Mitsubishi Lancer 2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Year: 2005 Codes Generation Code: CS/CT Platform Code: Mitsubishi Project Global (MITSUBA Global) 👋 Introduction Market Position Segment: Compact Sedan/Sports Sedan Target...

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标签: 2005 Car Cars Lancer Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer

Year:

Codes

Generation Code:

CS/CT

Platform Code:

Mitsubishi Project Global (MITSUBA Global)

👋 Introduction

Market Position

Segment:

Compact Sedan/Sports Sedan

Target Audience:

Enthusiast drivers, performance-oriented individuals, general consumers seeking reliable transportation

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Subaru Impreza, Mazda3

Key Features

Distinctive Selling Points:

Available performance variant (Lancer Evolution), balanced handling, durable powertrains, practical interior

Manual Benefit:

Empowers owners and technicians with factory-level knowledge for effective maintenance and repair, reducing reliance on expensive dealership services.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.0L 4G63 SOHC, 2.0L 4G63 MIVEC DOHC Turbo (Evolution)

Transmission Coverage:

5-Speed Manual, 4-Speed Automatic

Chassis Coverage:

Front-Wheel Drive (FWD), All-Wheel Drive (AWD - Evolution models)

Body Style Coverage:

Sedan (non-Evolution), Evolution (Sedan)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, piston and connecting rod, crankshaft, lubrication system, cooling system, fuel system, intake and exhaust manifolds, timing belt/chain, engine overhaul procedures

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system (MPI), engine control module (ECM) diagnostics, sensors (crankshaft position, camshaft position, MAP, TPS, O2, etc.), emission control systems

Transmission Manual:

Clutch, gearbox assembly, shift mechanism, removal and installation, overhaul, lubrication

Transmission Automatic:

Torque converter, planetary gear sets, hydraulic control system, valve body, transmission control module (TCM) diagnostics, removal and installation, overhaul, fluid specifications

Drivetrain:

Front axle, rear axle (AWD models), propeller shaft, drive shafts, differentials, wheel bearings

Suspension:

Front suspension (MacPherson strut), rear suspension (Multi-link), shock absorbers, springs, control arms, stabilizers, wheel alignment specifications

Steering:

Power steering system (hydraulic), steering column, steering gear, tie rod ends, troubleshooting

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, bleeding procedures, caliper and rotor replacement, master cylinder

Electrical System:

Battery, starter motor, alternator, lighting system (headlights, taillights, interior), wiring diagrams, fuses and relays, power windows, power locks, central locking, horn, wipers, washers

Body And Trim:

Exterior panels, doors, hood, trunk lid, bumpers, interior trim, seats, dashboard, sound insulation, glass replacement

HVAC:

Air conditioning system (refrigerant type, charging), heating system, climate control, blower motor, evaporator, condenser

Safety Systems:

Airbag system (SRS), seat belts, child seat anchors (ISOFIX)

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, brake pad inspection, tire rotation

Diagnostics:

Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation, electrical circuit testing, fuel system pressure testing, compression testing

Repair:

Step-by-step repair procedures for all major components, including engine teardown and rebuild, transmission overhaul, suspension and brake component replacement, electrical component repair

Installation:

Component installation procedures (e.g., engine, transmission, starter, alternator, AC compressor)

Adjustment:

Valve clearance adjustment, parking brake adjustment, clutch pedal adjustment

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed wiring diagrams and troubleshooting flowcharts.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text content

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Standard Engine:

2.0L 4G63 SOHC Inline-4

Performance Engine:

2.0L 4G63 MIVEC DOHC Turbocharged Inline-4 (Lancer Evolution VIII/IX)

Performance

Standard Horsepower:

~120-135 hp @ 6000 rpm (Varies by market/trim)

Standard Torque:

~130-135 lb-ft @ 4200 rpm (Varies by market/trim)

Evolution Horsepower:

271 hp @ 6500 rpm (Evo VIII), 286 hp @ 6500 rpm (Evo IX)

Evolution Torque:

273 lb-ft @ 3500 rpm (Evo VIII), 289 lb-ft @ 3500 rpm (Evo IX)

Fuel System

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (91 octane recommended for Evo models)

Engine Code Breakdown

4G63:

4-Cylinder, G-Series Engine, 6-Port Cylinder Head

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Optional

Transmission Type:

