Mitsubishi Lancer Evolution EVO 8 Service Repair Manual 2003-2005
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII (EVO 8) Platform: Mitsubishi Lancer (CS/CT platform) Generation Generation Name: Eighth Generation Generation Code: CT9A Codes Model Years Covered: 2003, 2004, 2005 Product Code Identifier: Lancer Evolution VIII Service Repair Manual 2003-2005 👋 Introduction Market Position Vehicle Segment: Performance Sedan / Rally Homologation Special Target Audience: Enthusiasts, Performance Driving Participants, Professional Technicians, Dedicated Owners Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Evolution VII/IX, Ford Focus RS, Volkswagen Golf R32 Key Features Performance Focus: Renowned for its turbocharged performance, sophisticated all-wheel-drive system, and rally-bred handling Manual Value Proposition: Provides in-depth, factory-accurate information for maintaining and repairing a highly specialized performance vehicle, crucial for preserving its performance and value. 📋 Manual Details Coverage Areas Manual Types Included: Factory Service Manual (FSM), Body Repair Manual, Technical Information Manual Page Count Estimated Page Count: Several Thousand (typical for comprehensive FSMs) Manual Type Manual Category: Comprehensive Workshop Manual Language Language: English (ENG) Format Primary File Format: PDF Alternative Format Option: ISO (upon request) 📖 Manual Coverage Systems Covered Mechanical Systems: Engine, Drivetrain (All-Wheel Drive), Transmission, Suspension, Steering, Brakes, Fuel System, Cooling System, Exhaust System, Lubrication System Electrical Systems: Engine Control Unit (ECU), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, SRS (Supplemental Restraint System), ABS (Anti-lock Braking System), ASC/TCL (Active Stability Control/Traction Control) Body And Chassis: Body Exterior Panels, Interior Trim, Chassis Components, Safety Structure, Glass, Doors, Seats Procedures Included Maintenance Procedures: Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Differential Fluids, Coolant, Brake Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection/Replacement Diagnostic Procedures: Troubleshooting Charts, DTC (Diagnostic Trouble Code) Interpretation, Component Testing, Wiring Diagram Analysis Repair Procedures: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Repair, Body Panel Repair and Replacement, Interior Component Repair Disassembly Reassembly: Detailed step-by-step instructions with numerous illustrations for component removal and installation Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine performance, drivetrain operation, and electronic systems Rebuild Procedures: Comprehensive guidance for complete engine and transmission rebuilds Wiring Diagrams: Complete, high-quality wiring diagrams for all electrical systems 📊 Manual Specifications File Format PDF Quality: High Quality Searchability: Likely searchable text within PDF (standard for professional manuals) Print Quality Print Capability: Fully Printable Binding Type Binding Recommendation: Professional binding recommended for usability in workshop environment Paper Type Paper Type Recommendation: Durable paper stock recommended for workshop use Navigation Bookmarking: Bookmarked for easy navigation ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (MIVEC) Engine Configuration: Inline 4-cylinder, turbocharged, intercooled Displacement: 2.0 Liters (1997 cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Output: 271 hp @ 6500 rpm (JDM spec), 286 hp @ 6500 rpm (USDM spec) Torque Output: 273 lb-ft @ 3500 rpm (JDM spec), 286 lb-ft @ 3500 rpm (USDM spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Port Injection Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management Engine Control Unit: Mitsubishi ECU (specific part numbers vary by region and emissions standards) Timing System: Dual Overhead Camshafts (DOHC), Variable Valve Timing (MIVEC on intake camshaft) 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission (Getrag Type) Optional Automatic Transmission: Not available on EVO VIII Features Drivetrain: Mitsubishi Super All-Wheel Control (S-AWC) system including Active Center Differential (ACD), Active Yaw Control (AYC) (rear differential), and viscous coupling front differential. Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 specification, typically SAE 75W-90 or 80W-90 Front Differential Fluid: Refer to manual for specific API GL-4, SAE 75W-90 Rear Differential Fluid: Refer to manual for specific API GL-5, SAE 75W-90 (with AYC differential) 📐 Dimensions Exterior Length: Approx. 4490 mm (176.8 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1450 mm (57.1 in) Wheelbase: Approx. 2600 mm (102.4 in) Ground Clearance: Approx. 130 mm (5.1 in) Weights Curb Weight: Approx. 1450-1500 kg (3197-3307 lbs) depending on trim and options Gross Vehicle Weight Rating: Refer to vehicle specific VIN plate Cargo Trunk Volume: Approx. 0.37 m³ (13.1 cu ft) 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Varies by model year and specific test, generally good for its era but not directly comparable to modern ratings. Active Features Active Stability Control: Active Stability Control (ASC) / Active Traction Control (ATC) standard Anti Lock Brakes: Anti-lock Braking System (ABS) standard Performance Braking: Brembo disc brakes (front and rear) on many models for enhanced stopping power. Passive Features Airbags: Front driver and passenger airbags standard. Side airbags optional on some trims. Seatbelts: 3-point front and rear seatbelts with pre-tensioners and force limiters Chassis Structure: Reinforced unibody construction with a focus on torsional rigidity for rally performance. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, often with premium sound system options (e.g., Rockford...
