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Mitsubishi Lancer Service Repair Manual 2001-2007

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Codes: CS, CT (Generation VIII, domestic market variations may differ)...
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Mitsubishi Lancer Service Repair Manual 2001-2007
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer
Model Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
Codes
Chassis Codes:
CS, CT (Generation VIII, domestic market variations may differ)
👋 Introduction
Market Position
Segment:
Compact car (C-segment)
Target Audience:
Budget-conscious buyers, young drivers, individuals seeking a reliable and practical sedan or hatchback.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Mazda3.
Key Features
Value Proposition:
Affordability, decent reliability, fuel efficiency, sporty styling for its class (especially later models).
Manual Utility:
Essential for DIY mechanics and professional technicians to maintain and repair the vehicle efficiently and correctly.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily North American and European specifications, with potential variations for other markets)
Page Count
Estimated Page Count:
1500-2500 pages (typical for comprehensive factory-style manuals of this era)
Manual Type
Type:
Workshop Service / Repair Manual
Language
Language:
English
Format
Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Engine:
Diagnosis, repair, overhaul, timing belt/chain, cooling system, lubrication system, fuel system, emission control systems.
Transmission:
Manual transmission (transaxle) service, automatic transmission service, clutch system, drive shafts, differentials.
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System) diagnosis and repair, brake fluid specifications, rotor/pad replacement, caliper service.
Suspension Steering:
Front and rear suspension components, shock absorbers, struts, ball joints, tie rod ends, power steering system, alignment specifications.
Electrical:
Wiring diagrams, fuse box layouts, lighting system, charging system (alternator, battery), starting system, ignition system, power accessories, body control modules (BCM).
Climate Control:
HVAC system diagnosis, refrigerant handling, A/C compressor, heater core, climate control module.
Body Chassis:
Body panel removal/installation, door mechanisms, interior trim, glass, seat mechanisms, chassis lubrication, structural repairs.
Diagnostic Tools:
OBD-II (On-Board Diagnostics II) troubleshooting, diagnostic trouble codes (DTCs) and their meanings, scan tool usage.
Procedures Included
Maintenance:
Routine maintenance tasks, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs.
Repair Overhaul:
Detailed step-by-step instructions for component removal, repair, and reinstallation, including engine and transmission rebuilds.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification and solutions.
Specifications:
Torque specifications for fasteners, diagnostic values, engine timing, electrical system parameters, alignment data.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems, aiding in electrical fault diagnosis.
Technical Depth
Depth:
Comprehensive (covers basic maintenance to complete engine and transmission overhauls, including advanced diagnostics).
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text, with clear diagrams and images. Printable pages.
Print Quality
Print Readability:
Designed for clear viewing and printing, ensuring legibility of text and diagrams.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Codes:
4G1 (e.g., 4G13, 4G15, 4G18), 4G6 (e.g., 4G63, 4G64, commonly in performance variants)
Displacement Options:
1.3L, 1.5L, 1.6L, 1.8L, 2.0L (Naturally Aspirated and Turbocharged options available)
Cylinder Configuration:
Inline 4-cylinder
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft), often with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some DOHC engines.
Performance
Horsepower Range:
Approx. 90 hp to 270+ hp (depending on engine and trim, e.g., Lancer Evolution models)
Torque Range:
Approx. 115 lb-ft to 260+ lb-ft (depending on engine and trim)
Fuel System
Injection Type:
Multi-point fuel injection (MPI) or GDI (Gasoline Direct Injection) on some later models.
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed manual transaxle
Optional
Transmission Type:
4-speed automatic transaxle (INVECS-II on some models)
Features
AWD Option:
Available on select performance models (e.g., Lancer Evolution) with advanced All-Wheel Control (AWC) system.
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Hatchback (Sportback)
Wheelbase:
Approx. 2600 mm (102.4 inches) - may vary slightly by model year and body style.
Length:
Approx. 4465 mm (175.8 inches) for Sedan, 4250 mm (167.3 inches) for Hatchback.
Width:
Approx. 1740 mm (68.5 inches)
Height:
Approx. 1445 mm (56.9 inches) for Sedan, 1450 mm (57.1 inches) for Hatchback.
Weights
Curb Weight Range:
Approx. 1150 kg to 1500+ kg (depending on engine, transmission, and trim)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Likely 4-star or 5-star ratings for driver and passenger in frontal impact (check specific year and test results).
IIHS Side Impact:
Likely 'Good' or 'Acceptable' ratings for side impact (check specific year and test results).
Active Features
ABS:
Standard on most trims, optional on lower trims for some model years.
E Brake Assist:
May be available on higher trims or later model years.
Passive Features
Airbags:
Front driver and passenger airbags standard. Side and curtain airbags available on higher trims or later models.
Seatbelts:
3-point seatbelts with pre-tensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player. Higher trims may feature Rockford Fosgate premium audio systems. Aux input might be available on later models or as an aftermarket addition.
Navigation:
Optional factory navigation system available on higher trim levels for select model years.
Driver Assistance
ABS Availability:
Standard on most, optional on entry-level models for some years.
Traction Control:
Available on select trims, often integrated with stability control systems on later models.
Connectivity
Bluetooth:
Not typically integrated as standard for this era; often an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used. Refer to manual for specifics.
Air Filter Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving environment.
Spark Plug Replacement:
Varies by spark plug type (e.g., copper, platinum, iridium). Iridium plugs often recommended for 60,000-100,000 miles (96,000-160,000 km).
Timing Belt Replacement:
Critical for 4G6 engines with timing belts; typically every 60,000-100,000 miles (96,000-160,000 km). Check manual or specific engine code.
Fluid Specifications
Engine Oil Viscosity:
Commonly SAE 5W-30 or 5W-20 for naturally aspirated engines. Performance models or turbocharged engines might specify different weights. Refer to manual for exact spec.
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent. Typically a pink or red ethylene glycol based coolant. Check manual for 'blue' or 'green' coolants if applicable to specific markets/engines.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, typically SAE 75W-90. Check manual for specific recommendations.
Transmission Fluid Automatic:
Mitsubishi Diamond ATF SP-III or equivalent. Crucial to use the correct specification to avoid transmission damage.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Problems Engine:
Premature wear on timing belt tensioner/water pump (if belt driven), oil consumption in higher mileage engines, occasional ignition coil failures.
Common Problems Transmission:
Automatic transmission clutch pack wear (especially under heavy use), manual clutch wear.
Common Problems Suspension Steering:
Worn ball joints and tie rod ends, strut/shock absorber degradation, power steering pump leaks.
Common Problems Electrical:
Failure of power window regulators, gauge cluster issues, alternator failures.
📚 Vehicle History
Brand Heritage
Brand Reputation:
Mitsubishi, a Japanese automaker known for its engineering prowess, particularly in rallying and performance vehicles (e.g., Lancer Evolution series).
Model Evolution
Generation:
This period covers the VIII Generation Lancer (2001-2007), a significant redesign from the previous generation, offering improved styling, chassis, and features.
Key Variants:
Includes standard models, sportier Ralliart trims, and the iconic Lancer Evolution (VIII and IX generations), which set benchmarks in performance rallying and AWD technology.
Production
Manufacturing Locations:
Primarily Japan, with significant production also in the United States (Illinois) for North American markets, and other global facilities.
🏆 Awards & Recognition
Recognitions
Performance Awards:
Lancer Evolution models (VIII and IX) are highly acclaimed and have received numerous awards for performance, handling, and rally-inspired capabilities.
Ratings
Reliability Rankings:
Generally considered average to good reliability, with specific model years and engine variants showing better performance in reliability surveys. The manual helps address common issues.
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