4-Speed INVECS-II Automatic

Features

Clutch Type:

Hydraulically operated, single dry plate (Manual)

Evolution AWD System:

S-AWC (Super All-Wheel Control) with Active Yaw Control (AYC) and ACD (Active Center Differential)

Fluid Specifications

Manual Transmission Fluid:

DIA-QUEEN SUPER MULTI GEAR OIL API GL-4 SAE 75W-90 (or equivalent)

Automatic Transmission Fluid:

DIA-QUEEN ATF-SP III (or equivalent)

📐 Dimensions

Exterior

Length:

~174.6 inches (Sedan), ~178.0 inches (Evolution)

Width:

~66.7 inches

Height:

~57.7 inches

Wheelbase:

~103.3 inches

Weights

Curb Weight:

~2800 - 3200 lbs (Varies by trim and drivetrain)

Gross Vehicle Weight Rating:

Typically around 4000-4300 lbs

Cargo

Trunk Volume:

~13.8 cubic feet (Sedan)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4 Stars (Driver), 4 Stars (Passenger)

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Standard on most trims

Standard on most trims, working with ABS

Passive Features

Airbags:

Frontal airbags standard. Optional side airbags and curtain airbags on some trims.

Seat Belts:

3-point ELR seat belts with pretensioners and force limiters

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM CD player, optional premium sound system (e.g., Rockford Fosgate on some trims).

Climate Control:

Manual or automatic climate control systems depending on trim level.

Driver Assistance

Standard Anti-lock Braking System

Traction Control:

Available on select models, part of the ASC (Active Stability Control) system.

Connectivity

Keyless Entry:

Standard on many trims, with remote keyless entry functionality.

Power Features:

Power windows, power door locks, power mirrors.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles or 6 months, whichever comes first (refer to manual for specific engine/oil type)

Spark Plug Replacement:

Approximately 60,000 miles for standard plugs, potentially shorter for performance plugs.

Timing Belt Replacement:

Approximately 60,000 miles or 5 years (for 4G63 SOHC/DOHC engines - critical for belt-driven models)

Fluid Specifications

Engine Oil Capacity:

Approximately 4.5 quarts (4.3L) with filter (4G63 SOHC), 5.0 quarts (4.7L) with filter (4G63 DOHC Turbo)

Engine Oil Recommendation:

API SN/SP, ILSAC GF-5/GF-6, SAE 5W-30 (synthetic recommended)

Coolant Type:

DIA-QUEEN SUPER LONG LIFE COOLANT (Green) or equivalent ethylene glycol based, 50/50 mix with distilled water

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine Wear:

Possible piston ring land wear or ring failure in high-mileage/hard-driven 4G63 engines (especially turbocharged variants). Mention of 'ringland failure' is common.

Turbocharger:

Potential for turbocharger wear or failure if not maintained properly (oil changes, proper warm-up/cool-down).

Suspension Components:

Wear in bushings, ball joints, and strut mounts due to road conditions.

Clutch Wear:

Clutch wear is typical for manual transmissions, especially with aggressive driving.

Rust And Corrosion:

Prone to rust, particularly in the rocker panels, rear wheel arches, and underbody, in areas with exposure to road salt.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Motorsport Legacy:

Strong ties to rally racing, particularly with the Lancer Evolution series.

Model Evolution

Ninth Generation:

This 2005 model falls within the eighth (CT9A) and ninth (CT9A facelift) generations of the Lancer Evolution, and the seventh generation of the standard Lancer (CS/CT).

Performance Upgrade:

The 2005 model year saw updates to the Evolution IX, including MIVEC engine technology and the introduction of the Super Active Yaw Control (S-AWC) system.

Production

Manufacturing Locations:

Japan (Primary), Australia, North America (CK/CM models)

Production Period For Generation:

2000-2007 (CS/CT Generation), 2003-2005 (CT9A Evolution VIII), 2005-2007 (CT9A Evolution IX)

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Lancer Evolution models consistently praised for their performance, handling, and rally-bred capabilities by automotive journalists.

Ratings

Consumer Reports:

Varied reliability ratings depending on the specific powertrain and model year, with some issues noted for earlier generations and turbocharged models.

Certifications

Emissions Compliance:

Meets EPA and CARB emissions standards for the model year.