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Mitsubishi Lancer Evolution 8 Service Repair Manual
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Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Generation: VIII Model Code: CT9A (JDM), VIII (Global) Codes Chassis Code: CT9A Engine Code: 4G63 (MIVEC) Introduction Market Position Market Position:...
Typ: Cars
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Art.-Nr: 428065
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| Basic Information | |
| Identification | |
| Make: | Mitsubishi |
| Model: | Lancer Evolution VIII |
| Generation: | VIII |
| Model Code: | CT9A (JDM), VIII (Global) |
| Codes | |
| Chassis Code: | CT9A |
| Engine Code: | 4G63 (MIVEC) |
| Introduction | |
| Market Position | |
| Market Position: | Performance rally-bred homologation special, enthusiast-focused sports sedan |
| Competitive Analysis | |
| Competitors: | Subaru WRX STI, Lancia Delta Integrale, Ford Focus RS, Audi S3 |
| Key Features | |
| Key Features: | Symmetrical All-Wheel Drive (SAWD), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), potent turbocharged engine, robust chassis |
| Target Audience | |
| Target Audience: | Enthusiasts, DIY mechanics, performance tuners, owners seeking in-depth technical understanding |
| Unique Selling Proposition | |
| Usp: | Unrivaled all-wheel-drive system and rally heritage translated to a road-going performance icon. |
| Manual Details | |
| Coverage Areas | |
| Coverage: | Complete Service and Repair |
| Page Count | |
| Page Count: | Likely 1000+ pages (typical for comprehensive service manuals) |
| Manual Type | |
| Manual Type: | Official Factory Service Manual (FSM) |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital Download (PDF) |
| Manual Coverage | |
| Systems Covered | |
| Engine: | 4G63 MIVEC Turbocharged, lubrication, cooling, fuel, ignition, emissions control, starting, charging |
| Transmission: | 6-speed manual (Getrag), drivetrain components, propeller shaft, rear differential, driveshafts |
| Brakes: | ABS, EBD, front Brembo 4-piston calipers, rear Brembo 2-piston calipers, brake fluid, bleeding procedures |
| Suspension: | Front MacPherson struts, rear multi-link, springs, shock absorbers, sway bars, alignment procedures |
| Steering: | Power assisted rack and pinion, steering column, tie rods |
| Electrical: | Battery, alternator, starter, lighting, ignition system, CAN bus, ECU, sensors, wiring diagrams, fuses, relays |
| Bodywork: | Exterior panels, interior trim, doors, windows, locks, glass, bumpers, aerodynamics |
| HVAC: | Heating, Ventilation, and Air Conditioning system components, refrigerant, troubleshooting |
| Safety Systems: | SRS airbags, seatbelts, seatbelt pretensioners |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and replacements |
| Troubleshooting: | Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, fault diagnosis for all major systems |
| Repair: | Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component repair |
| Disassembly Assembly: | Step-by-step instructions for removing, installing, and reassembling all major components |
| Diagnostics: | OBD-II diagnostics, ECU data interpretation, sensor testing, actuator testing |
| Specifications: | Torque specifications for all fasteners, engine clearances, fluid capacities, pressure specifications |
| Technical Depth | |
| Depth: | Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics) |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Searchable: | Yes (if OCR processed) |
| Print Quality | |
| Print Quality: | High-resolution, suitable for printing individual pages or the entire manual |
| Binding Type | |
| Binding Type: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 4G63 MIVEC Inline-4 DOHC Turbocharged |
| Displacement: | 2.0 Liters (1997 cc) |
| Bore X Stroke: | 85.0 mm x 88.0 mm |
| Compression Ratio: | 8.8:1 |
| Power Output Hp: | 275 hp (205 kW) @ 6500 rpm (JDM Spec), 276 hp (206 kW) @ 6500 rpm (US Spec) |
| Torque Output Lb Ft: | 273 lb-ft (370 Nm) @ 3500 rpm (JDM Spec), 286 lb-ft (388 Nm) @ 3500 rpm (US Spec) |
| Performance | |
| Redline: | 7000 rpm |
| Fuel System | |
| Fuel Type: | Premium Unleaded Gasoline (91+ Octane) |
| Fuel Delivery: | Electronic Fuel Injection (EFI) with Turbocharger |
| Turbocharger: | Mitsubishi TD05H-16G (Single Scroll) |
| Engine Management | |
| ECU: | Multi-point Fuel Injection, Electronic Ignition Control |
| Transmission | |
| Standard | |
| Transmission Type: | 6-speed Manual (Getrag Type D) |
| Optional | |
| Optional Transmission: | None (Manual was standard) |
| Features | |
| Drivetrain: | All-Wheel Drive (SAWD) with Active Center Differential (ACD) |
