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Mitsubushi LANCER EVOLUTION 8 & MR 2003 2004 2005 BODY Repair Technical Information And Service Repair Workshop Manual

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๐Ÿท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Variant: MR Model Years Covered: 2003, 2004, 2005 Generation Generation: CT9A Codes Chassis Code: CT9A ๐Ÿ‘‹ Introduction Market Position Market Position: High-performance rally-bred sport compact sedan, iconic JDM legend. Competitive Analysis Competitive Analysis: Competed against vehicles like Subaru Impreza WRX STI, Mitsubishi Eclipse GT, and other performance-oriented sedans and coupes of its era. Key Features Key Features: Advanced All-Wheel Drive (AWD) system with Active Center Differential (ACD), Twin-Scroll Turbocharger, Intercooler, potent 4G63 engine, robust chassis, high-performance braking system, distinctive aggressive styling. ๐Ÿ“‹ Manual Details Coverage Areas Coverage Areas: Body Repair, Technical Information, Workshop Repair Page Count Page Count: Not Specified (estimated comprehensive) Manual Type Manual Type: Factory Service Manual, Technical Information Manual, Body Repair Manual Language Language: English Format Format: PDF (Adobe Acrobat) Accessibility: Viewable on PC, Mac, iPad, Android Tablets, iPhone, Android phones. ๐Ÿ“– Manual Coverage Systems Covered Systems Covered: Engine mechanical, lubrication, fuel system, engine cooling, intake and exhaust, engine electrical, engine and emission control, clutch, manual transaxle, propeller shaft, front axle, rear axle, wheels and tires, power plant mounts, front suspension, rear suspension, service brakes, parking brakes, steering, body, exterior, interior, supplemental restraint system (SRS), chassis electrical, HVAC, electrical wiring, body repair Body Repair Procedures: Detailed procedures for body panel replacement (fenders, doors, hoods, trunk lids), structural integrity repair, unibody straightening, welding specifications, sealant and adhesive application, glass replacement, bumper repair, and exterior trim fitting. Engine Management: Detailed coverage of the 4G63 engine, including timing belt replacement, turbocharger maintenance and repair, intercooler system, fuel delivery system, ignition timing, and emissions control systems. Interior Components: Coverage for dashboard removal and installation, center console disassembly, seat removal, door panel trim, headliner, and interior lighting. Supplemental Restraint System: Detailed information on airbag deployment mechanisms, SRS control module diagnostics, and sensor calibration procedures. Procedures Included Procedures Included: General maintenance, troubleshooting, diagnostics, repair procedures, component removal and installation, body panel replacement, structural repairs, electrical system diagnostics and repair, HVAC system service, suspension and steering alignment, brake system maintenance and overhaul Suspension And Steering Repair: Procedures for strut and shock absorber replacement, control arm removal and installation, ball joint servicing, steering rack repair, power steering pump and hose replacement, and wheel alignment specifications. Air Conditioning Service: Refrigerant system service, component replacement (compressor, evaporator, condenser), blower motor repair, and HVAC control system diagnostics. Engine Rebuild Procedures: Step-by-step instructions for engine disassembly, component inspection, internal part replacement (pistons, rings, bearings, valves), and reassembly with torque specifications. Technical Depth Technical Depth: Comprehensive (from basic maintenance to complete overhaul and body structural repair) Electrical System Diagnostics: In-depth diagnostic procedures for the engine control unit (ECU), ignition system, fuel injection system, lighting, instrument cluster, power accessories, SRS system, and chassis electrical components. Includes wiring diagrams for all systems. Chassis And Suspension Tuning: Details on adjustable suspension components, alignment parameters, and chassis stiffness for optimal performance handling. ๐Ÿ“Š Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (user-dependent quality) Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: Not Applicable (digital format) โš™๏ธ Engine Specifications Primary Engine Primary Engine: 2.0L 16-Valve DOHC Intercooled Turbocharged 4G63 inline-4 Performance Horsepower: Approx. 270-276 hp (varies by market and specific tuning) Torque: Approx. 280-287 lb-ft (varies by market and specific tuning) Engine Design: Inline 4-cylinder, DOHC, 16 valves, turbocharged, intercooled Fuel System Fuel System: Multi-point Fuel Injection (MPI), Electronic Fuel Control System (ECU) Engine Codes Engine Code: 4G63 ๐Ÿ”ง Transmission Standard Standard Transmission: 6-Speed Manual Transmission (Getrag) Optional Optional Transmission: None for Evolution VIII MR (MR typically exclusively manual) Features Features: Heavy-duty construction, close gear ratios, designed for high-torque applications. Features the ACD (Active Center Differential) for variable torque distribution. AWD System: Active Center Differential (ACD) allowing variable torque distribution between front and rear axles, with driver-selectable modes (Tarmac, Gravel, Snow). ๐Ÿ“ Dimensions Exterior Length: Approx. 4,490 mm (176.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Track Width Front: Approx. 1,500 mm (59.1 in) Track Width Rear: Approx. 1,505 mm (59.3 in) Weights Curb Weight: Approx. 1,440 kg (3,175 lbs) Wheelbase: Approx. 2,600 mm (102.4 in) ๐Ÿ›ก๏ธ Safety Features Ratings Safety Ratings: Varies by region and testing authority. Generally designed to meet performance driving safety standards. Active Features Active Features: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Active Center Differential (ACD), Super Active Yaw Control (Super AYC) (on some models/markets) Passive Features Passive Features: Front airbags, side airbags (optional/market dependent), reinforced body structure, three-point seatbelts with pretensioners. Seat Design: Sport-oriented front seats with enhanced bolstering for lateral support during high-G cornering. ๐Ÿ’ก Technology Features Infotainment Infotainment System: Basic AM/FM stereo with CD player, potentially upgraded audio systems depending on trim. Driver Assistance Driver Assistance Features: ABS, EBD, Traction Control (Active Stability Control - ASC, may be standard or...
