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2002 2003 Mitsubishi Lancer Evolution VII (EVO 7) Lancer Evolution VIII (EVO 8) Service Repair Factory Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VII / VIII Model Code Evo Vii: CT9A Model Code Evo Viii: CT9A Codes Platform: Mitsubishi GS platform (shared with Lancer Cedia) 👋 Introduction Market Position Segment: Performance compact sedan / Rally homologation special. Reputation: Legendary status in the rally and performance car community, known for its advanced All-Wheel Drive (AWD) system and powerful turbocharged engine. Competitive Analysis Rivals: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (in spirit, though different classes). Key Features Powertrain: Iconic 4G63T 2.0L inline-4 DOHC turbocharged engine, advanced electronically controlled All-Wheel Drive (AYC/ACD). Chassis: Reinforced chassis derived from rally homologation requirements, performance-tuned suspension, potent braking systems (often Brembo). Aerodynamics: Aggressive body kit, large rear spoiler, functional aerodynamic enhancements for stability at high speeds. 📋 Manual Details Coverage Areas Coverage: Complete service, repair, and diagnostic coverage for Mitsubishi Lancer Evolution VII and VIII models. Page Count Pages: Extensive (typically 1000+ pages combined or per model, actual count not specified in product info, but inferred by depth of coverage) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English (inferred from common market availability for these models) Format Format: Digital Download (PDF or similar electronic format) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (4G63T), fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharger system. Drivetrain: Manual transmission (Getrag 5-speed for VII, Getrag 6-speed for VIII), transfer case, front differential, rear differential (Active Yaw Control - AYC, Super Active Yaw Control - Super AYC). Chassis: Suspension (MacPherson struts front, multi-link rear), steering system (power-assisted rack and pinion), braking system (Brembo calipers often standard), wheels, tires. Electrical: Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), immobilizer system, audio system. Body: Exterior body panels, interior trim, doors, windows, seats, HVAC system, safety systems (airbags, seatbelts). Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, spark plug replacement. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, testing procedures for sensors and actuators, wiring diagrams. Repair: Step-by-step repair instructions for all major components and systems, including engine overhaul, transmission rebuild, suspension replacement, brake caliper servicing. Specifications: Torque specifications for all fasteners, engine specifications, dimensions, electrical specifications, performance data. Technical Depth Depth: Comprehensive (from basic fluid changes to advanced engine and transmission rebuilds, including electronic diagnostics and system calibration). 📊 Manual Specifications File Format Format: Likely PDF; searchable text is highly probable for modern digital manuals. Print Quality Quality: High-resolution digital images and diagrams, typically equivalent to or exceeding OEM print quality. Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) Accessibility Searchability: Typically searchable PDF allowing for quick access to specific information. Updates Version Control: Represents factory service information for the specified model years; may not include later technical service bulletins (TSBs) unless explicitly stated. ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L (1997cc) Inline-4, DOHC, 16-valve, turbocharged and intercooled. Performance Horsepower Evo Vii: Approx. 280 PS (276 hp / 206 kW) - JDM spec. Varies by market and specific tuning. Torque Evo Vii: Approx. 373 Nm (275 lb-ft) - JDM spec. Horsepower Evo Viii: Approx. 271 hp (202 kW) in US spec, ~280 PS (206 kW) in other markets. Higher output in RS/MR variants. Torque Evo Viii: Approx. 286 lb-ft (388 Nm) in US spec. Fuel System Induction: Electronic Fuel Injection (EFI), Turbocharged, Intercooled. Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Cooling System Coolant Type: Mitsubishi DIA QUEEN SUPER LONG LIFE COOLANT (or equivalent ethylene glycol based coolant with long-life additives). Lubrication System Oil Capacity: Approx. 4.5 liters (4.8 US quarts) with filter change. Oil Specification: API SG, SH, SJ or ILSAC GF-2, GF-3. Viscosity: SAE 10W-30 or 10W-40 recommended for most conditions. Engine Management ECU: Engine Control Unit (ECU) with sophisticated engine management for turbocharging, ignition timing, and fuel delivery. 🔧 Transmission Standard Transmission Type: Mitsubishi F5M33 (Evo VII - 5-speed manual) / Mitsubishi KM220 (Evo VIII - 6-speed manual - RS/GSR models). Optional Transmission Type: No automatic transmission option was typically offered for these performance variants. Features All Wheel Drive: Active Centre Differential (ACD) and Active Yaw Control (AYC) or Super AYC for advanced torque distribution and handling control. Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5 gear oil, SAE 75W-90 is common. Refer to manual for specific AYC/ACD fluid. Fluid Capacity Manual Transmission Capacity: Approximately 2.0-2.5 liters (Evo VII) / 2.0-2.3 liters (Evo VIII). Check manual for exact fill level. 📐 Dimensions Exterior Length: Approx. 4400-4440 mm (173.2-174.8 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1415-1430 mm (55.7-56.3 in) Wheelbase: Approx. 2600 mm (102.4 in) Weights Curb Weight: Approx. 1450-1500 kg (3197-3307 lbs) depending on trim and options. Gross Vehicle...