| Differential Control: | ACD with tarmac, gravel, and snow modes; Super AYC (Active Yaw Control) for rear differential torque vectoring |
| Fluid Specs | |
| Transmission Fluid Type: | API GL-4 or GL-5 (check specific manual for exact spec, often synthetic) |
| 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) |
| Ground Clearance: | 135 mm (5.3 in) |
| Weights | |
| Curb Weight: | Approx. 1450 kg (3197 lbs) |
| Gross Vehicle Weight Rating: | Approx. 1800 kg (3968 lbs) |
| Wheels Tires | |
| Wheel Size: | 17 x 8.0 inches (standard GSR/MR) |
| Tire Size: | 235/45R17 (standard) |
| Bolt Pattern: | 5x114.3 mm (5x4.5 inch) |
| Offset: | ET38 (standard) |
| Safety Features | |
| Ratings | |
| NHTSA Front Impact: | Not explicitly rated by NHTSA for this specific model year, but generally good for its class. |
| IIHS Side Impact: | Not explicitly rated by IIHS for this specific model year, but generally good for its class. |
| Active Features | |
| ABS: | Standard (Bosch 5.3 ABS) |
| Ebd: | Standard (Electronic Brake-force Distribution) |
| Acd: | Standard (Active Center Differential) |
| Sayc: | Standard on MR trim, optional/integrated with ACD on GSR |
| Passive Features | |
| Airbags: | Driver and Passenger Airbags (SRS) |
| Seatbelts: | 3-point front and rear seatbelts with pretensioners |
| Roll Cage: | Reinforced chassis structure, often referred to as a 'safety cage' for rally homologation |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Basic factory CD player with AM/FM radio. Later models might have options for upgraded head units. |
| Speakers: | Typically 6-speaker system. |
| Driver Assistance | |
| Driver Assistance Features: | ABS, EBD, ACD, S-AYC (on MR trim). |
| Connectivity | |
| Connectivity Options: | Limited. Primarily basic audio inputs. Aftermarket solutions for Bluetooth/USB. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 3,750 - 5,000 miles or 6 months, whichever comes first (depending on driving conditions; severe use requires more frequent changes). |
| Air Filter Replacement: | Every 15,000 - 30,000 miles or as needed based on inspection. |
| Spark Plug Replacement: | Every 30,000 - 60,000 miles (depending on plug type and manufacturer recommendation). |
| Timing Belt Replacement: | Crucial: Every 60,000 - 90,000 miles or 5-7 years. Failure is catastrophic. |
| Coolant Flush: | Every 30,000 - 60,000 miles or 2-4 years. |
| Transmission Fluid Change: | Every 30,000 - 60,000 miles, especially for spirited driving. |
| Fluid Specifications | |
| Engine Oil Capacity: | Approx. 4.5 - 5.0 Liters (with filter) |
| Engine Oil Recommendation: | 0W-30, 5W-30, or 5W-40 Synthetic (API SN or higher, ACEA A3/B4 recommended for performance). |
| Coolant Type: | Mitsubishi Super Long Life Coolant (DIA-QUEEN SUPER LONG LIFE COOLANT) or equivalent OAT/HOAT coolant, typically red or pink. |
| Brake Fluid Type: | DOT 3 or DOT 4 (preferably DOT 4 for higher performance). |
| Known Issues | |
| Engine: | Head gasket failures (especially on modified engines), turbocharger wear, piston ring wear, connecting rod bearing failures (high mileage/abuse). |
| Drivetrain: | ACD/AYC pump failures, manual transmission synchro wear, rear differential issues. |
| Electrical: | Faulty ACD/AYC pump relays, ABS sensor failures, ECU failures. |
| Suspension Steering: | Worn suspension bushings, strut mounts, power steering pump leaks. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Mitsubishi has a long and storied history in the World Rally Championship (WRC), with the Lancer Evolution series being its flagship rally homologation model. |
| Model Evolution | |
| Evolution Lineage: | The Evo VIII (CT9A) followed the Evo VII and was part of a continuous development cycle driven by rally success. It introduced significant chassis and drivetrain improvements. |
| Production | |
| Production Years: | 2003-2005 |
| Assembly Location: | Japan |
| Variants | |
| Notable Variants: | GSR (standard, often more creature comforts), RS (lighter, stripped-down, rally-focused), MR (premium trim, Bilstein suspension, Recaro seats, usually a more aggressive ACD/AYC setup) |
| Awards & Recognition | |
| Recognitions | |
| Performance Awards: | Consistently recognized by automotive media for its handling, performance, and rally-inspired driving dynamics. Often praised as one of the best affordable performance cars of its era. |
| Ratings | |
| Enthusiast Ratings: | Highly rated by enthusiasts for its tuning potential and engaging driving experience. |
| Certifications | |
| Homologation Status: | Rally homologation special, built to meet FIA regulations for Group A rallying. |