Mitsubishi Lancer Evolution 8 2003-2005 WSM Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo VIII Production Years Covered: 2003, 2004, 2005 Codes Chassis Code: CT9A Engine Code Primary: 4G63 Engine Code Variant: 4G63T (DOHC, turbocharged, MIVEC) 👋 Introduction Market Position Market Segment: Performance Compact Sedan / Rally Homologation Special Competitor Set: Subaru Impreza WRX STI, Mitsubishi Lancer (non-Evolution variants), Ford Focus RS (later generations), Honda Civic Type R (later generations) Competitive Analysis Key Differentiators: Advanced AWD system (ACD), powerful turbocharged engine, rally-bred chassis, performance braking (Brembo), aggressive styling, homologation pedigree. Key Features Performance Focus: Designed for high-performance driving, track use, and rallying. Emphasizes handling, acceleration, and braking capabilities. Technical Sophistication: Features advanced drivetrain management (ACD, AYC - Active Yaw Control, although AYC was more prominent in prior generations, ACD is key for Evo VIII), powerful MIVEC engine technology, and robust chassis engineering. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Specific Regions Covered: Global (technical specifications applicable across markets) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service Manual (WSM) Additional Manual Types Indicated: Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Cooling System, Fuel System, Lubrication System, Ignition System, Exhaust System, Engine Management System (ECU/ECM) Transmission Drivetrain: Manual Transmission (Getrag 5-speed), Transfer Case, ACD (Active Center Differential), Rear Differential, Driveshafts, Axles Suspension Steering: Front Suspension (MacPherson Strut), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Wheels, Tires Brakes: Front Brakes (Brembo 4-piston calipers), Rear Brakes (Brembo 2-piston calipers), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Parking Brake Electrical: Battery, Charging System (Alternator), Starting System (Starter Motor), Lighting System, Instrumentation, Audio System, Power Accessories, SRS (Supplemental Restraint System) / Airbags Body Chassis: Body Exterior Panels, Doors, Hood, Trunk, Bumpers, Chassis Frame, Interior Trim, Seats Climate Control: HVAC (Heating, Ventilation, Air Conditioning) System Diagnostics: OBD-II (On-Board Diagnostics II) System, DTC (Diagnostic Trouble Codes) listing and troubleshooting Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection/Replacement Repair: Engine Overhaul/Rebuild, Transmission Rebuild, Clutch Replacement, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues Diagnostics Programming: ECU/ECM diagnostics, sensor testing, actuator testing, immobilizer system checks Installation Adjustment: Component installation and removal procedures, alignment specifications, timing belt adjustment Technical Depth Depth: Professional Level - Covers detailed disassembly, assembly, inspection, measurement, and repair procedures for all major vehicle systems. Diagnostic Capabilities: Advanced diagnostic procedures, wiring diagrams, component testing specifications, and diagnostic trouble code explanations. Rebuild Specifications: Includes critical torque specifications, clearances, and tolerances for engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text content (assuming professional quality scan/creation) Print Quality Print Quality Recommendation: Printable on standard office printers Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Engine Code Specific: 4G63T (Evo VIII specific tuning) Performance Horsepower Hp Approx: 271 hp @ 6500 rpm (JDM/European spec), 265 hp @ 6500 rpm (USDM spec) Torque Lb-Ft Approx: 273 lb-ft @ 3500 rpm (JDM/European spec), 275 lb-ft @ 3500 rpm (USDM spec) Redline: 7,000 rpm Fuel System Fuel Type: Unleaded Gasoline (Premium Unleaded Recommended, 91+ Octane) Fuel Delivery: Multi-Point Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G (or similar variant depending on market) Intercooler: Air-to-Air Front-Mounted Intercooler 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Transmission Manufacturer Standard: Getrag (Model 232) Optional Transmission Type Optional: None (Manual transmission only for Evolution VIII) Features Drivetrain Configuration: All-Wheel Drive (AWD) Transfer Case: Center Differential with ACD (Active Center Differential) Rear Differential: Helical Limited-Slip Differential (LSD) Front Differential: Open Differential Acd Modes: Tarmac, Gravel, Snow 📐 Dimensions Exterior Length Mm: 4490 mm Width Mm: 1770 mm Height Mm: 1415 mm Wheelbase Mm: 2625 mm Track Width Front Mm: 1510 mm Track Width Rear Mm: 1505 mm Weights Curb Weight Kg Approx: 1400 - 1450 kg (depending on market and options) Gross Vehicle Weight Rating Kg Approx: 1850 kg Cargo Trunk Volume Liters Approx: 280 Liters 🛡️ Safety Features Ratings NHTSA Front Crash Rating: 4 Stars (for driver and passenger, based on available data for similar models) IIHS Crash Test Ratings: Good (for frontal offset, based on similar models/generations) Active Features ABS: Standard (Anti-lock Braking System) Ebd: Standard (Electronic Brake-force Distribution) Traction Control: Standard (TC-SST not applicable to this manual transmission model) AWD System: ACD (Active Center Differential) with driver-selectable modes enhances traction and stability. Passive Features Airbags: Driver and Front Passenger Airbags (SRS) Seatbelts: Three-point front and rear seatbelts with pre-tensioners and...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo VIII

