Mitsubishi Lancer Evolution 8 2003-2005 All Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Generation: VIII Model Years Covered: 2003, 2004, 2005 Codes Chassis Code: CT9A 👋 Introduction Market Position Positioning: Iconic rally homologation special, renowned for its performance, handling, and advanced all-wheel-drive system. Positioned as a high-performance sports sedan. Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (other generations), Ford Focus RS, Audi S3, BMW M3 (for performance enthusiasts). Key Features Performance: Powerful turbocharged engine, advanced AWD system with torque vectoring, performance-tuned suspension, powerful Brembo brakes. Handling: Exceptional grip and agility due to S-AWC system, driver-selectable modes for ACD and AYC, responsive steering. Value Proposition Manual Utility: Essential for owners and independent mechanics aiming to maintain, repair, and diagnose the complex systems of the Evo VIII, enabling cost savings and ensuring proper upkeep of a performance vehicle. 📋 Manual Details Coverage Areas Primary Coverage: North America (for sale purposes, though manual may be global in scope) Page Count Estimated Page Count: 1500+ Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Engine: 4G63T (2.0L MIVEC Turbocharged Inline-4) Transmission: 6-speed Manual Transmission (Getrag MD743703) Drivetrain: All-Wheel Drive (S-AWC - Super All Wheel Control), ACD (Active Center Differential), AYC (Active Yaw Control), Super Active Yaw Control Suspension: Front MacPherson Struts, Rear Multi-Link Independent Suspension Brakes: Front: Brembo 4-piston calipers, 13-inch ventilated discs. Rear: Brembo 2-piston calipers, 13-inch ventilated discs. Electrical System: Engine Control Module (ECU), Powertrain Control Module (PCM), Ignition System, Lighting, Accessories, Instrumentation, Body Control Modules (BCM) Body And Interior: Body Panels, Doors, Windows, Seats, Dashboard, Trim, Climate Control, Audio System Diagnostics: OBD-II system, DTC (Diagnostic Trouble Codes) interpretation and troubleshooting procedures Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad/rotor replacement, belt inspection and replacement. Repair: Engine overhaul, cylinder head service, turbocharger assembly/disassembly, clutch replacement, differential service, suspension component replacement, brake caliper overhaul, electrical component testing and replacement. Troubleshooting: Diagnostic flowcharts for various symptoms (engine performance, starting issues, electrical faults, braking problems, etc.). Specifications: Torque specifications for all fasteners, engine timing procedures, alignment specifications, electrical schematics, wiring diagrams. Installation: Component removal and installation procedures for all major systems, including engine, transmission, drivetrain components, suspension and brake assemblies. Technical Depth Depth: Comprehensive: Covers from basic maintenance and fluid changes to full engine rebuilds, transmission overhauls, and detailed electrical diagnostics. 📊 Manual Specifications File Format Format: PDF (Searchable Text, Printable Pages) Print Quality Quality: High-resolution scans of original manufacturer documentation. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L (1997cc) DOHC 16-valve turbocharged inline-4 Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Hp: 271 hp @ 6500 rpm (USDM spec, may vary slightly by region) Torque Lb-Ft: 273 lb-ft @ 3500 rpm (USDM spec, may vary slightly by region) Redline: 7000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Electronic Fuel Pump Fuel Type: Unleaded Premium Gasoline (91 octane or higher recommended) Turbocharging Turbocharger Model: Mitsubishi TD05H-16G (or similar variant) Intercooler: Front-mounted, air-to-air intercooler 🔧 Transmission Standard Type: 6-speed Manual Transmission Manufacturer: Getrag Model Code: MD743703 Optional Type: N/A (Only Manual Transmission Offered for Evo VIII) Features Clutch: Hydraulically operated, multi-plate clutch system (designed for high torque transfer). Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (Refer to manual for exact OEM specification and capacity, typically around 2.0-2.5 liters). 📐 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: 1515 mm (59.6 in) Rear Track: 1510 mm (59.4 in) Weights Curb Weight: Approx. 1450-1500 kg (3197-3307 lbs), depending on trim and options Gross Vehicle Weight Rating: Refer to vehicle VIN plate Cargo Trunk Volume: Approx. 0.31 m³ (11.0 cu ft) Wheels And Tires Standard Wheel Size: 17x8.0 inches (Enkei) Optional Wheel Size: 17x8.5 inches (BBS, on some special editions like MR) Standard Tire Size: 235/45R17 Bolt Pattern: 5x114.3 mm Offset: ET+38 to +43 (approximate, check specific wheels) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for all years/trims in the same manner as modern vehicles, but built with structural integrity for performance. IIHS Crash Test Performance: Generally performed well for its era in frontal and side impact tests, though specific ratings can vary. Active Features Traction Control: Standard Traction Control System (TCL) Stability Control: Active Stability Control (ASC) available on some models ABS: Anti-lock Braking System (ABS) standard AWD System: Super All-Wheel Control (S-AWC) incorporating ACD, AYC (and Super AYC on MR models) Passive Features Airbags: Driver and front passenger airbags standard, side curtain airbags available on some trims. Seatbelts: 3-point front and rear seatbelts...