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2002 2003 Mitsubishi Lancer Evolution VII (EVO 7) Lancer Evolution VIII (EVO 8) Service Repair Factory Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VII / VIII
Model Code Evo Vii:
CT9A
Model Code Evo Viii:
CT9A
Codes
Platform:
Mitsubishi GS platform (shared with Lancer Cedia)
👋 Introduction
Market Position
Segment:
Performance compact sedan / Rally homologation special.
Reputation:
Legendary status in the rally and performance car community, known for its advanced All-Wheel Drive (AWD) system and powerful turbocharged engine.
Competitive Analysis
Rivals:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (in spirit, though different classes).
Key Features
Powertrain:
Iconic 4G63T 2.0L inline-4 DOHC turbocharged engine, advanced electronically controlled All-Wheel Drive (AYC/ACD).
Chassis:
Reinforced chassis derived from rally homologation requirements, performance-tuned suspension, potent braking systems (often Brembo).
Aerodynamics:
Aggressive body kit, large rear spoiler, functional aerodynamic enhancements for stability at high speeds.
📋 Manual Details
Coverage Areas
Coverage:
Complete service, repair, and diagnostic coverage for Mitsubishi Lancer Evolution VII and VIII models.
Page Count
Pages:
Extensive (typically 1000+ pages combined or per model, actual count not specified in product info, but inferred by depth of coverage)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English (inferred from common market availability for these models)
Format
Format:
Digital Download (PDF or similar electronic format)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (4G63T), fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharger system.
Drivetrain:
Manual transmission (Getrag 5-speed for VII, Getrag 6-speed for VIII), transfer case, front differential, rear differential (Active Yaw Control - AYC, Super Active Yaw Control - Super AYC).
Chassis:
Suspension (MacPherson struts front, multi-link rear), steering system (power-assisted rack and pinion), braking system (Brembo calipers often standard), wheels, tires.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), immobilizer system, audio system.
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, safety systems (airbags, seatbelts).
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, spark plug replacement.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, testing procedures for sensors and actuators, wiring diagrams.
Repair:
Step-by-step repair instructions for all major components and systems, including engine overhaul, transmission rebuild, suspension replacement, brake caliper servicing.
Specifications:
Torque specifications for all fasteners, engine specifications, dimensions, electrical specifications, performance data.
Technical Depth
Depth:
Comprehensive (from basic fluid changes to advanced engine and transmission rebuilds, including electronic diagnostics and system calibration).
📊 Manual Specifications
File Format
Format:
Likely PDF; searchable text is highly probable for modern digital manuals.
Print Quality
Quality:
High-resolution digital images and diagrams, typically equivalent to or exceeding OEM print quality.
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Type:
Not applicable (Digital Download)
Accessibility
Searchability:
Typically searchable PDF allowing for quick access to specific information.
Updates
Version Control:
Represents factory service information for the specified model years; may not include later technical service bulletins (TSBs) unless explicitly stated.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) Inline-4, DOHC, 16-valve, turbocharged and intercooled.
Performance
Horsepower Evo Vii:
Approx. 280 PS (276 hp / 206 kW) - JDM spec. Varies by market and specific tuning.
Torque Evo Vii:
Approx. 373 Nm (275 lb-ft) - JDM spec.
Horsepower Evo Viii:
Approx. 271 hp (202 kW) in US spec, ~280 PS (206 kW) in other markets. Higher output in RS/MR variants.
Torque Evo Viii:
Approx. 286 lb-ft (388 Nm) in US spec.
Fuel System
Induction:
Electronic Fuel Injection (EFI), Turbocharged, Intercooled.
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Cooling System
Coolant Type:
Mitsubishi DIA QUEEN SUPER LONG LIFE COOLANT (or equivalent ethylene glycol based coolant with long-life additives).
Lubrication System
Oil Capacity:
Approx. 4.5 liters (4.8 US quarts) with filter change.
Oil Specification:
API SG, SH, SJ or ILSAC GF-2, GF-3. Viscosity: SAE 10W-30 or 10W-40 recommended for most conditions.
