Mitsubishi Lancer Evolution 8 2003 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo VIII Year: 2003 Codes Chassis Code: CT9A Engine Code: 4G63 👋 Introduction Market Position Positioning: High-performance rally-bred sports sedan, positioned as a homologation special for motorsport competition. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (though generally a class above), Mitsubishi Lancer Evolution VII predecessor. Key Features Performance Focus: Exceptional handling, acceleration, and braking for its class, advanced AWD system. Rally Heritage: Direct lineage from Mitsubishi's WRC (World Rally Championship) program. Value Proposition Manual Value: Essential resource for owners and enthusiasts seeking to maintain, repair, and optimize the performance of their Evo VIII. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Manual Additional Coverage: Maintenance, Troubleshooting, Repair, Diagnostics, Specifications Page Count Estimated Page Count: Approx. 1000+ pages (typical for comprehensive factory manuals) Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 4G63 MIVEC Turbocharged inline-4; Engine Mechanical, Lubrication, Cooling, Fuel System, Ignition System, Emission Control, Engine Control System (ECU), Turbocharger System, MIVEC System Transmission: 6-speed Manual Transmission (Type TY856WB1CA); Gearbox, Clutch, Drive Shafts, Differential (Front, Center, Rear ACD) Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD), Super Active Yaw Control (S-AYC) Suspension: Front MacPherson Struts, Rear Multi-link; Shock Absorbers, Springs, Bushings, Control Arms, Anti-roll Bars Brakes: Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers; Brake System Diagnosis, Hydraulic System, Parking Brake Steering: Power Rack and Pinion Steering System Electrical: Wiring Diagrams, Fuses, Relays, Battery, Charging System, Starting System, Lighting System, Instruments and Gauges, HVAC Controls, Power Windows, Door Locks, Audio System Body And Chassis: Body Structure, Exterior Panels, Interior Trim, Doors, Hood, Trunk, Glass, Seats, Safety Belts, Airbag System Climate Control: HVAC System, Air Conditioning (A/C), Heater, Defroster, Ventilation Diagnostics: OBD-II (On-Board Diagnostics II), Trouble Code Diagnosis, Diagnostic Tool Procedures, Sensor Testing Procedures Included Maintenance: Oil Change, Filter Replacement, Spark Plug Replacement, Fluid Checks and Replacements (Coolant, Brake Fluid, Power Steering Fluid, Transmission Fluid), Belt Inspection and Replacement Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service, Electrical Component Repair, Body Panel Repair Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, fault finding trees Specifications: Torque Specifications for all fasteners, Fluid Capacities, Electrical Specifications, Diagnostic Parameters Disassembly And Assembly: Detailed instructions for component removal and reinstallation with illustrations Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Detail Level: Factory level detail with clear diagrams and step-by-step instructions 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (text-based PDF) Printable: Yes Print Quality Quality: High-resolution scans of original factory documents Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Completeness Completeness: Full Factory Service Manual covering all systems and procedures ⚙️ Engine Specifications Primary Engine Engine Type: 4G63 MIVEC Turbocharged Inline-4 Displacement: 2.0 Liters (1997cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Valvetrain: DOHC (Dual Overhead Camshafts), 16 Valves, MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft Performance Horsepower Bhp: 270 bhp @ 6500 rpm (JDM/UK Spec), 265 bhp @ 6500 rpm (US Spec) Torque Lb-Ft: 273 lb-ft @ 3500 rpm (JDM/UK Spec), 272 lb-ft @ 3500 rpm (US Spec) Fuel System Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Injection System: Multi-point Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G6-10.5T (or similar variant depending on market) Fluid Specifications Engine Oil: API SG/SH/SJ, ACEA A2/A3, SAE 10W-30 or 5W-40 (refer to manual for specific climate conditions) Coolant: Mitsubishi Genuine Super Long Life Coolant (or equivalent ethylene glycol based, silicate-free) Oil Capacity Quarts: 4.5 quarts (4.3 liters) with filter change 🔧 Transmission Standard Transmission Type: 6-Speed Manual Transmission Transmission Model: TY856WB1CA Optional Optional Transmission: None (Manual transmission was standard for Evo VIII) Features Drivetrain Features: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) Transmission Fluid: Mitsubishi Genuine DiaQueen LSD Gear Oil (GL-5, 75W-90) for rear differential (LSD), GL-5, 75W-90 for front and center differentials and transmission Fluid Capacity Transmission Oil Capacity Liters: Approximately 3.0 liters (refer to manual for exact) 📐 Dimensions Exterior Length Mm: 4490 mm Width Mm: 1770 mm Height Mm: 1415 mm Wheelbase Mm: 2625 mm Front Track Mm: 1515 mm Rear Track Mm: 1510 mm Weights Curb Weight Kg: 1450 kg (approx.) Gross Weight Kg: 1910 kg (approx.) Wheel And Tire Standard Wheel Size: 17x8.0JJ Standard Tire Size: 235/45R17 Bolt Pattern: 5x114.3 mm Offset: +38 mm (typical) 🛡️ Safety Features Ratings NHTSA Ratings: No specific NHTSA ratings available for this era/model in many markets due to low volume/specialty status. Often based on general Lancer safety structure. Active Features ABS: Yes (Anti-lock Braking System) Traction Control: Yes (Active Stability Control - ASC, often linked with ACD/AYC) AWD System: ACD (Active Center Differential) and...