Iconic rally homologation special, renowned for its performance, handling, and advanced all-wheel-drive system. Positioned as a high-performance sports sedan.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (other generations), Ford Focus RS, Audi S3, BMW M3 (for performance enthusiasts).
Key Features
Performance:
Powerful turbocharged engine, advanced AWD system with torque vectoring, performance-tuned suspension, powerful Brembo brakes.
Handling:
Exceptional grip and agility due to S-AWC system, driver-selectable modes for ACD and AYC, responsive steering.
Value Proposition
Manual Utility:
Essential for owners and independent mechanics aiming to maintain, repair, and diagnose the complex systems of the Evo VIII, enabling cost savings and ensuring proper upkeep of a performance vehicle.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America (for sale purposes, though manual may be global in scope)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
4G63T (2.0L MIVEC Turbocharged Inline-4)
Transmission:
6-speed Manual Transmission (Getrag MD743703)
Drivetrain:
All-Wheel Drive (S-AWC - Super All Wheel Control), ACD (Active Center Differential), AYC (Active Yaw Control), Super Active Yaw Control
Suspension:
Front MacPherson Struts, Rear Multi-Link Independent Suspension
Diagnostic flowcharts for various symptoms (engine performance, starting issues, electrical faults, braking problems, etc.).
Specifications:
Torque specifications for all fasteners, engine timing procedures, alignment specifications, electrical schematics, wiring diagrams.
Installation:
Component removal and installation procedures for all major systems, including engine, transmission, drivetrain components, suspension and brake assemblies.
Technical Depth
Depth:
Comprehensive: Covers from basic maintenance and fluid changes to full engine rebuilds, transmission overhauls, and detailed electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF (Searchable Text, Printable Pages)
Print Quality
Quality:
High-resolution scans of original manufacturer documentation.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) DOHC 16-valve turbocharged inline-4
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Hp:
271 hp @ 6500 rpm (USDM spec, may vary slightly by region)
Torque Lb-Ft:
273 lb-ft @ 3500 rpm (USDM spec, may vary slightly by region)
Redline:
7000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Fuel Pump
Fuel Type:
Unleaded Premium Gasoline (91 octane or higher recommended)
Turbocharging
Turbocharger Model:
Mitsubishi TD05H-16G (or similar variant)
Intercooler:
Front-mounted, air-to-air intercooler
🔧 Transmission
Standard
Type:
6-speed Manual Transmission
Manufacturer:
Getrag
Model Code:
MD743703
Optional
Type:
N/A (Only Manual Transmission Offered for Evo VIII)
Features
Clutch:
Hydraulically operated, multi-plate clutch system (designed for high torque transfer).
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (Refer to manual for exact OEM specification and capacity, typically around 2.0-2.5 liters).
