Mitsubishi Lancer Evolution VIII MR Service/Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII MR Model Code: CT9A Generation: 8th Generation Lancer Evolution 👋 Introduction Market Position Market Position: The Mitsubishi Lancer Evolution VIII MR was positioned as a high-performance, rally-bred sport sedan, a halo car for the Lancer lineup, appealing to enthusiasts and motorsport followers. It competed directly with other homologation specials and performance-oriented sedans of its era. Competitive Analysis Competitive Analysis: Key competitors included the Subaru Impreza WRX STI, Ford Focus RS, and Audi S3. The Evo VIII MR distinguished itself with its sophisticated all-wheel-drive system (Super Active Yaw Control - AYC), advanced differential technology, and aggressive styling. Key Features Key Features: The MR (Mitsubishi Racing) designation signified a more track-focused and refined version of the Evo VIII, often featuring a close-ratio 6-speed manual transmission, Bilstein suspension components, Recaro seats, a Momo steering wheel, and unique aero enhancements. This manual provides in-depth technical information for all these specific MR features. Manual Utility Manual Utility: This PDF manual is designed for ease of use, allowing technicians and enthusiasts to access critical repair and maintenance information on any digital device or to print specific sections for workshop use. Its portability and searchability offer significant advantages over traditional printed manuals. 📋 Manual Details Coverage Areas Coverage Areas: Complete service and repair coverage for Mitsubishi Lancer Evolution VIII MR Page Count Page Count: Estimated 2000+ pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Service/Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Engine Control System, Fuel System, Emission Control Systems, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Exhaust System, Transmission (Manual Transaxle System), Clutch System, Drivetrain (Front Drive Shaft, Rear Axle), Suspension (Front and Rear Suspension Systems), Steering System, Brake System, Wheel and Tire System, Body and Chassis, Electrical System (Wiring Diagrams, Lighting System, Audio & Visual System), HVAC System (Heater & Air Conditioner), Supplemental Restraint System (Airbags), Interior and Exterior Trim, Maintenance Procedures Wiring Diagrams Coverage: Detailed and comprehensive wiring diagrams for all electrical systems, including engine management, lighting, audio, power windows, climate control, airbags, and chassis control modules (ACD/AYC). Procedures Included Procedures Included: General maintenance, troubleshooting, diagnostic procedures, component removal and installation, torque specifications, overhaul procedures, wiring harness repair, fluid capacities and types, replacement part specifications, emissions diagnostics, chassis and body repair, interior component servicing, HVAC system servicing, safety system diagnostics and repair Component Identification: Precise location and identification of all major and minor components, including sensors, actuators, control modules, and mechanical parts, aided by exploded views and diagrams. Technical Depth Technical Depth: Comprehensive, covering everything from routine maintenance and adjustments to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repairs. Includes detailed diagnostic trees and troubleshooting flowcharts. 📊 Manual Specifications File Format File Format: Searchable PDF, easily navigable and printable. Searchability: Fully text-searchable PDF allowing users to quickly find specific topics, keywords, and part numbers. Print Quality Print Quality: High-resolution scans suitable for printing, ensuring clear text and legible diagrams. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Primary Engine: 4G63T 2.0L DOHC 16-valve turbocharged inline-4 cylinder engine Performance Horsepower: Approximately 276 hp (206 kW) @ 6500 rpm (JDM/European specs); US-spec models often had slightly higher output due to less restrictive emissions equipment. Torque: Approximately 289 lb-ft (392 Nm) @ 3500 rpm (JDM/European specs) Fuel System Fuel System: Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI), Turbocharged Engine Code Engine Code: 4G63 (Internally designated for the Evo VIII) Bore X Stroke Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio Compression Ratio: 8.8:1 Turbocharger Turbocharger: Mitsubishi TD05H-16G turbocharger with intercooler Ignition System Ignition System: Electronic ignition system with coil-on-plug (COP) ignition Cooling System Cooling System: Pressurized liquid cooling system with aluminum radiator and electric cooling fan. 🔧 Transmission Standard Standard: 6-speed manual transmission (Getrag-based design, specifically for MR models) Optional Optional: No automatic transmission option for the MR model. Standard Evo VIII models offered a 5-speed manual. Features Features: Close-ratio gearing, helical limited-slip front differential, mechanical limited-slip rear differential, AYC (Active Yaw Control) system integrated with the rear differential for enhanced cornering stability. Fluid Type Fluid Type: Manual Transmission Fluid (MTF) - Typically a GL-4 or GL-5 rated gear oil, specific viscosity to be confirmed in manual (e.g., SAE 75W-90). Clutch Type Clutch Type: Hydraulically operated, single-plate dry clutch. 📐 Dimensions Exterior Length: Approx. 4,400 mm (173.2 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,450 mm (57.1 in) Wheelbase: Approx. 2,600 mm (102.4 in) Weights Curb Weight: Approx. 1,400 kg (3,086 lbs) - varies slightly by market and specification Gross Vehicle Weight: Typically around 1,800 kg (3,968 lbs) Cargo Trunk Volume: Approx. 0.371 m³ (13.1 cu ft) - trunk space is limited due...
