Mitsubishi Evolution 8 MR 2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII MR Year: 2004 Codes Chassis Code: CT9A Engine Code: 4G63T 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Positioning: The Evolution VIII MR (Mitsubishi Racing) was the pinnacle of the Evo VIII line, offering enhanced performance and specific handling upgrades over the standard Evo VIII. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (FN2). Key Features Performance Focus: Developed from rally racing technology, emphasizing all-wheel drive, turbocharged performance, and agile handling. Driver Engagement: Focus on driver feedback, precise controls, and a connected driving experience. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive factory service and repair for Mitsubishi Lancer Evolution VIII MR (2004 model year). Page Count Estimated Pages: Approximately 1500-2000 (typical for full factory manuals of this era). Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, timing belt, seals, gaskets, lubrication system, cooling system. Engine Management: Fuel injection, ignition system, emissions control, sensors, ECU diagnostics and repair. Transmission: Manual transmission (6-speed), clutch system, driveline, transfer case, propeller shaft, driveshafts. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, sway bars, alignment specifications. Brakes: Brake system components (Brembo), hydraulic lines, ABS system, parking brake, rotor and pad replacement, bleeding procedures. Steering: Power steering system, steering rack, tie rod ends, steering column, wheel alignment. Electrical: Complete wiring diagrams, starter, alternator, battery, lighting, fuses, relays, comfort systems, diagnostic connectors. Body And Interior: Body panel removal and installation, interior trim, seats, doors, windows, bumpers, structural components. HVAC: Heating, Ventilation, and Air Conditioning system components and service. Body Electrical: Power windows, locks, mirrors, audio system, security system. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement. Diagnostics: Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, symptom-based diagnosis, component testing. Repair: Detailed step-by-step repair procedures for all major systems and components, including torques and clearances. Rebuilding: Comprehensive instructions for engine and transmission rebuilding. Specifications: Tightening torques, clearances, fluid capacities, pressure specifications. Technical Depth Depth: Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for quick information retrieval. Print Quality Diagram Quality: High-quality, clear, and detailed diagrams and illustrations. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-cylinder, turbocharged, intercooled, DOHC, 16-valve Displacement: 1998 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Us Spec: 276 hp @ 6500 rpm (DIN rating, often higher in actual testing) Torque Us Spec: 289 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with electronic control Fuel Type: Unleaded Premium (91 Octane or higher recommended) Turbocharger: Mitsubishi TD05H-16G turbocharger with intercooler 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission (Getrag) Optional Transmission Type: N/A (MR model exclusively featured the 6-speed manual) Features All Wheel Drive: Mitsubishi's Active Center Differential (ACD) and Super Active Yaw Control (S-AYC). Gear Ratios: Specific gear ratios will be detailed in the manual, crucial for performance tuning and repair. 📐 Dimensions Exterior Length: 4490 mm (176.8 inches) Width: 1770 mm (69.7 inches) Height: 1415 mm (55.7 inches) Wheelbase: 2625 mm (103.3 inches) Weights Curb Weight Approx: 1450 kg (3197 lbs) Gross Weight Rating: Detailed in manual. 🛡️ Safety Features Ratings NHTSA Front Impact: 4 Stars (for 2004 model year in general, specific Evo ratings may vary) IIHS Side Impact: Good (for comparable models in its class) Active Features ABS: Standard, often with specific performance tuning for Evo. Traction Control: Standard (integrated with AWD system). Electronic Stability Control: Not standard on all models, but the S-AYC provides similar stability enhancement. Passive Features Airbags: Frontal airbags for driver and passenger, side airbags (optional/standard depending on region). Seatbelts: 3-point seatbelts with pre-tensioners. Body Structure: Reinforced chassis and safety cage design for rally homologation. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player, often with premium sound system options. Display: Basic digital display for climate control and audio; no integrated navigation or advanced infotainment screens. Driver Assistance Advanced Features: ACD and S-AYC systems represent advanced torque vectoring and stability management for its time. Connectivity Bluetooth: Not standard. Usb: Not standard. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (severe use requires more frequent changes). Timing Belt Replacement: Typically every 60,000 - 90,000 miles or 5-7 years (critical inspection and replacement recommended). Spark Plugs: Refer to manual for specific type and interval; platinum or iridium plugs typically last longer. Fluid Specifications Engine Oil Type: Synthetic SAE 5W-30 or 5W-40 recommended for turbocharged engines, meeting API...