Engine Management
ECU:
Engine Control Unit (ECU) with sophisticated engine management for turbocharging, ignition timing, and fuel delivery.
🔧 Transmission
Standard
Transmission Type:
Mitsubishi F5M33 (Evo VII - 5-speed manual) / Mitsubishi KM220 (Evo VIII - 6-speed manual - RS/GSR models).
Optional
Transmission Type:
No automatic transmission option was typically offered for these performance variants.
Features
All Wheel Drive:
Active Centre Differential (ACD) and Active Yaw Control (AYC) or Super AYC for advanced torque distribution and handling control.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 is common. Refer to manual for specific AYC/ACD fluid.
Fluid Capacity
Manual Transmission Capacity:
Approximately 2.0-2.5 liters (Evo VII) / 2.0-2.3 liters (Evo VIII). Check manual for exact fill level.
📐 Dimensions
Exterior
Length:
Approx. 4400-4440 mm (173.2-174.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415-1430 mm (55.7-56.3 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs) depending on trim and options.
Gross Vehicle Weight Rating:
Typically around 1850-1900 kg (4079-4189 lbs).
Cargo
Trunk Volume:
Approx. 0.43 m³ (15.2 cu ft) - may vary slightly between VII and VIII.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency. In the US, models of this era generally had good, but not perfect, ratings. Check specific NHTSA or IIHS reports for detailed data.
Active Features
Traction Control:
Standard with advanced AWD systems (ACD/AYC).
Electronic Stability Control:
Available on some later Evo VIII models (often labeled ASTC or similar).
Antilock Brakes:
Standard, often integrated with the AWD system.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags available on some trims.
Seatbelts:
Three-point seatbelts with pretensioners for front seats.
Body Structure:
Reinforced chassis and safety cell designed for rally performance and occupant protection.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player with 6 speakers. Higher trims may have premium audio options.
Gauges:
Comprehensive instrument cluster including boost gauge, oil pressure gauge, and voltmeter (depending on trim and market).
Driver Assistance
Advanced AWD:
Active Center Differential (ACD) and Active Yaw Control (AYC) are the primary driver assistance technologies, directly impacting handling dynamics.
Connectivity
Auxiliary Input:
Typically not present on stock units of this era. Aftermarket head unit installations common.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, under normal driving conditions. More frequent changes recommended for spirited driving or track use.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plug Replacement:
Typically every 60,000-100,000 miles (96,000-160,000 km) for platinum or iridium plugs. Check manual for specific type and interval.
Timing Belt Replacement:
Crucial: Every 60,000-70,000 miles (96,000-112,000 km) or 5 years due to the interference nature of the 4G63T engine.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. High-performance driving may benefit from DOT 4 racing fluid.
Power Steering Fluid:
Dexron III/Mercon ATF or specific Mitsubishi power steering fluid.
Fluid Capacities
Coolant Capacity:
Approx. 7.0 liters (7.4 US quarts).
Known Issues
Engine Reliability:
The 4G63T is robust, but prone to head gasket failure under high boost or poor tuning. Bearing failure can occur if oil starvation is present. Rod knock is a serious concern.
Turbocharger:
Turbocharger can fail due to oil coking if heat cycles are not managed properly (e.g., extended idling after hard driving). Cracked exhaust manifolds are also a known issue on some generations.
Ayc System:
AYC pump and sensors can fail, leading to warning lights and degraded handling. Fluid leaks are also possible.
Clutch:
Clutch wear is high under spirited driving conditions. Upgraded clutches are common.
Common Upgrades
Performance Parts:
Popular upgrades include aftermarket ECUs, larger turbochargers, upgraded intercoolers, high-flow fuel injectors, performance exhausts, and upgraded suspension components.
📚 Vehicle History
Brand Heritage
Motorsport Link:
Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) Lancer Evolution program.
Model Evolution
Evo Vii Introduction:
Introduced in February 2001, featuring a revised engine, transmission, and chassis with focus on improved handling via AYC.
Evo Viii Introduction:
Introduced in January 2003, featuring a larger turbocharger, revised intercooler, stronger gearbox (6-speed on GSR/RS), and Bilstein suspension on some models. Notably, the first Evolution officially sold in the USA.
Production
Production Period:
Lancer Evolution VII: 2001-2002. Lancer Evolution VIII: 2003-2004.
Major Markets:
Japan, Europe, Australia, North America (Evo VIII onwards).
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive media for its rally-bred performance, handling, and AWD system. Often cited as a benchmark for performance sedans.
Track Day Performance:
Widely recognized for its track day capabilities, though it requires careful maintenance and driver input.
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