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2003 Mitsubishi LANCER EVO 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Code: CT9A Year: 2003 Codes Chassis Code: CT9A Engine Code: 4G63T 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Target Audience: Enthusiasts, performance drivers, rally participants, dedicated DIY mechanics Competitive Analysis Key Competitors: Subaru WRX STI, Ford Focus RS, Honda Civic Type R (in spirit, though different classes) Key Features Rally Heritage: Direct descendant of the World Rally Championship Lancer Evolution series Performance Focus: Designed for high-performance driving and track capability AWD System: Advanced Mitsubishi All-Wheel Control (AWC) system with Active Center Differential (ACD) and Active Yaw Control (AYC) 📋 Manual Details Coverage Areas Regions Covered: Global (primarily focused on markets where the Evo VIII was officially sold, with potential for regional variations) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system Engine Electrical: Ignition system, fuel injection system, starting system, charging system, sensor diagnostics, ECU (Engine Control Unit) operation Transmission: Manual transmission (6-speed), clutch system, driveline, transfer case, rear differential, driveline components Suspension: Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, alignment specifications Brakes: Front and rear brake systems (Brembo on many models), hydraulic system, ABS (Anti-lock Braking System), parking brake, rotor and pad replacement Steering: Power steering system, steering column, tie rods, steering rack, alignment Electrical System: Wiring diagrams, lighting, power windows, power locks, mirrors, audio system, HVAC controls, body control module (BCM) Body And Chassis: Body construction, doors, hood, trunk lid, bumpers, interior trim, chassis components, corrosion protection HVAC: Heating, Ventilation, and Air Conditioning system diagnostics and repair Fuel System: Fuel tank, fuel pump, fuel lines, fuel injectors, EVAP system Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement intervals, belt inspections Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical diagnostics Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment Rebuilding: Detailed procedures for engine and transmission rebuilds Specifications And Tolerances: Torque specifications, clearances, fluid capacities, alignment settings Special Tools: Identification and usage of specialized tools required for specific repairs Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including diagnostics and component-level repair. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable for quick information retrieval Print Quality Quality: High-resolution scans of original factory documentation Binding Type Type: N/A (Digital PDF format) Paper Type Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 2.0L DOHC 16-valve turbocharged inline-4 Engine Code: 4G63T Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Usdm: 276 hp @ 6500 rpm Torque Usdm: 286 lb-ft @ 3500 rpm Redline: 7500 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) with electronic control Fuel Type: Unleaded premium gasoline (91 octane or higher recommended) Turbocharger: Mitsu TD05H-16G turbocharger with intercooler Fluid Capacity Engine Oil Capacity: 4.5 liters (4.8 US quarts) with filter change Fluid Specifications Engine Oil Type: API SG or SH, ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations) 🔧 Transmission Standard Transmission Type: 6-speed manual transmission Optional Transmission Type: None (only manual offered) Features Awc System: Active Center Differential (ACD), Active Yaw Control (AYC) on rear differential Fluid Capacity Manual Transmission Fluid Capacity: Approx. 2.2 liters (2.3 US quarts) GL-4 or GL-5 SAE 75W-90 Fluid Specifications Manual Transmission Fluid Type: GL-4 or GL-5 SAE 75W-90 (refer to manual for specific recommendations) 📐 Dimensions Exterior Length: 4400 mm (173.2 in) Width: 1770 mm (69.7 in) Height: 1450 mm (57.1 in) Wheelbase: 2625 mm (103.3 in) Weights Curb Weight: Approximately 1450 kg (3197 lbs) Gross Vehicle Weight Rating: N/A (Specific GVWR not commonly cited for performance models) 🛡️ Safety Features Ratings NHTSA Front Impact: Not officially rated in all markets, but generally considered robust. IIHS Side Impact: Not officially rated in all markets. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Active Traction Control (TCL) Electronic Stability: Standard Active Stability Control (ASC) (often integrated with AWC) Passive Features Airbags: Driver and front passenger airbags, side airbags (optional or standard depending on market) Seatbelts: 3-point ELR seatbelts with pretensioners and load limiters Structure: Reinforced chassis and safety cell construction 💡 Technology Features Infotainment Head Unit: Factory-provided AM/FM/CD audio system (upgrades common) Display: Basic multi-information display in instrument cluster Driver Assistance Awc System: Mitsubishi All-Wheel Control (AWC) system with driver-selectable ACD modes (Tarmac, Gravel, Snow) Connectivity Bluetooth: Not typically equipped from factory (aftermarket solutions common) 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months,...
