and driving dynamics, solidifying its reputation as a formidable machine for both spirited road use and track performance. This comprehensive Factory Service Repair Manual provides detailed guidance for the Lancer Evolution IX, covering a wide array of systems and procedures. It encompasses in-depth information on engine mechanicals, including the 4G63T MIVEC, as well as engine management, manual transmissions (5-speed and 6-speed), the sophisticated AWC system, suspension, brakes, steering, and the complete electrical system. The manual details routine maintenance, troubleshooting, diagnostic procedures, component removal and installation, engine and transmission overhauls, and necessary calibration adjustments. With high-resolution diagrams and precise technical data, this resource is an essential tool for owners, mechanics, and technicians to ensure the optimal maintenance, repair, and longevity of their Lancer Evolution IX.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Chassis Code:
CT9A
Codes
Engine Code Primary:
4G63T (MIVEC)
Transmission Codes:
F5M33 (5-speed manual), RM01A (6-speed manual - JDM RS/MR)
Awc System Code:
Super Active Yaw Control (Super AYC)
👋 Introduction
Market Position
Market Segment:
Performance Compact Sedan / Rally Homologation Special
Reputation:
Iconic, homologation special revered for its rallying pedigree and driving dynamics.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (later generations).
Key Features
Powertrain:
Legendary 4G63T 2.0L turbocharged inline-4 engine with MIVEC.
Drivetrain:
Advanced All-Wheel Control (AWC) system with Active Center Differential (ACD) and Super Active Yaw Control (Super AYC).
Chassis:
Reinforced chassis derived from rally competition, performance-tuned suspension.
Aerodynamics:
Aggressive body kit including large rear wing, front splitter, and vented hood.
Braking System:
Often equipped with high-performance Brembo brakes.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual (Workshop Manual)
Language:
English
Format:
PDF Download
Page Count:
Hundreds (estimated 1500+ pages for comprehensive factory manual)
Source:
Official Mitsubishi Factory Documentation
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, assembly, inspection, and overhaul procedures for the 4G63T MIVEC engine.
Engine Management:
Fuel injection, ignition system, emissions control, turbocharging system, MIVEC operation, ECU diagnosis.
Transmission Manual:
Service and repair of 5-speed and 6-speed manual transmissions, including clutch system.
Transmission AWD:
Operation and service of the All-Wheel Control (AWC) system, including Super AYC and ACD (Active Center Differential).
Suspension:
Front and rear suspension components, geometry, alignment, shock absorbers, springs, bushings.
Brakes:
Brake system components (Brembo on many models), hydraulic system, ABS, rotor and pad replacement.
Steering:
Power steering system, steering rack, column, and linkage.
Electrical System:
Wiring diagrams, battery, alternator, starter, lighting, power windows, central locking, audio system.
Body Exterior:
Body panel repair, door mechanisms, glass replacement, aerodynamic components.
Body Interior:
Interior trim, seats, dashboard, HVAC system, airbags.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections.
Troubleshooting Diagnostics:
System-specific diagnostic procedures, common fault identification, OBD-II code interpretation.
Component Removal Installation:
Detailed step-by-step guides for removing and installing virtually all mechanical and electrical components.
Engine Rebuild:
Full engine overhaul procedures, including piston ring replacement, bearing services, cylinder head rebuilding.
Transmission Overhaul:
Complete rebuild procedures for manual transmissions and related drivetrain components.
Calibration Adjustment:
Wheel alignment specifications, brake system bleeding, and other critical adjustments.
Safety System Repair:
Airbag system diagnosis and repair, ABS component replacement.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds.
Diagnostic Information:
In-depth diagnostic flowcharts, electrical schematics, and troubleshooting trees.
Special Tools:
Lists and descriptions of specific tools required for various repair procedures.
Torque Specifications:
Detailed torque values for all fasteners, critical for engine and chassis integrity.
Clearances Tolerances:
Precise measurements for engine components and other parts to ensure proper operation.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Searchability:
Text-searchable content for quick information retrieval.
Printability:
Printable pages for convenient use in a workshop environment.
Digital Access:
Instant download provides immediate access to repair information.
Print Quality
Image Resolution:
High-resolution diagrams, illustrations, and photographs.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T MIVEC
Configuration:
Inline-4, DOHC, 16-valve, turbocharged with intercooler.
Displacement:
2.0 Liters (1997 cc)
Bore X Stroke:
85.0 mm x 88.0 mm
Performance
Horsepower:
276 hp @ 6500 rpm (JDM/European), 271 hp @ 6500 rpm (USDM)
Torque:
289 lb-ft @ 3500 rpm (JDM/European), 273 lb-ft @ 3500 rpm (USDM)
Redline:
7000 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with electronic fuel pump.