The Mitsubishi Lancer Evolution VIII MR was positioned as a high-performance, rally-bred sport sedan, a halo car for the Lancer lineup, appealing to enthusiasts and motorsport followers. It competed directly with other homologation specials and performance-oriented sedans of its era.
Competitive Analysis
Competitive Analysis:
Key competitors included the Subaru Impreza WRX STI, Ford Focus RS, and Audi S3. The Evo VIII MR distinguished itself with its sophisticated all-wheel-drive system (Super Active Yaw Control - AYC), advanced differential technology, and aggressive styling.
Key Features
Key Features:
The MR (Mitsubishi Racing) designation signified a more track-focused and refined version of the Evo VIII, often featuring a close-ratio 6-speed manual transmission, Bilstein suspension components, Recaro seats, a Momo steering wheel, and unique aero enhancements. This manual provides in-depth technical information for all these specific MR features.
Manual Utility
Manual Utility:
This PDF manual is designed for ease of use, allowing technicians and enthusiasts to access critical repair and maintenance information on any digital device or to print specific sections for workshop use. Its portability and searchability offer significant advantages over traditional printed manuals.
📋 Manual Details
Coverage Areas
Coverage Areas:
Complete service and repair coverage for Mitsubishi Lancer Evolution VIII MR
Page Count
Page Count:
Estimated 2000+ pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Service/Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine Mechanical, Engine Control System, Fuel System, Emission Control Systems, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Exhaust System, Transmission (Manual Transaxle System), Clutch System, Drivetrain (Front Drive Shaft, Rear Axle), Suspension (Front and Rear Suspension Systems), Steering System, Brake System, Wheel and Tire System, Body and Chassis, Electrical System (Wiring Diagrams, Lighting System, Audio & Visual System), HVAC System (Heater & Air Conditioner), Supplemental Restraint System (Airbags), Interior and Exterior Trim, Maintenance Procedures
Wiring Diagrams Coverage:
Detailed and comprehensive wiring diagrams for all electrical systems, including engine management, lighting, audio, power windows, climate control, airbags, and chassis control modules (ACD/AYC).
Procedures Included
Procedures Included:
General maintenance, troubleshooting, diagnostic procedures, component removal and installation, torque specifications, overhaul procedures, wiring harness repair, fluid capacities and types, replacement part specifications, emissions diagnostics, chassis and body repair, interior component servicing, HVAC system servicing, safety system diagnostics and repair
Component Identification:
Precise location and identification of all major and minor components, including sensors, actuators, control modules, and mechanical parts, aided by exploded views and diagrams.
Technical Depth
Technical Depth:
Comprehensive, covering everything from routine maintenance and adjustments to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repairs. Includes detailed diagnostic trees and troubleshooting flowcharts.
📊 Manual Specifications
File Format
File Format:
Searchable PDF, easily navigable and printable.
Searchability:
Fully text-searchable PDF allowing users to quickly find specific topics, keywords, and part numbers.
Print Quality
Print Quality:
High-resolution scans suitable for printing, ensuring clear text and legible diagrams.
Approximately 276 hp (206 kW) @ 6500 rpm (JDM/European specs); US-spec models often had slightly higher output due to less restrictive emissions equipment.
Torque:
Approximately 289 lb-ft (392 Nm) @ 3500 rpm (JDM/European specs)
Fuel System
Fuel System:
Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI), Turbocharged
Engine Code
Engine Code:
4G63 (Internally designated for the Evo VIII)
Bore X Stroke
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio
Compression Ratio:
8.8:1
Turbocharger
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler
Ignition System
Ignition System:
Electronic ignition system with coil-on-plug (COP) ignition
Cooling System
Cooling System:
Pressurized liquid cooling system with aluminum radiator and electric cooling fan.
🔧 Transmission
Standard
Standard:
6-speed manual transmission (Getrag-based design, specifically for MR models)
Optional
Optional:
No automatic transmission option for the MR model. Standard Evo VIII models offered a 5-speed manual.
Features
Features:
Close-ratio gearing, helical limited-slip front differential, mechanical limited-slip rear differential, AYC (Active Yaw Control) system integrated with the rear differential for enhanced cornering stability.