Production Years Covered:

2003, 2004, 2005

Codes

Chassis Code:

Engine Code Primary:

Engine Code Variant:

4G63T (DOHC, turbocharged, MIVEC)

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Competitor Set:

Subaru Impreza WRX STI, Mitsubishi Lancer (non-Evolution variants), Ford Focus RS (later generations), Honda Civic Type R (later generations)

Competitive Analysis

Key Differentiators:

Advanced AWD system (ACD), powerful turbocharged engine, rally-bred chassis, performance braking (Brembo), aggressive styling, homologation pedigree.

Key Features

Performance Focus:

Designed for high-performance driving, track use, and rallying. Emphasizes handling, acceleration, and braking capabilities.

Technical Sophistication:

Features advanced drivetrain management (ACD, AYC - Active Yaw Control, although AYC was more prominent in prior generations, ACD is key for Evo VIII), powerful MIVEC engine technology, and robust chassis engineering.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive

Specific Regions Covered:

Global (technical specifications applicable across markets)

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Service Manual (WSM)

Additional Manual Types Indicated:

Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Cooling System, Fuel System, Lubrication System, Ignition System, Exhaust System, Engine Management System (ECU/ECM)

Transmission Drivetrain:

Manual Transmission (Getrag 5-speed), Transfer Case, ACD (Active Center Differential), Rear Differential, Driveshafts, Axles

Suspension Steering:

Front Suspension (MacPherson Strut), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Wheels, Tires

Brakes:

Front Brakes (Brembo 4-piston calipers), Rear Brakes (Brembo 2-piston calipers), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Parking Brake

Electrical:

Battery, Charging System (Alternator), Starting System (Starter Motor), Lighting System, Instrumentation, Audio System, Power Accessories, SRS (Supplemental Restraint System) / Airbags

Body Chassis:

Body Exterior Panels, Doors, Hood, Trunk, Bumpers, Chassis Frame, Interior Trim, Seats

Climate Control:

HVAC (Heating, Ventilation, Air Conditioning) System

Diagnostics:

OBD-II (On-Board Diagnostics II) System, DTC (Diagnostic Trouble Codes) listing and troubleshooting

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection/Replacement

Repair:

Engine Overhaul/Rebuild, Transmission Rebuild, Clutch Replacement, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues

Diagnostics Programming:

ECU/ECM diagnostics, sensor testing, actuator testing, immobilizer system checks

Installation Adjustment:

Component installation and removal procedures, alignment specifications, timing belt adjustment

Technical Depth

Depth:

Professional Level - Covers detailed disassembly, assembly, inspection, measurement, and repair procedures for all major vehicle systems.

Diagnostic Capabilities:

Advanced diagnostic procedures, wiring diagrams, component testing specifications, and diagnostic trouble code explanations.

Rebuild Specifications:

Includes critical torque specifications, clearances, and tolerances for engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely searchable text content (assuming professional quality scan/creation)

Print Quality

Print Quality Recommendation:

Printable on standard office printers

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Engine Code Specific:

4G63T (Evo VIII specific tuning)

Performance

Horsepower Hp Approx:

271 hp @ 6500 rpm (JDM/European spec), 265 hp @ 6500 rpm (USDM spec)

Torque Lb-Ft Approx:

273 lb-ft @ 3500 rpm (JDM/European spec), 275 lb-ft @ 3500 rpm (USDM spec)

Redline:

7,000 rpm

Fuel System

Fuel Type:

Unleaded Gasoline (Premium Unleaded Recommended, 91+ Octane)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Turbocharger:

Mitsubishi TD05HR-16G (or similar variant depending on market)

Intercooler:

Air-to-Air Front-Mounted Intercooler

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Transmission Manufacturer Standard:

Getrag (Model 232)

Optional

Transmission Type Optional:

None (Manual transmission only for Evolution VIII)

Features

Drivetrain Configuration:

All-Wheel Drive (AWD)

Transfer Case:

Center Differential with ACD (Active Center Differential)

Rear Differential:

Helical Limited-Slip Differential (LSD)

Front Differential:

Open Differential

Acd Modes:

Tarmac, Gravel, Snow

📐 Dimensions

Exterior

Length Mm:

4490 mm

Width Mm:

1770 mm

Height Mm:

