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2005 Mitsubishi Lancer EVO IX Maintenance Repair and Troubleshooting Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IX Year: 2005 Market Segment: Performance Compact / Sports Sedan Codes Chassis Code: CT9A Engine Code: 4G63 MIVEC 👋 Introduction Market...
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2005 Mitsubishi Lancer EVO IX Maintenance Repair and Troubleshooting Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IX
Year:
2005
Market Segment:
Performance Compact / Sports Sedan
Codes
Chassis Code:
CT9A
Engine Code:
4G63 MIVEC
👋 Introduction
Market Position
Heritage:
The Lancer Evolution IX represents the pinnacle of Mitsubishi's rally-bred performance heritage, a highly sought-after homologation special.
Competitors:
Competed against iconic performance vehicles such as the Subaru Impreza WRX STI, Subaru WRX, Mitsubishi Lancer Ralliart, and other sports sedans of its era.
Key Features
Powertrain Focus:
Renowned for its potent turbocharged engine, advanced all-wheel-drive system, and sophisticated drivetrain technology.
Driver Experience:
Designed for exhilarating driving dynamics, precise handling, and confident all-weather performance.
📋 Manual Details
Coverage Areas
Primary Markets:
Global (with potential regional variations noted in manual)
Trim Levels Covered:
GSR, RS, MR (and any specific regional variants like SE)
Page Count
Estimated Pages:
1500-2000 (typical for comprehensive service manuals)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Scope:
Includes maintenance, troubleshooting, diagnostics, repair, and overhaul procedures.
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, exhaust, engine control system (ECU/ECM), turbocharger system.
Transmission Drivetrain:
Manual transmission (Getrag Getrag 235 - 5-speed for RS, 6-speed for GSR/MR), Twin-Clutch Sportronic (TC-SST) automatic transmission (optional on some markets), ACD (Active Center Differential), AYC (Active Yaw Control), Super AYC (rear differential), driveshafts, axles, wheel hubs.
Chassis Suspension:
Front suspension (MacPherson strut), Rear suspension (multi-link), steering system (power assisted rack and pinion), brake system (front Brembo calipers, rear calipers, ABS, EBD).
Electrical Electronics:
Battery, charging system, starting system, lighting, instruments, wipers/washers, HVAC controls, body electrical components, ECU diagnostics, wiring diagrams, immobilizer system, audio system (standard/premium).
Body Exterior Interior:
Body construction, exterior panels, doors, windows, mirrors, seats, dashboard, interior trim, safety restraints (airbags, seatbelts).
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, timing belt/chain inspection (as applicable), general inspection checklists.
Troubleshooting:
Diagnostic flowcharts for common symptoms, fault code explanations (OBD-II), electrical system diagnosis, component testing procedures.
Repair Rebuild:
Engine overhaul, transmission repair/rebuild, turbocharger replacement, suspension component replacement, brake system overhauls, electrical component replacement, body panel repair.
Adjustments Settings:
Wheel alignment specifications, idle speed adjustment (where applicable), clutch adjustment, brake bias adjustment (if applicable).
Technical Depth
Diagnostic Tools:
Coverage of MUT-III (Mitsubishi Multi-Use Tester) functionality and scan tool data interpretation.
Electrical Diagrams:
Detailed wiring schematics for all vehicle systems, including power distribution, ground points, and connector pinouts.
Torque Specifications:
Comprehensive list of all critical fastener torque values for engine, transmission, suspension, brakes, and chassis components.
Precision Measurements:
Serviceable wear limits for engine components (pistons, rings, bearings, valve guides), brake rotor thickness, etc.
📊 Manual Specifications
File Format
Compatibility:
Viewable on all standard PDF readers (Adobe Acrobat Reader recommended).
Print Quality
Readability:
High-resolution scans ensuring clear text, legible diagrams, and sharp images.
Binding Type
Physical Manual:
N/A (Digital PDF)
Paper Type
Physical Manual:
N/A (Digital PDF)
Searchability
Text Search:
Fully searchable text content, allowing for quick access to specific information.
Interactivity
Hyperlinks:
May include internal hyperlinks for easier navigation between sections (depending on PDF creation).
⚙️ Engine Specifications
Primary Engine
Engine Type:
DOHC 16-valve, turbocharged and intercooled inline-4
Displacement:
2.0 Liters (1997cc)
Performance
Horsepower:
287 hp @ 6500 rpm (JDM/Euro Spec), 276 hp @ 6500 rpm (US Spec - often slightly underrated)
Torque:
289 lb-ft @ 3500 rpm (JDM/Euro Spec), 286 lb-ft @ 3500 rpm (US Spec)
Redline:
7500 rpm
Fuel System
Fuel Injection:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Technology
Variable Valve Timing:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system for intake camshaft.