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Mitsubushi LANCER EVOLUTION 8 & MR 2003 2004 2005 BODY Repair Technical Information And Service Repair Workshop Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII
Model Variant:
MR
Model Years Covered:
2003, 2004, 2005
Generation
Generation:
CT9A
Codes
Chassis Code:
CT9A
๐Ÿ‘‹ Introduction
Market Position
Market Position:
High-performance rally-bred sport compact sedan, iconic JDM legend.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like Subaru Impreza WRX STI, Mitsubishi Eclipse GT, and other performance-oriented sedans and coupes of its era.
Key Features
Key Features:
Advanced All-Wheel Drive (AWD) system with Active Center Differential (ACD), Twin-Scroll Turbocharger, Intercooler, potent 4G63 engine, robust chassis, high-performance braking system, distinctive aggressive styling.
๐Ÿ“‹ Manual Details
Coverage Areas
Coverage Areas:
Body Repair, Technical Information, Workshop Repair
Page Count
Page Count:
Not Specified (estimated comprehensive)
Manual Type
Manual Type:
Factory Service Manual, Technical Information Manual, Body Repair Manual
Language
Language:
English
Format
Format:
PDF (Adobe Acrobat)
Accessibility:
Viewable on PC, Mac, iPad, Android Tablets, iPhone, Android phones.
๐Ÿ“– Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, lubrication, fuel system, engine cooling, intake and exhaust, engine electrical, engine and emission control, clutch, manual transaxle, propeller shaft, front axle, rear axle, wheels and tires, power plant mounts, front suspension, rear suspension, service brakes, parking brakes, steering, body, exterior, interior, supplemental restraint system (SRS), chassis electrical, HVAC, electrical wiring, body repair
Body Repair Procedures:
Detailed procedures for body panel replacement (fenders, doors, hoods, trunk lids), structural integrity repair, unibody straightening, welding specifications, sealant and adhesive application, glass replacement, bumper repair, and exterior trim fitting.
Engine Management:
Detailed coverage of the 4G63 engine, including timing belt replacement, turbocharger maintenance and repair, intercooler system, fuel delivery system, ignition timing, and emissions control systems.
Interior Components:
Coverage for dashboard removal and installation, center console disassembly, seat removal, door panel trim, headliner, and interior lighting.
Supplemental Restraint System:
Detailed information on airbag deployment mechanisms, SRS control module diagnostics, and sensor calibration procedures.
Procedures Included
Procedures Included:
General maintenance, troubleshooting, diagnostics, repair procedures, component removal and installation, body panel replacement, structural repairs, electrical system diagnostics and repair, HVAC system service, suspension and steering alignment, brake system maintenance and overhaul
Suspension And Steering Repair:
Procedures for strut and shock absorber replacement, control arm removal and installation, ball joint servicing, steering rack repair, power steering pump and hose replacement, and wheel alignment specifications.
Air Conditioning Service:
Refrigerant system service, component replacement (compressor, evaporator, condenser), blower motor repair, and HVAC control system diagnostics.
Engine Rebuild Procedures:
Step-by-step instructions for engine disassembly, component inspection, internal part replacement (pistons, rings, bearings, valves), and reassembly with torque specifications.
Technical Depth
Technical Depth:
Comprehensive (from basic maintenance to complete overhaul and body structural repair)
Electrical System Diagnostics:
In-depth diagnostic procedures for the engine control unit (ECU), ignition system, fuel injection system, lighting, instrument cluster, power accessories, SRS system, and chassis electrical components. Includes wiring diagrams for all systems.
