🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution

Generation:

VII

Product Type:

Factory Service Repair Workshop Manual

Chassis Codes:

CT9A

Engine Codes:

4G63

👋 Introduction

Vehicle Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, performance car owners, tuners, professional mechanics specializing in performance vehicles.

Key Competitors:

Subaru WRX STI, Ford Focus RS, Volkswagen Golf R, Honda Civic Type R (in relevant markets/segments).

Performance Focus:

The manual is tailored for the high-performance variant of the Lancer, reflecting its advanced mechanical and electronic systems.

Rally Heritage:

The Lancer Evolution is a legendary nameplate with deep roots in the World Rally Championship (WRC), and its design and engineering reflect this performance pedigree.

Technical Complexity:

The manual acknowledges and addresses the technical complexity of the Evo, including its advanced all-wheel-drive system (S-AWC - Super All Wheel Control) and potent turbocharged engine.

📋 Manual Details

Model Years:

2003, 2004, 2005

Regions:

Global (specific to models equipped with 4G63 engine)

Estimated Pages:

Over 2000 (typical for comprehensive factory service manuals)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (PDF, often provided as a downloadable file)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul procedures for 4G63 engine, including cylinder head, block, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system.

Engine Performance:

Fuel injection system, ignition system, turbocharger system, emissions control system, engine management system (ECU).

Transmission:

Manual transmission (5-speed and 6-speed depending on specific Evo VII variant), clutch system, transfer case, rear differential (including AYC - Active Center Differential).

Drivetrain:

Driveshafts, CV joints, wheel bearings, driveline lubrication.

Suspension:

Front and rear suspension components (struts, springs, control arms, bushings), shock absorber replacement, alignment specifications.

Brakes:

Hydraulic brake system, ABS (Anti-lock Braking System), brake pad and rotor replacement, caliper service, brake fluid specifications, bleeding procedures.

Steering:

Power steering system, steering rack, tie rods, steering column, alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams.

Electronics:

ECU, sensors (crankshaft position, camshaft position, oxygen, mass air flow), immobilizer system, audio system, climate control.

Body And Frame:

Body panel removal/installation, interior trim, glass replacement, door mechanisms, hood and trunk latches, underbody coatings, rust prevention.

Climate Control:

HVAC system components, refrigerant specifications, troubleshooting, component replacement (compressor, condenser, evaporator).

Safety Systems:

Airbag system (SRS), seatbelt mechanisms, safety compliance.

Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, drivetrain fluid changes, belt inspections and replacements.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), electrical system diagnosis, engine performance issues, system-specific fault finding.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service, body panel repairs.

Installation:

Procedures for installing new or replacement parts, accessory installation, major component replacement.

Adjustment:

Engine idle speed, clutch pedal free play, parking brake adjustment.

Torque Specifications:

Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage.

Depth:

Comprehensive; covers everything from basic scheduled maintenance and routine repairs to complex engine and transmission overhauls, advanced diagnostics, and electrical system troubleshooting.

Diagnostic Tools:

Details on using diagnostic scan tools (e.g., MUT-III or compatible aftermarket), understanding sensor data, and interpreting DTCs.

Special Tools:

Identification of required special tools for specific procedures, often with part numbers or descriptions.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable (if OCR'd properly), allowing for quick information retrieval.

Illustrations:

High-quality factory diagrams, schematics, and detailed step-by-step illustrations.

Text Clarity:

Clear, concise technical language typical of OEM manuals.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

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

Engine Code:

4G63

Displacement:

2.0 Liters (1997 cc)

Horsepower:

Approximately 271-280 PS (267-276 hp) depending on market and specific tuning.

Torque:

Approximately 370-380 Nm (273-280 lb-ft) depending on market and specific tuning.

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (high octane recommended, typically 95 RON or higher)

Turbocharger Details:

MHI TD05HR-16G (or similar variant) twin-scroll turbocharger with intercooler.

🔧 Transmission

Transmission Type:

5-speed manual (most common) or 6-speed manual (Evo VII GSR)

Optional Transmission:

N/A for this generation's performance variants; typically manual only.

All Wheel Drive:

Advanced S-AWC (Super All Wheel Control) system, integrating AYC (Active Center Differential), ACD (Active Center Differential), and G-sensor for optimal traction and handling.

Clutch Type:

Hydraulically operated, multi-plate (specifics vary by model/trim)

📐 Dimensions

Length:

Approx. 4,440 mm (174.8 in)

Width:

Approx. 1,770 mm (69.7 in)

Height:

Approx. 1,415 mm (55.7 in)

Wheelbase:

Approx. 2,600 mm (102.4 in)

Curb Weight:

Approx. 1,400-1,500 kg (3,086-3,307 lbs), varies by trim and specifications.

🛡️ Safety Features

Crash Test Ratings:

Varies by market. Typically featured front airbags and ABS. Refer to market-specific safety reports for detailed ratings.

Active Safety:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), AYC/ACD (Active Center Differential) for enhanced stability and traction control.

Passive Safety:

Front airbags, 3-point seat belts with pretensioners, reinforced chassis and safety cell.

💡 Technology Features

Infotainment System:

Basic audio systems with CD player and radio. May have options for premium sound systems. Navigation was not standard on all models.

Driver Assistance Features:

ABS, EBD, AYC/ACD are primary electronic aids. Traction control was not as sophisticated as in later generations but integrated into the AWD system.

Connectivity Options:

Limited by modern standards. Typically featured basic audio inputs. No Bluetooth or USB connectivity standard.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first, especially under spirited driving conditions.

Timing Belt Replacement:

Crucial component. Typically recommended every 60,000-80,000 miles (96,000-128,000 km) or 5-7 years. Failure can lead to catastrophic engine damage.

Transmission Fluid Change:

Recommended every 30,000-50,000 miles (48,000-80,000 km) for manual transmission and transfer case/rear differential fluids.

Engine Oil:

API SG, SH, SJ, or higher; SAE 10W-30 or 10W-40 recommended. Check owner's manual for specific grades based on climate.

Coolant:

Mitsubishi Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors) mixed 50/50 with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Manual:

API GL-4 or GL-5 SAE 75W-90 gear oil. Consult manual for specific AYC/ACD fluid requirements.

Engine:

Head gasket failures (especially if poorly maintained or modified), turbocharger wear, piston ring issues (if abused). The 4G63 is robust when properly maintained.

Drivetrain:

AYC pump failure, clutch wear due to aggressive driving, differential wear if fluid maintenance is neglected.

Electrical:

Occasional sensor failures, power window motor issues, corrosion on connectors in humid climates.

📚 Vehicle History

Mitsubishi Motors:

Mitsubishi Motors has a long history in motorsport, particularly rallying, which heavily influenced the development of the Lancer Evolution.

Evolution Lineage:

The Lancer Evolution (often abbreviated as Evo) is the seventh generation of Mitsubishi's legendary performance sedan, a homologation special for WRC. It evolved significantly from its predecessors, introducing advanced electronics and chassis technologies.

Production Period:

The Evo VII was produced from 2001 to 2003, with this manual covering the 2003 model year (and potentially late 2002/early 2003 production). The manual covers the 2003-2005 model years for the specific market it was intended for.

🏆 Awards & Recognition

Motorsport Awards:

The Lancer Evolution platform itself has a storied history of victories and championships in WRC, signifying its inherent engineering prowess and performance capabilities.

Performance Reviews:

Consistently lauded by automotive press for its exceptional handling, acceleration, and all-wheel-drive system. Often cited as a benchmark for performance compact cars.