Turbocharger:
Mitsubishi TD05HR-16G 8cm² twin-scroll turbocharger with intercooler.
🔧 Transmission
Standard
Type:
6-speed manual (GSR/MR), 5-speed manual (RS)
Optional
Type:
6-speed Twin-Clutch Sportronic (TC-SST) automatic (limited availability on select models/markets).
Features
Acd:
Active Center Differential (ACD) – electronically controlled torque distribution between front and rear axles.
Ayc:
Active Yaw Control (AYC) – electronically controlled torque split at the rear axle (standard on GSR/MR, may be omitted on RS).
Ayc
Super Ayc:
Super Active Yaw Control (Super AYC) – further enhances yaw control by actively vectoring torque between rear wheels (on some higher-spec models).
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (Check manual for specific Mitsubishi part numbers).
Fluid Capacities
Manual Transmission Capacity:
Approx. 2.5 Liters (check specific manual).
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Front Track:
1520 mm (59.8 in)
Rear Track:
1520 mm (59.8 in)
Weights
Curb Weight:
1440 - 1480 kg (3175 - 3263 lbs) - varies by trim and options
Gross Vehicle Weight Rating:
Approx. 1800 kg (check specific manual).
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for models tested)
IIHS Side Impact:
Good (for models tested)
Active Features
ABS:
Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD)
Traction Control:
Traction Control System (TCS) - often integrated with AWD.
Electronic Stability:
Active Stability Control (ASC) or Electronic Stability Control (ESC) may be present on some models/markets.
Passive Features
Airbags:
Front driver and passenger airbags; side-impact airbags (optional/standard on certain trims).
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
Body Structure:
Reinforced chassis and body structure designed for crash energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional Rockford Fosgate premium audio system with subwoofer.
Display:
Digital odometer, trip computer, climate control display, warning lights.
Driver Assistance
Acd:
Active Center Differential provides intelligent torque distribution for enhanced traction and handling.
Ayc:
Active Yaw Control system actively manages rear wheel torque for improved cornering stability and responsiveness.
Connectivity
Bluetooth:
Not typically available from the factory in 2005, aftermarket solutions common.
Usb:
Not typically available from the factory in 2005.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe duty).
Engine Oil Filter:
Replace with every oil change.
Spark Plugs:
Inspect every 30,000 miles (48,000 km), replace as needed. (Iridium spark plugs recommended).
Transmission Fluid:
Every 30,000 miles (48,000 km) or 24 months.
Differential Fluid Front Rear:
Every 30,000 miles (48,000 km) or 24 months (includes ACD/AYC fluid if applicable).
Fluid Specifications
Engine Oil:
API SG or higher, ACEA A3/B3, SAE 5W-30 synthetic recommended (check manual for specific Mitsubishi part numbers and viscosity ranges).
Coolant:
Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant with a 50/50 mix of distilled water.
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific recommendation).
Known Issues
Engine Oil Consumption:
Some 4G63 engines can consume oil, especially when driven hard. Regular checks are essential. Piston ring wear can be a cause.
Acd Ayc Pump:
The ACD/AYC hydraulic pump can fail, leading to system errors. Ensure proper fluid levels and pump operation.
Clutch Wear:
High-performance clutch can wear faster with aggressive driving. Manual transmission clutch can require replacement over time.
Turbocharger Wear:
While robust, aggressive use without proper warm-up/cool-down cycles can lead to premature turbo wear.
Maintenance Items
Timing Belt Serpentine Belt:
Serpentine belt requires inspection and replacement per schedule. Timing belt is not applicable as the 4G63 uses a timing chain.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
The Lancer Evolution lineage is deeply rooted in World Rally Championship (WRC) success, with the Evo IX being a direct descendant of homologation specials.
Model Evolution
Previous Generation:
Evolved from the Lancer Evolution VIII, featuring significant enhancements in engine technology (MIVEC), turbocharger, and drivetrain management (ACD/AYC refinements).
Specific Enhancements Ix:
Introduction of MIVEC on the 4G63 engine, updated turbocharger for improved response, revised ACD/AYC systems, and a 6-speed transmission on higher trims.
Production
Production Years:
2005-2007 (as the Evolution IX generation, succeeding the Evolution VIII and preceding the Evolution X).
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Titles:
Multiple WRC manufacturer and driver championships, the Evo IX is a direct beneficiary of this development.
Automotive Journalism Awards:
Frequently lauded by automotive publications for its performance, handling, and value in the performance car segment.
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