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2003 Mitsubishi LANCER EVO 8 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII
Model Code:
CT9A
Year:
2003
Codes
Chassis Code:
CT9A
Engine Code:
4G63T
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, performance drivers, rally participants, dedicated DIY mechanics
Competitive Analysis
Key Competitors:
Subaru WRX STI, Ford Focus RS, Honda Civic Type R (in spirit, though different classes)
Key Features
Rally Heritage:
Direct descendant of the World Rally Championship Lancer Evolution series
Performance Focus:
Designed for high-performance driving and track capability
AWD System:
Advanced Mitsubishi All-Wheel Control (AWC) system with Active Center Differential (ACD) and Active Yaw Control (AYC)
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily focused on markets where the Evo VIII was officially sold, with potential for regional variations)
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for comprehensive service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system
Engine Electrical:
Ignition system, fuel injection system, starting system, charging system, sensor diagnostics, ECU (Engine Control Unit) operation
Transmission:
Manual transmission (6-speed), clutch system, driveline, transfer case, rear differential, driveline components
Suspension:
Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, alignment specifications
Brakes:
Front and rear brake systems (Brembo on many models), hydraulic system, ABS (Anti-lock Braking System), parking brake, rotor and pad replacement
Steering:
Power steering system, steering column, tie rods, steering rack, alignment
Electrical System:
Wiring diagrams, lighting, power windows, power locks, mirrors, audio system, HVAC controls, body control module (BCM)
Body And Chassis:
Body construction, doors, hood, trunk lid, bumpers, interior trim, chassis components, corrosion protection
HVAC:
Heating, Ventilation, and Air Conditioning system diagnostics and repair
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel injectors, EVAP system
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement intervals, belt inspections
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical diagnostics
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment
Rebuilding:
Detailed procedures for engine and transmission rebuilds
Specifications And Tolerances:
Torque specifications, clearances, fluid capacities, alignment settings
Special Tools:
Identification and usage of specialized tools required for specific repairs
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including diagnostics and component-level repair.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable for quick information retrieval
Print Quality
Quality:
High-resolution scans of original factory documentation
Binding Type
Type:
N/A (Digital PDF format)
Paper Type
Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2.0L DOHC 16-valve turbocharged inline-4
Engine Code:
4G63T
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Usdm:
276 hp @ 6500 rpm
Torque Usdm:
286 lb-ft @ 3500 rpm
Redline:
7500 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with electronic control
Fuel Type:
Unleaded premium gasoline (91 octane or higher recommended)
Turbocharger:
Mitsu TD05H-16G turbocharger with intercooler
Fluid Capacity
Engine Oil Capacity:
4.5 liters (4.8 US quarts) with filter change
Fluid Specifications
Engine Oil Type:
API SG or SH, ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations)
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission
Optional
Transmission Type:
None (only manual offered)
Features
Awc System:
Active Center Differential (ACD), Active Yaw Control (AYC) on rear differential
Fluid Capacity
Manual Transmission Fluid Capacity:
Approx. 2.2 liters (2.3 US quarts) GL-4 or GL-5 SAE 75W-90
Fluid Specifications
Manual Transmission Fluid Type:
GL-4 or GL-5 SAE 75W-90 (refer to manual for specific recommendations)
📐 Dimensions
Exterior
Length:
4400 mm (173.2 in)
Width:
1770 mm (69.7 in)
Height:
1450 mm (57.1 in)
Wheelbase:
2625 mm (103.3 in)
Weights
Curb Weight:
Approximately 1450 kg (3197 lbs)
Gross Vehicle Weight Rating:
N/A (Specific GVWR not commonly cited for performance models)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not officially rated in all markets, but generally considered robust.
IIHS Side Impact:
Not officially rated in all markets.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Active Traction Control (TCL)
Electronic Stability:
Standard Active Stability Control (ASC) (often integrated with AWC)
Passive Features
Airbags:
Driver and front passenger airbags, side airbags (optional or standard depending on market)
Seatbelts:
3-point ELR seatbelts with pretensioners and load limiters
Structure:
Reinforced chassis and safety cell construction
💡 Technology Features
Infotainment
Head Unit:
Factory-provided AM/FM/CD audio system (upgrades common)
Display:
Basic multi-information display in instrument cluster
Driver Assistance
Awc System:
Mitsubishi All-Wheel Control (AWC) system with driver-selectable ACD modes (Tarmac, Gravel, Snow)
Connectivity
Bluetooth:
Not typically equipped from factory (aftermarket solutions common)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (severe use may require more frequent changes)
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Every 60,000 miles (iridium type)
Timing Belt Replacement:
Every 105,000 miles or 7 years (critical component, consult manual for specific procedure)
Fluid Specifications
Coolant Type:
Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant
Brake Fluid Type:
DOT 3 or DOT 4 compatible (refer to manual)
Known Issues
Engine Reliability:
Generally robust 4G63T, but susceptible to issues from aggressive modification, poor maintenance, or oil starvation. Check for rod knock.
Turbocharger:
Turbocharger can develop issues if oil is not changed regularly or if oil feed/return lines become clogged.
Clutch Wear:
Clutch can wear prematurely with aggressive driving or track use.
Suspension Bushings:
Rubber suspension bushings can degrade over time, leading to less precise handling.
Rust Corrosion:
Subframes, sills, and wheel wells are common areas for rust, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi Motors has a long history in motorsport, particularly in rallying with the Lancer Evolution lineage.
Model Evolution
Evolution Series:
The Lancer Evolution VIII is the eighth generation of Mitsubishi's iconic performance car, building upon decades of rally-bred technology and development.
Key Changes From Evo Vii:
Updated ACD, revised AYC, new 6-speed transmission, improved suspension geometry, and engine tuning.
Production
Production Years:
2003-2005
Manufacturing Location:
Japan (Mizushima Plant)
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Consistently praised by automotive journalists and enthusiasts for its exceptional handling, acceleration, and rally-bred performance. Often cited as a benchmark for affordable performance cars.
Ratings
Car And Driver Ranking:
Often featured on '10Best' lists or praised in comparison tests against competitors.
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