📐 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:
1515 mm (59.6 in)
Rear Track:
1510 mm (59.4 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs), depending on trim and options
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate
Cargo
Trunk Volume:
Approx. 0.31 m³ (11.0 cu ft)
Wheels And Tires
Standard Wheel Size:
17x8.0 inches (Enkei)
Optional Wheel Size:
17x8.5 inches (BBS, on some special editions like MR)
Standard Tire Size:
235/45R17
Bolt Pattern:
5x114.3 mm
Offset:
ET+38 to +43 (approximate, check specific wheels)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated for all years/trims in the same manner as modern vehicles, but built with structural integrity for performance.
IIHS Crash Test Performance:
Generally performed well for its era in frontal and side impact tests, though specific ratings can vary.
Active Features
Traction Control:
Standard Traction Control System (TCL)
Stability Control:
Active Stability Control (ASC) available on some models
ABS:
Anti-lock Braking System (ABS) standard
AWD System:
Super All-Wheel Control (S-AWC) incorporating ACD, AYC (and Super AYC on MR models)
Passive Features
Airbags:
Driver and front passenger airbags standard, side curtain airbags available on some trims.
Seatbelts:
3-point front and rear seatbelts with pretensioners
Body Structure:
Reinforced safety cell, energy-absorbing crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with 6 speakers (upgraded Infinity or Rockford Fosgate systems available on some trims).
Climate Control:
Manual or Automatic Climate Control (depending on trim).
Instrumentation:
Comprehensive gauge cluster including tachometer, speedometer, boost gauge, and ACD/AYC mode indicators.
Driver Assistance
Advanced Features:
Key technology is the S-AWC system which integrates ACD, AYC, ABS, and ASC for optimal traction and handling in various conditions.
Connectivity
Standard Features:
Limited by era; no integrated Bluetooth or navigation systems typically offered from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (severe driving conditions/performance driving recommended more frequent changes).
Air Filter Replacement:
Every 15,000-30,000 miles or annually, or as needed based on driving environment.
Spark Plug Replacement:
Every 30,000-60,000 miles (depending on plug type, platinum/iridium recommended).
Timing Belt Replacement:
Every 60,000-90,000 miles or 5-7 years. Crucial for the 4G63T engine.
Fluid Specifications
Engine Oil Type:
Synthetic 5W-30 or 10W-30 (refer to manual for specific viscosity based on climate and load).
Engine Oil Capacity:
Approx. 4.5 - 4.7 liters (4.8 - 5.0 US quarts) with filter change.
Coolant Type:
Ethylene Glycol based, Mitsubishi Super Long Life Coolant (or equivalent)
Coolant Capacity:
Approx. 7.0 - 7.5 liters (7.4 - 7.9 US quarts)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact spec)
Power Steering Fluid Type:
Mitsubishi Power Steering Fluid (or equivalent DEXRON III/MERCON compatible fluid)
Known Issues
Engine Component:
Head gasket failure (especially on modified engines), turbocharger wear, connecting rod bearing issues at high mileage/abuse.
Drivetrain Component:
ACD pump failure, AYC system leaks, differential wear with aggressive driving.
Highly susceptible to premature wear or failure if not maintained diligently or if subjected to aggressive driving without proper upgrades.
📚 Vehicle History
Brand Heritage
Rally Roots:
The Lancer Evolution line is directly derived from Mitsubishi's World Rally Championship (WRC) success, with the Evo VIII serving as a homologation special for rally competition.
Model Evolution
Predecessors:
Lancer Evolution I-VII
Successors:
Lancer Evolution IX, Lancer Evolution X
Production
Introduction Year:
2003
End Year:
2005
Assembly Location:
Japan
Key Variants:
GSR (standard), MR (Ralliart tuning package, often with BBS wheels and Recaro seats), RS (homologation special with fewer amenities).
🏆 Awards & Recognition
Recognitions
Performance Reviews:
Consistently lauded by automotive publications for its incredible handling, grip, and performance capabilities. Often cited as a benchmark for AWD sports sedans.
Enthusiast Following:
Cult following among tuners and enthusiasts due to its robust engine and aftermarket support.
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