Renowned for its turbocharged performance, sophisticated all-wheel-drive system, and rally-bred handling
Manual Value Proposition:
Provides in-depth, factory-accurate information for maintaining and repairing a highly specialized performance vehicle, crucial for preserving its performance and value.
📋 Manual Details
Coverage Areas
Manual Types Included:
Factory Service Manual (FSM), Body Repair Manual, Technical Information Manual
Mitsubishi Super All-Wheel Control (S-AWC) system including Active Center Differential (ACD), Active Yaw Control (AYC) (rear differential), and viscous coupling front differential.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 specification, typically SAE 75W-90 or 80W-90
Front Differential Fluid:
Refer to manual for specific API GL-4, SAE 75W-90
Rear Differential Fluid:
Refer to manual for specific API GL-5, SAE 75W-90 (with AYC differential)
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1450 mm (57.1 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Ground Clearance:
Approx. 130 mm (5.1 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs) depending on trim and options
Gross Vehicle Weight Rating:
Refer to vehicle specific VIN plate
Cargo
Trunk Volume:
Approx. 0.37 m³ (13.1 cu ft)
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Varies by model year and specific test, generally good for its era but not directly comparable to modern ratings.
Active Features
Active Stability Control:
Active Stability Control (ASC) / Active Traction Control (ATC) standard
Anti Lock Brakes:
Anti-lock Braking System (ABS) standard
Performance Braking:
Brembo disc brakes (front and rear) on many models for enhanced stopping power.
Passive Features
Airbags:
Front driver and passenger airbags standard. Side airbags optional on some trims.
Seatbelts:
3-point front and rear seatbelts with pre-tensioners and force limiters
Chassis Structure:
Reinforced unibody construction with a focus on torsional rigidity for rally performance.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with premium sound system options (e.g., Rockford Fosgate) on higher trims.
Climate Control:
Manual or automatic climate control depending on trim level.
Driver Assistance
Performance Modes:
Driver-selectable modes for the ACD system (Tarmac, Gravel, Snow) to optimize torque distribution.
Traction Control Systems:
Advanced traction and stability control (ASC/ATC) designed to manage the high-performance output.
Connectivity
Auxiliary Inputs:
Limited connectivity by modern standards. Auxiliary audio input may be present on later models or aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Refer to manual for specific recommendation based on usage (e.g., track use requires more frequent changes).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed.
Spark Plugs:
Replace every 60,000 miles (96,000 km) for standard plugs, or as recommended for iridium plugs (if applicable).
Timing Belt:
Crucial replacement interval for the 4G63T. Typically 60,000-100,000 miles (96,000-160,000 km). Consult manual for precise interval and recommended tensioner/water pump replacement.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change. Use high-quality synthetic oil, e.g., 5W-30 or 5W-40.
Coolant Type:
Ethylene Glycol based, long-life coolant. Refer to manual for exact specification and mixture ratio (typically 50/50).
Brake Fluid:
DOT 3 or DOT 4. High-performance driving may benefit from DOT 4 or higher for better heat resistance.
Known Issues
Engine Reliability:
The 4G63T is generally robust, but known issues can include piston ring land failure under extreme abuse, turbocharger wear, and valve stem seal deterioration with age.
Drivetrain Wear:
Clutch wear, AYC pump failure, and center differential wear can occur with aggressive driving or high mileage.
Suspension Components:
Bushings and ball joints can wear over time, impacting handling and alignment.
Rust And Corrosion:
As with many cars of this era, underbody rust can be an issue in regions with harsh winters and salt use.
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi's long and successful history in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution line.
Model Evolution
Evo Vii To Viii Changes:
Introduction of the MIVEC engine, revised body styling, improved S-AWC system with ACD and AYC, and stronger chassis components.
Evo Viii Variants:
GSR (standard), MR (more focused variant with Bilstein suspension, Enkei wheels, and revised interior), RS (homologation special, often lighter, RWD biased in some markets).
Production
Production Years Global:
2003-2005
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Consistently ranked among the best performance cars of its era by automotive publications for its handling, acceleration, and all-wheel-drive capability.
Rally Heritage Recognition:
Regarded as a direct descendant of Mitsubishi's rally-winning machines.