Chassis And Suspension Tuning:
Details on adjustable suspension components, alignment parameters, and chassis stiffness for optimal performance handling.
๐Ÿ“Š Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable (user-dependent quality)
Binding Type
Binding Type:
Digital Download (no physical binding)
Paper Type
Paper Type:
Not Applicable (digital format)
โš™๏ธ Engine Specifications
Primary Engine
Primary Engine:
2.0L 16-Valve DOHC Intercooled Turbocharged 4G63 inline-4
Performance
Horsepower:
Approx. 270-276 hp (varies by market and specific tuning)
Torque:
Approx. 280-287 lb-ft (varies by market and specific tuning)
Engine Design:
Inline 4-cylinder, DOHC, 16 valves, turbocharged, intercooled
Fuel System
Fuel System:
Multi-point Fuel Injection (MPI), Electronic Fuel Control System (ECU)
Engine Codes
Engine Code:
4G63
๐Ÿ”ง Transmission
Standard
Standard Transmission:
6-Speed Manual Transmission (Getrag)
Optional
Optional Transmission:
None for Evolution VIII MR (MR typically exclusively manual)
Features
Features:
Heavy-duty construction, close gear ratios, designed for high-torque applications. Features the ACD (Active Center Differential) for variable torque distribution.
AWD System:
Active Center Differential (ACD) allowing variable torque distribution between front and rear axles, with driver-selectable modes (Tarmac, Gravel, Snow).
๐Ÿ“ Dimensions
Exterior
Length:
Approx. 4,490 mm (176.8 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Track Width Front:
Approx. 1,500 mm (59.1 in)
Track Width Rear:
Approx. 1,505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1,440 kg (3,175 lbs)
Wheelbase:
Approx. 2,600 mm (102.4 in)
๐Ÿ›ก๏ธ Safety Features
Ratings
Safety Ratings:
Varies by region and testing authority. Generally designed to meet performance driving safety standards.
Active Features
Active Features:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Active Center Differential (ACD), Super Active Yaw Control (Super AYC) (on some models/markets)
Passive Features
Passive Features:
Front airbags, side airbags (optional/market dependent), reinforced body structure, three-point seatbelts with pretensioners.
Seat Design:
Sport-oriented front seats with enhanced bolstering for lateral support during high-G cornering.
๐Ÿ’ก Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with CD player, potentially upgraded audio systems depending on trim.
Driver Assistance
Driver Assistance Features:
ABS, EBD, Traction Control (Active Stability Control - ASC, may be standard or optional).
Connectivity
Connectivity:
Limited by era; typically includes power accessories, power steering.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles or 6 months (severe duty recommendation for performance driving)
Timing Belt Replacement:
Refer to manual; generally around 60,000-90,000 miles. Critical due to interference engine design.
Brake Fluid Change Interval:
Typically every 2 years or as needed based on fluid condition.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or ILSAC GF-2 or GF-3 compatible synthetic or semi-synthetic oil. Viscosity typically 5W-30 or 10W-30 depending on climate.
Coolant Type:
Ethylene glycol-based coolant (Mitsubishi Super Long Life Coolant or equivalent). 50/50 mix with distilled water.
Transmission Fluid Type:
Manual transmission fluid (MTF) meeting specific GL-4 or GL-5 specifications. Consult manual for precise fluid type and quantity.
Differential Fluid Type:
Specific gear oil for front and rear differentials, and ACD unit. Consult manual for precise GL rating and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Consult manual for specific recommendations and bleeding procedures.
Known Issues
Known Issues:
Oil consumption, turbocharger issues (if not properly maintained), clutch wear (due to performance driving), carbon buildup in engine, differential noise or failure if fluid is neglected, exhaust manifold cracking.
Electrical Gremlins:
Some owners report intermittent issues with window regulators, power locks, or alarm systems, often related to aging wiring or modules.
๐Ÿ“š Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a strong heritage in motorsport, particularly in the World Rally Championship (WRC), with the Lancer Evolution being its flagship rally homologation special.
Model Evolution
Model Evolution:
The Evolution VIII built upon the success of previous generations, introducing chassis improvements, revised aerodynamics, and the introduction of the MR ('Mitsubishi Racing') variant which often featured specific tuning and equipment upgrades.
Mr Variant Distinction:
The MR variant often featured Bilstein shock absorbers, a carbon fiber front lip spoiler, a Momo steering wheel, a titanium-shift knob, and specific interior trim enhancements, signifying a higher performance focus.
Production
Production Years:
2003-2005 (for Evo VIII generation)
๐Ÿ† Awards & Recognition
Recognitions
Recognitions:
Consistently praised by automotive journalists for its handling, performance, and rally-bred capabilities. Considered a benchmark in its class.
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