1415 mm

Wheelbase Mm:

2625 mm

Track Width Front Mm:

1510 mm

Track Width Rear Mm:

1505 mm

Weights

Curb Weight Kg Approx:

1400 - 1450 kg (depending on market and options)

Gross Vehicle Weight Rating Kg Approx:

1850 kg

Cargo

Trunk Volume Liters Approx:

280 Liters

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

4 Stars (for driver and passenger, based on available data for similar models)

IIHS Crash Test Ratings:

Good (for frontal offset, based on similar models/generations)

Active Features

Standard (Anti-lock Braking System)

Standard (Electronic Brake-force Distribution)

Traction Control:

Standard (TC-SST not applicable to this manual transmission model)

AWD System:

ACD (Active Center Differential) with driver-selectable modes enhances traction and stability.

Passive Features

Airbags:

Driver and Front Passenger Airbags (SRS)

Seatbelts:

Three-point front and rear seatbelts with pre-tensioners and force limiters

Rollover Protection:

Reinforced body structure

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, often with premium speaker options (e.g., Rockford Fosgate).

Display Type:

Analog gauges, basic LCD trip computer and climate controls.

Driver Assistance

Standard ABS system is a key driver assistance feature.

Traction Control:

Standard traction control system complements the AWD.

Torque Vectoring:

While not explicitly electronic torque vectoring in the modern sense, the ACD system allows for variable torque distribution to enhance cornering.

Connectivity

Connectivity Features:

Limited by era; typically no Bluetooth, USB, or smartphone integration. May have power antenna and basic speaker outputs.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval Km Miles:

7,500 km or 6 months (whichever comes first), or 3,750 km / 3 months for severe driving conditions.

Oil Filter Replacement Interval:

At every oil change

Air Filter Replacement Interval:

15,000 km or 12 months, inspect more frequently

Spark Plug Replacement Interval:

45,000 km for standard spark plugs, 90,000 km for iridium-tipped plugs (check specific plug type)

Timing Belt Replacement Interval:

105,000 km or 7 years (critical component, inspect regularly)

Fluid Specifications

Engine Oil Type:

API SG or SH, ILSAC GF-II or GF-III, Viscosity SAE 5W-30 or 10W-40 (check manual for specific climate recommendations)

Engine Oil Capacity Liters:

4.5 Liters (with filter)

Transmission Fluid Type:

API GL-4, SAE 75W-90 Hypoid Gear Oil (for manual transmission)

Transfer Case Fluid Type:

API GL-5, SAE 75W-90 Hypoid Gear Oil

Rear Differential Fluid Type:

API GL-5, SAE 75W-90 Hypoid Gear Oil (consider LSD additive if specified)

Coolant Type:

Ethylene Glycol based coolant (Mitsubishi Genuine Super Long Life Coolant or equivalent)

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific recommendation)

Power Steering Fluid Type:

ATF Dexron II or III (check manual for exact specification)

Known Issues

Engine:

Head gasket failures (especially on heavily modified engines), turbocharger wear, piston ring issues (less common on stock), valve seat wear.

Transmission:

Grinding gears (especially 2nd and 5th), worn synchros, clutch wear.

Acd System:

ACD pump failures, sensor issues, fluid leaks.

Suspension Steering:

Worn control arm bushings, premature wear on ball joints and tie rod ends due to aggressive driving.

Electrical:

Alternator failures, power window motor issues, SRS warning light illumination.

Rust Corrosion:

Can be susceptible to rust in common areas like wheel wells, rocker panels, and subframes, especially in regions with road salt.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mitsubishi Motors, known for its engineering prowess, particularly in rallying and performance vehicles.

Model Evolution

Evolution Series Origin:

The Lancer Evolution lineage began in 1992 as a homologation special for the World Rally Championship (WRC).

Evo Viii Introduction:

The Evolution VIII was launched in 2003, marking a significant evolution in performance and technology for the series.

Key Changes From Evo Vii:

Updated turbocharger (TD05HR-16G), revised ACD system, stronger chassis, and improved aerodynamic elements. Introduction of the 'F' designation for some models indicating engine enhancements.

Production

Production Start Year:

Production End Year For Model:

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Rally Connection:

The Evo VIII was developed with rally homologation in mind, directly influencing its chassis, drivetrain, and engine design.

🏆 Awards & Recognition

Recognitions

Sport Compact Car Of The Year:

Often cited by automotive publications as a benchmark performance car.

Wrc Legacy:

Continues the highly successful WRC heritage of the Lancer Evolution line, recognized for its motorsport pedigree.

Ratings

Handling Performance Rankings:

Consistently ranked among the best-handling cars of its era by automotive journalists.

Certifications

Emissions Compliance:

Complies with relevant emissions standards for the model year and market of sale.