Mitsubishi TD05HR-16G6-10.5T (or similar variant depending on market)
Fluid Specifications
Engine Oil:
API SG/SH/SJ, ACEA A2/A3, SAE 10W-30 or 5W-40 (refer to manual for specific climate conditions)
Coolant:
Mitsubishi Genuine Super Long Life Coolant (or equivalent ethylene glycol based, silicate-free)
Oil Capacity Quarts:
4.5 quarts (4.3 liters) with filter change
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission
Transmission Model:
TY856WB1CA
Optional
Optional Transmission:
None (Manual transmission was standard for Evo VIII)
Features
Drivetrain Features:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC)
Transmission Fluid:
Mitsubishi Genuine DiaQueen LSD Gear Oil (GL-5, 75W-90) for rear differential (LSD), GL-5, 75W-90 for front and center differentials and transmission
Fluid Capacity
Transmission Oil Capacity Liters:
Approximately 3.0 liters (refer to manual for exact)
📐 Dimensions
Exterior
Length Mm:
4490 mm
Width Mm:
1770 mm
Height Mm:
1415 mm
Wheelbase Mm:
2625 mm
Front Track Mm:
1515 mm
Rear Track Mm:
1510 mm
Weights
Curb Weight Kg:
1450 kg (approx.)
Gross Weight Kg:
1910 kg (approx.)
Wheel And Tire
Standard Wheel Size:
17x8.0JJ
Standard Tire Size:
235/45R17
Bolt Pattern:
5x114.3 mm
Offset:
+38 mm (typical)
🛡️ Safety Features
Ratings
NHTSA Ratings:
No specific NHTSA ratings available for this era/model in many markets due to low volume/specialty status. Often based on general Lancer safety structure.
Active Features
ABS:
Yes (Anti-lock Braking System)
Traction Control:
Yes (Active Stability Control - ASC, often linked with ACD/AYC)
AWD System:
ACD (Active Center Differential) and S-AYC (Super Active Yaw Control) significantly enhance dynamic stability and traction.
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seatbelts:
3-point front seatbelts with pretensioners, 3-point rear seatbelts
Body Structure:
Reinforced chassis and body structure designed for rally competition resilience.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional Rockford Fosgate audio upgrade.
Display:
Basic digital climate control display, instrument cluster with multiple gauges.
Driver Assistance
Stability Control:
ASC (Active Stability Control) integrated with AWD system.
Traction Control:
ACD and AYC systems provide advanced traction and handling assistance.
Connectivity
Connectivity Features:
Limited by modern standards; typically includes power windows, power mirrors, central locking. No Bluetooth or advanced connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles Km:
Every 3,750 miles (6,000 km) or 6 months (whichever comes first) for severe driving conditions (typical for performance vehicles).
Engine Oil Filter Replacement:
Replace with every oil change.
Air Filter Replacement:
Inspect every 7,500 miles (12,000 km), replace as needed.
Spark Plug Replacement:
Approximately 30,000-60,000 miles (48,000-96,000 km) depending on plug type (iridium recommended).
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 2 years for normal use, more frequent for spirited driving/track use.
Brake Fluid Flush:
Every 24 months (2 years) or 15,000 miles (24,000 km).
Fluid Specifications
Power Steering Fluid:
Dexron III/VI ATF or equivalent power steering fluid.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues Performance:
Head gasket failures (especially on modified engines), turbocharger wear, clutch wear due to aggressive driving, differential (ACD/AYC) system issues if not properly maintained.
Common Issues General:
Rust/corrosion in certain climates, minor electrical gremlins (e.g., power window switches), exhaust system corrosion.
Maintenance Part Numbers
Oil Filter Oem:
MD345655 or equivalent (e.g., Wix 57060, K&N HP-1008)
Air Filter Oem:
MR552207 or equivalent
Spark Plugs Oem:
NGK BKR7E-11 (standard) or NGK BKR7EIX-11 (Iridium, recommended for performance)
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation, known for its engineering prowess, particularly in turbocharged engines and four-wheel-drive systems.
Model Evolution
Evolution Series Origin:
Born from homologation requirements for the World Rally Championship (WRC).
Evolution Viii Introduction:
Launched in 2003 for the 2003 model year, representing the eighth generation of the Lancer Evolution.
Evolution Viii Distinction:
Key advancements included the MIVEC engine and the introduction of the Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) systems, significantly enhancing its dynamic capabilities.
Production
Production Years:
2003-2005 (for Evo VIII)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently praised by automotive media for its exhilarating performance, handling, and rally-inspired driving dynamics. Often featured in 'best sports car' or 'performance car' lists for its era.
Motorsport Success:
The Lancer Evolution platform has a storied history of success in the World Rally Championship (WRC), contributing to its performance reputation.