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Mitsubishi Lancer 2000-2007 Factory Service Repair Manual

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The Mitsubishi Lancer, covering model years 2000 through 2007, is a compact car known for its sharp, angular styling and a reputation for offering a compelling blend of sportiness and...
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Mitsubishi Lancer 2000-2007 Factory Service Repair ManualMitsubishi Lancer 2000-2007 Factory Service Repair ManualMitsubishi Lancer 2000-2007 Factory Service Repair ManualMitsubishi Lancer 2000-2007 Factory Service Repair Manual
The Mitsubishi Lancer, covering model years 2000 through 2007, is a compact car known for its sharp, angular styling and a reputation for offering a compelling blend of sportiness and value. This generation, built on the CS/CT chassis, was available with various engine options, including the 1.5L 4G15, 1.8L 4G93, and the 2.0L 4G94, catering to different performance and efficiency needs. Mitsubishi's engineering heritage, particularly its rally success with the Lancer Evolution models, influenced the design and handling of these vehicles, making them a popular choice for budget-conscious buyers and those seeking an engaging driving experience. With a focus on robust powertrains and a solid chassis, the Lancer provided a reliable platform for daily commuting and spirited driving alike. This comprehensive Factory Service Repair Manual (FSRM) provides complete technical information for the maintenance, diagnosis, and repair of the Mitsubishi Lancer models from 2000 to 2007. It covers all major systems, including powertrain, chassis, and electrical components, offering detailed procedures for routine maintenance, troubleshooting, and component overhauls. Owners, technicians, and mechanics will find step-by-step instructions, diagnostic flowcharts, torque specifications, and wiring diagrams essential for keeping the vehicle in optimal condition. The manual's extensive scope ensures that both minor service tasks and major repairs can be addressed with accuracy and efficiency, promoting the longevity and performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Codes
Chassis Code Range:
CS (North America), CT (Global)
Engine Code Range:
4G93, 4G94, 4G15 (depending on market/trim)
👋 Introduction
Market Position
Vehicle Segment:
Compact/Small Family Car
Target Audience:
Budget-conscious buyers, first-time car owners, enthusiasts seeking a reliable and affordable platform.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cobalt.
Mitsubishi Advantage:
Often offered a compelling blend of sportiness (especially in higher trims like the GT or GTS), value, and long-term reliability, with a reputation for robust powertrains.
Key Features
Design Philosophy:
The Lancer of this generation was known for its sharp, angular styling, a departure from softer designs of previous eras, aiming for a more aggressive and modern aesthetic.
Performance Variants:
Offered various trim levels, including the base ES, sportier LS, and the performance-oriented GTS/GT models, which often featured enhanced suspension and engine options.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair information
Documentation Type:
Factory Service Repair Manual (FSRM)
Page Count
Estimated Page Count:
Hundreds (specific count not provided, but typical for FSRM)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/ECM), manual transmission, automatic transmission, clutch system, drivetrain components (drive shafts, CV joints).
Chassis:
Suspension (front and rear), steering system, braking system (disc, drum, ABS), wheel alignment specifications.
Electrical:
Body electrical systems, lighting, power windows, power locks, mirrors, seats, wipers, horn, audio system, instrument cluster, engine control wiring diagrams, chassis wiring diagrams, body wiring diagrams, diagnostic trouble codes (DTCs).
Body:
Body panel removal and installation, interior trim, exterior trim, bumpers, doors, hood, trunk lid, glass, body repair procedures, corrosion protection.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, belt inspections and replacement, spark plug replacement, brake pad/shoe replacement, tire rotation.
Diagnostics And Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical troubleshooting flowcharts, fault code interpretation.
Repair And Rebuild:
Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for major vehicle systems (engine, transmission, brakes, suspension, steering, etc.).
Technical Specifications:
Torque specifications for all fasteners, clearances and tolerances for mechanical components, fluid capacities and types, wiring diagrams, schematics, diagnostic data.
