2003-2005 Mitsubishi Lancer Evolution Service Repair Factory Manual (2003 2004 2005)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Code: CT9A (Evo VIII/IX) Generation: Eighth Generation (Evo VIII) & Ninth Generation (Evo IX) Codes Production Years Covered: 2003, 2004,...

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标签: 2003 2004 2005 Car Cars Lancer Evolution Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Model Code:

CT9A (Evo VIII/IX)

Generation:

Eighth Generation (Evo VIII) & Ninth Generation (Evo IX)

Codes

Production Years Covered:

2003, 2004, 2005

👋 Introduction

Market Position

Segment:

High-performance compact sedan, rally homologation special.

Target Audience:

Enthusiasts, performance drivers, owners seeking in-depth knowledge for maintenance and modification.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Honda Civic Type R, Volkswagen Golf R, Ford Focus RS.

Key Features

Performance Focus:

All-wheel drive, powerful turbocharged engine, sophisticated active center differential (ACD) and Super Active Yaw Control (S-AYC).

Rally Heritage:

Direct lineage from WRC-winning Lancer Evolution models.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair information for the 2003-2005 Mitsubishi Lancer Evolution.

Page Count

Estimated Page Count:

Varies, typically 2000+ pages (comprehensive factory manuals are extensive)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Electronic Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63T DOHC Turbocharged, including timing belt, lubrication, cooling, fuel injection, emissions control, and engine management.

Transmission:

Manual (Getrag 5-speed, optional 6-speed for Evo IX MR), including clutch, driveline, transfer case, and differential servicing.

Suspension:

Front MacPherson strut, rear multi-link, including shock absorbers, springs, bushings, and alignment specifications.

Brakes:

Front Brembo (4-piston), Rear Brembo (2-piston) or equivalent, ABS, EBD, brake fluid flush procedures, caliper and rotor replacement.

Electrical:

Complete wiring diagrams, fuse box layouts, starter, alternator, battery, lighting systems, audio, climate control, SRS (Airbag) system.

Body:

Exterior panels, doors, hood, trunk, glass, interior trim, structural repairs, chassis components.

Heating Cooling:

HVAC system, A/C compressor, condenser, evaporator, heater core, blower motor, refrigerant recharge procedures.

Fuel:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure testing.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug changes, fluid flushes, belt inspections and replacements.

Diagnostics:

Troubleshooting guides based on symptoms, OBD-II diagnostic codes, sensor testing, component diagnosis.

Repair:

Engine rebuilding, transmission overhaul, suspension component replacement, brake caliper rebuild, electrical component repair.

Installation:

Component replacement (e.g., turbocharger, injectors, clutch), body panel alignment.

Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, diagnostic data.

Technical Depth

Depth:

Extremely high. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable, allowing quick navigation to specific topics.

Print Quality

Quality:

High-resolution scans, suitable for printing individual pages or sections.

Binding Type

Binding:

Not applicable for digital download, but original factory manuals were typically bound for durability.

Paper Type

Paper Type:

Not applicable for digital download.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline-4, DOHC, 16-valve, turbocharged and intercooled.

Displacement:

2.0 Liters (1997cc)

Performance

Horsepower Evo Viii:

271 hp @ 6500 rpm (JDM/USDM variations may differ slightly)

Torque Evo Viii:

273 lb-ft @ 3500 rpm (JDM/USDM variations may differ slightly)

Horsepower Evo Ix:

286 hp @ 6500 rpm (JDM/USDM variations may differ slightly)

Torque Evo Ix:

289 lb-ft @ 3500 rpm (JDM/USDM variations may differ slightly)

Redline:

Approx. 7000-7500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

Premium Unleaded Gasoline (91+ octane)

🔧 Transmission

Standard

Type Evo Viii:

5-speed Manual Transmission (Getrag F5M51)

Optional

Type Evo Ix Mr:

6-speed Manual Transmission (Getrag RS6F51R)

Features

Drivetrain:

All-Wheel Drive (AWD)

Center Differential:

Active Center Differential (ACD)

Rear Differential:

Helical Limited-Slip Differential (LSD) for Evo VIII, Super Active Yaw Control (S-AYC) for Evo IX.

Fluid Specifications

Manual Gearbox Fluid:

GL-4 SAE 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil or equivalent)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2625 mm (103.3 in)

Length:

Approx. 4415 mm (173.8 in)

Width:

Approx. 1770 mm (69.7 in)

Height:

Approx. 1415 mm (55.7 in)

Weights

Curb Weight:

Approx. 1400-1450 kg (3086-3197 lbs)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Wheel Size:

17x8.0 inch (standard)

Tire Size:

235/45R17 (standard)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Not comprehensively rated for all configurations, but generally considered robust.

IIHS Side Impact:

Not comprehensively rated for all configurations.

Active Features

Standard, often with Electronic Brakeforce Distribution (EBD).

Traction Control:

Active on demand, integrated with ACD/AYC systems.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags were optional on some trims.

Seatbelts:

3-point front and rear seatbelts with pretensioners and force limiters.

Chassis Construction:

Reinforced unibody construction with front and rear crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory Mitsubishi CD player with radio, optional Rockford Fosgate premium audio system.

Display:

Basic digital display for climate control and audio functions. No integrated navigation or touchscreens in these model years.

Driver Assistance

Acd System:

Active Center Differential adjusts torque distribution between front and rear axles based on steering angle and throttle input.

Ayc System:

Super Active Yaw Control (Evo IX) actively distributes torque between rear wheels to enhance cornering stability.

Connectivity

Bluetooth:

Not standard. Aftermarket solutions common.

Not standard. Aftermarket solutions common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 - 7,500 miles (or 6 months), depending on driving conditions. Refer to manual for specific recommendations.

Timing Belt Replacement:

Every 60,000 - 105,000 miles or 5-7 years. Critical for 4G63T engine; failure can cause catastrophic damage. Manual specifies exact interval.

Spark Plug Replacement:

Typically every 30,000 - 60,000 miles, depending on plug type (Iridium recommended).

Fluid Specifications

Engine Oil:

5W-30 or 10W-30 synthetic oil (API SN or higher, ILSAC GF-5 or higher). Capacity: Approx. 4.5 Liters (4.8 US Quarts) with filter.

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent P-HOAT coolant. Capacity: Approx. 7.0 Liters.

Brake Fluid:

DOT 3 or DOT 4 High Performance Brake Fluid.

Power Steering Fluid:

Dexron III/Mercon Automatic Transmission Fluid or equivalent.

Known Issues

Engine Wear:

Camshaft seal leaks, piston ring wear (in high-mileage or heavily modified engines).

Turbocharger:

Oil feed line restriction can lead to turbo failure; regular oil changes are crucial.

Clutch:

Wear can be accelerated with aggressive driving.

Electronics:

Occasional issues with the ACD pump or sensors, power window regulators.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Long history in motorsport, particularly in rallying with the Lancer platform.

Model Evolution

Evo Viii Introduction:

Introduced in 2003 for the US market, bringing the legendary performance to North America.

Evo Ix Introduction:

Introduced in 2005 with updates including the MIVEC variable valve timing system and a new 6-speed transmission option (MR).

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Run:

Eighth generation (2003-2005 MY), Ninth generation (2005-2007 MY).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Often featured or highly regarded by automotive publications for its performance and handling.

Sport Compact Car Of The Year:

Received numerous awards from specialist automotive magazines for its class-leading performance.

Ratings

Handling Reputation:

Universally praised for exceptional grip, steering feel, and chassis dynamics.