Fluid Type
Fluid Type:
Manual Transmission Fluid (MTF) - Typically a GL-4 or GL-5 rated gear oil, specific viscosity to be confirmed in manual (e.g., SAE 75W-90).
Clutch Type
Clutch Type:
Hydraulically operated, single-plate dry clutch.
📐 Dimensions
Exterior
Length:
Approx. 4,400 mm (173.2 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,450 mm (57.1 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,400 kg (3,086 lbs) - varies slightly by market and specification
Gross Vehicle Weight:
Typically around 1,800 kg (3,968 lbs)
Cargo
Trunk Volume:
Approx. 0.371 m³ (13.1 cu ft) - trunk space is limited due to AWD components.
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
Not directly rated by NHTSA for this specific generation and market context at the time of its release; however, it featured robust safety engineering.
Active Features
Active Features:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), AYC (Active Yaw Control), ACD (Active Center Differential), Brembo braking system (typically front and rear).
Passive Features
Passive Features:
Driver and front passenger airbags, side airbags (optional/market dependent), reinforced body structure with crumple zones, three-point seatbelts with pre-tensioners, collapsible steering column.
Brakes Front
Brakes Front:
Ventilated discs, typically 13-inch (330mm) Brembo calipers.
Brakes Rear
Brakes Rear:
Ventilated discs, typically 13-inch (330mm) Brembo calipers.
💡 Technology Features
Infotainment
Infotainment:
Basic audio systems typically included AM/FM radio, CD player, and sometimes a cassette player. Speaker systems varied by trim. Connectivity was limited to analog auxiliary inputs if present.
Driver Assistance
Driver Assistance:
Primary driver assistance features were mechanical and electronic systems related to AWD, traction control (ACD), and yaw control (AYC). No advanced electronic driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist were available.
Connectivity
Connectivity:
Limited to basic audio system connections. No Bluetooth, USB, or smartphone integration.
🔧 Maintenance
Service Intervals
Service Intervals:
Recommended oil changes: every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions. Other service intervals (spark plugs, filters, timing belt/chain, etc.) are detailed in the manual.
Fluid Specifications
Engine Oil Specification:
API SG/SH/SJ or ILSAC GF-2/GF-3 certified synthetic or semi-synthetic oil. Viscosity typically 0W-30, 5W-30, or 5W-40 depending on climate. Specific Mitsubishi recommendation is critical. Oil capacity: ~4.5 liters (4.8 quarts) with filter.
Coolant Type:
Ethylene glycol-based antifreeze coolant (green or specific color as per Mitsubishi). Mixture ratio: 50% coolant / 50% distilled water. Total capacity: ~7.5 liters (7.9 quarts).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Check manual for exact specification. Capacity: ~1 liter.
Power Steering Fluid Type:
Dexron III ATF or specified power steering fluid. Capacity: ~1 liter.
Differential Fluid Type:
Front/Rear Differential: GL-5 rated gear oil, SAE 75W-90. AYC/ACD fluid specifications are unique and must be adhered to as per manual. Capacity: Front ~1.2L, Rear ~1.0L.
Engine Oil Capacity:
4.5 L (4.8 US qt) with filter change
Coolant Capacity:
7.5 L (7.9 US qt)
Transmission Fluid Capacity:
2.2 L (2.3 US qt)
Rear Differential Fluid Capacity:
1.0 L (1.1 US qt)
Known Issues
Known Issues:
Potential issues include wear on the Active Yaw Control (AYC) pump and sensors, turbocharger wear, clutch wear, transmission synchro wear in high-mileage vehicles, and possible cooling system leaks. The manual addresses diagnosis and repair for these common concerns.
Timing Belt Or Chain
Timing Belt Or Chain:
Timing Chain (4G63 engine is a chain-driven design, not a belt, requiring less frequent replacement but still subject to wear and tensioner issues over time).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long and successful history in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution lineage gained iconic status. This racing pedigree directly informed the engineering and development of the production models.
Model Evolution
Model Evolution:
The Lancer Evolution VIII was introduced in 2003, succeeding the Evo VII. The MR variant, launched later in the Evo VIII's lifecycle, represented a refinement and enhancement of the performance capabilities, specifically targeting driving purists and track enthusiasts.
Production
Production Years:
Lancer Evolution VIII: 2003-2005. MR variant produced within this period.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Recognitions:
The Lancer Evolution VIII, in its various forms including the MR, consistently received accolades from automotive media for its performance, handling, and rally-inspired capabilities. Often featured in 'best performance car' lists and enthusiast publications.
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