Technical Depth
Depth Of Coverage:
Comprehensive, covering routine maintenance to major overhauls and diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely (standard for factory PDF manuals)
Print Quality
Image Resolution:
High quality, suitable for printing diagrams and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common Na:
4G94 (2.0L SOHC/DOHC)
Engine Code Common Global:
4G93 (1.8L DOHC), 4G15 (1.5L SOHC)
Engine Type:
Inline-4 Cylinder, Naturally Aspirated
Performance
Horsepower Range:
Approx. 110 hp (1.5L) to 162 hp (2.0L DOHC MIVEC)
Torque Range:
Approx. 105 lb-ft (1.5L) to 142 lb-ft (2.0L DOHC MIVEC)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Technical Details
Bore X Stroke 2.0L:
86.0 mm x 86.0 mm (typical for 4G94)
Compression Ratio 2.0L:
9.5:1 to 10.0:1 (depending on variant)
🔧 Transmission
Standard
Transmission Standard:
5-speed Manual
Optional
Transmission Optional:
4-speed Automatic (with INVECS-II technology)
Features
Automatic Transmission Features:
Sportronic (manual shifting mode) available on some models.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact spec)
Automatic Transmission Fluid:
DIA QUEEN ATF-SP III (or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 4480 mm (176.4 in)
Width:
Approx. 1740 mm (68.5 in)
Height:
Approx. 1445 mm (56.9 in)
Wheelbase:
Approx. 2630 mm (103.5 in)
Cargo
Trunk Volume:
Approx. 390 liters (13.8 cu ft)
Weights
Curb Weight Range:
Approx. 1250 kg to 1350 kg (2755 lbs to 2976 lbs), depending on trim and options.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (for comparable models/years, specific ratings vary)
NHTSA Front Impact Passenger:
4-star (for comparable models/years, specific ratings vary)
IIHS Front Offset:
Good (for comparable models/years, specific ratings vary)
Active Features
ABS:
Standard on most models, optional on base trims.
Traction Control:
Available on higher trims or as an option.
Passive Features
Airbags:
Frontal airbags standard. Side-impact airbags and curtain airbags available on higher trims or as options.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System Features:
Base models typically featured an AM/FM stereo with CD player. Higher trims offered enhanced audio systems, often with more speakers and steering wheel controls.
Navigation:
Optional factory navigation system available on select higher trim levels.
Driver Assistance
Cruise Control:
Standard on most trims, optional on base models.
Connectivity
Auxiliary Input:
Rare on base models, may be present on upgraded sound systems or aftermarket additions.
Bluetooth:
Not typically available from the factory for this model year range; often an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for precise recommendation).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) for conventional plugs; longer for iridium/platinum.
Fluid Specifications
Engine Oil Type:
API SN/SP or ILSAC GF-5/GF-6; Viscosity: 5W-20 or 5W-30 (check manual for specific engine variant and temperature range).
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent G12/G12+ type coolant.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Issues:
Occasional oil consumption, potential for sludge buildup if maintenance is neglected, timing belt replacement (if applicable to specific engine variant) is critical.
Transmission Issues:
Automatic transmission shifting issues or solenoid failures can occur with high mileage; manual clutch wear.
Suspension Components:
Worn bushings and ball joints leading to clunks or instability, especially on higher mileage vehicles.
Electrical Issues:
Faulty power window regulators, SRS (airbag) warning lights due to faulty sensors or wiring, corroded connectors.
Body Corrosion:
Rust can develop in wheel wells, rocker panels, and around window seals in corrosive climates.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a long history in automotive manufacturing, known for its robust engineering and rally heritage, particularly with the Lancer Evolution models.
Model Evolution
Lancer Generation Overview:
The 2000-2007 Lancer represents the 8th generation (CS/CT chassis), which saw a significant styling update and platform improvements over its predecessor.
Performance Evolution:
This generation paved the way for the highly acclaimed Lancer Evolution VIII and IX, sharing some fundamental design and engineering principles.
Production
Manufacturing Locations:
Primarily Japan, with assembly also occurring in other global locations depending on the market.
🏆 Awards & Recognition
Recognitions
Vehicle Awards:
While specific major awards for the standard Lancer are less prominent than for the Evo, it was often praised for its value proposition and sporty handling in its class during its production run.
Ratings
Consumer Reports Reliability:
Reliability ratings varied by year and specific powertrain; generally average to above average, with some model years receiving higher marks than others. The manual highlights the importance of preventative maintenance.
Certifications
Safety Certifications:
Met all relevant federal motor vehicle safety standards (FMVSS) for its respective model years.
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