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger:
Mitsubishi TD05HR-16G.7 Twin-Scroll Turbocharger.
Intercooler:
Front-mounted air-to-air intercooler.
🔧 Transmission
Standard
Type:
5-speed manual (most global markets)
Optional
Type:
6-speed manual (JDM RS and MR trims)
Features
Awc Integration:
Integrated with Active Center Differential (ACD) and Super Active Yaw Control (Super AYC).
Clutch:
Hydraulically actuated single-plate dry clutch.
Gear Ratios 5Mt:
Refer to manual for specific ratios (e.g., 1st: 3.143, 2nd: 1.778, 3rd: 1.330, 4th: 0.976, 5th: 0.760, Reverse: 3.067)
Gear Ratios 6Mt:
Refer to manual for specific ratios (e.g., 1st: 3.143, 2nd: 1.833, 3rd: 1.310, 4th: 1.032, 5th: 0.822, 6th: 0.705, Reverse: 3.067)
Fluid Spec
Transmission Fluid Type:
Refer to manual for specific API GL-4 or GL-5 gear oil, viscosity typically 75W-90.
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2625 mm (103.3 in)
Wheel Bolt Pattern:
5x114.3 mm
Weights
Curb Weight:
Approx. 1450-1490 kg (3197-3285 lbs), varies by trim and market.
🛡️ Safety Features
Ratings
NHTSA Front Crash:
Refer to specific model year testing; generally good ratings for its era but often lacked side airbags in early models.
Active Features
Traction Control:
Yes (integrated with AWC system)
Stability Control:
Yes (integrated with AWC system)
ABS:
Yes (Anti-lock Braking System)
Electronic Brake Force Distribution:
Yes (EBD)
Passive Features
Airbags:
Front airbags standard; side airbags and curtain airbags optional or standard on higher trims (MR).
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners and force limiters.
Body Structure:
Reinforced RISE (Reinforced Impact Safety Evolution) body structure.
💡 Technology Features
Infotainment
Audio System:
Factory CD player with AM/FM radio, often with Rockford Fosgate premium audio option on some trims.
Display:
Basic digital display for climate control and audio information.
Driver Assistance
Cruise Control:
Standard feature.
Performance Meters:
Some trims included turbo boost gauges and G-force meters.
Connectivity
Bluetooth:
Not typically factory-equipped; aftermarket solutions available.
Usb Aux:
Not factory-equipped; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe usage recommended for performance driving).
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000-45,000 miles (48,000-72,000 km), depending on plug type (iridium recommended).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years (critical component, inspect periodically).
Fluid Specifications
Engine Oil Type:
Refer to manual: Typically SAE 5W-30 or 5W-40 synthetic engine oil meeting API SN/SP or ILSAC GF-6.
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant, green color).
Brake Fluid Type:
DOT 3 or DOT 4 High-Temperature Brake Fluid.
Power Steering Fluid:
Refer to manual: Usually ATF Dexron II or III, or specific Mitsubishi power steering fluid.
Known Issues
Engine Reliability:
Generally robust 4G63T, but prone to head gasket failure if overheated or poorly maintained. Connecting rod failures can occur with excessive modification and aggressive tuning without proper supporting components.
Turbocharger Wear:
Original turbochargers can experience wear over time, leading to decreased boost pressure or oil leaks into the intake/exhaust.
Awc System Issues:
ACD pump failure, AYC sensor failures, and differential leaks can occur. Regular fluid changes are crucial.
Clutch Wear:
High-performance clutches can wear faster under aggressive driving conditions.
Rust Corrosion:
As with many cars of this era, rust can be an issue in areas with harsh winters and road salt. Check wheel arches, sills, and undercarriage.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Direct lineage from Mitsubishi's WRC (World Rally Championship) Lancer Evolution models.
Model Evolution
Previous Generations:
Evolved from earlier Lancer Evolution models (I-VIII).
Distinguishing Features Of Ix:
Introduction of MIVEC variable valve timing on the 4G63 engine, new turbocharger design, updated AWC system.
Variants:
GSR, RS, MR (JDM specific for MR with 6-speed)
Production
Production Years:
2005-2007 (Model Years 2005, 2006, 2007, 2008 depending on market introduction)
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Evo IX was praised by many automotive publications for its performance and handling, though specific 10Best inclusions for this exact model year vary.
Rally Pedigree:
Car & Driver recognized its homologation status and rally roots, contributing to its desirable image.
Ratings
Performance Handling Reviews:
Consistently lauded for exceptional grip, agility, and feedback by automotive journalists.
Certifications
Emissions Compliance:
Meets relevant emissions standards for its respective model years and markets.
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