Performance Compact Sedan / Rally Homologation Special
Positioning:
The Evolution VIII MR (Mitsubishi Racing) was the pinnacle of the Evo VIII line, offering enhanced performance and specific handling upgrades over the standard Evo VIII.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (FN2).
Key Features
Performance Focus:
Developed from rally racing technology, emphasizing all-wheel drive, turbocharged performance, and agile handling.
Driver Engagement:
Focus on driver feedback, precise controls, and a connected driving experience.
📋 Manual Details
Coverage Areas
Coverage Summary:
Comprehensive factory service and repair for Mitsubishi Lancer Evolution VIII MR (2004 model year).
Page Count
Estimated Pages:
Approximately 1500-2000 (typical for full factory manuals of this era).
276 hp @ 6500 rpm (DIN rating, often higher in actual testing)
Torque Us Spec:
289 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with electronic control
Fuel Type:
Unleaded Premium (91 Octane or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler
🔧 Transmission
Standard
Transmission Type:
6-speed Manual Transmission (Getrag)
Optional
Transmission Type:
N/A (MR model exclusively featured the 6-speed manual)
Features
All Wheel Drive:
Mitsubishi's Active Center Differential (ACD) and Super Active Yaw Control (S-AYC).
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning and repair.
📐 Dimensions
Exterior
Length:
4490 mm (176.8 inches)
Width:
1770 mm (69.7 inches)
Height:
1415 mm (55.7 inches)
Wheelbase:
2625 mm (103.3 inches)
Weights
Curb Weight Approx:
1450 kg (3197 lbs)
Gross Weight Rating:
Detailed in manual.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (for 2004 model year in general, specific Evo ratings may vary)
IIHS Side Impact:
Good (for comparable models in its class)
Active Features
ABS:
Standard, often with specific performance tuning for Evo.
Traction Control:
Standard (integrated with AWD system).
Electronic Stability Control:
Not standard on all models, but the S-AYC provides similar stability enhancement.
Passive Features
Airbags:
Frontal airbags for driver and passenger, side airbags (optional/standard depending on region).
Seatbelts:
3-point seatbelts with pre-tensioners.
Body Structure:
Reinforced chassis and safety cage design for rally homologation.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player, often with premium sound system options.
Display:
Basic digital display for climate control and audio; no integrated navigation or advanced infotainment screens.
Driver Assistance
Advanced Features:
ACD and S-AYC systems represent advanced torque vectoring and stability management for its time.
Connectivity
Bluetooth:
Not standard.
Usb:
Not standard.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (severe use requires more frequent changes).
Timing Belt Replacement:
Typically every 60,000 - 90,000 miles or 5-7 years (critical inspection and replacement recommended).
Spark Plugs:
Refer to manual for specific type and interval; platinum or iridium plugs typically last longer.
Fluid Specifications
Engine Oil Type:
Synthetic SAE 5W-30 or 5W-40 recommended for turbocharged engines, meeting API SN or newer and ACEA A3/B4.
Engine Oil Capacity:
Approximately 4.5 - 5.0 Liters (4.7 - 5.3 US Quarts) with filter change.
Transmission Fluid:
Manual transmission fluid (MTF) meeting Mitsubishi specification or equivalent (e.g., GL-4 or GL-5 specific, check manual).
Coolant:
Long-life (green or pink) ethylene glycol based coolant, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Wear:
Piston ring wear, valve stem seal issues, potential for turbocharger wear if not maintained properly.
Transmission Wear:
Clutch wear is common due to performance driving; synchro wear in the 6-speed transmission can occur with high mileage or hard use.
Suspension Wear:
Bushings and ball joints can wear, affecting handling.
Electrical:
Occasional issues with window regulators, immobilizer system glitches.
📚 Vehicle History
Brand Heritage
Motorsport Influence:
Direct lineage from Mitsubishi's WRC (World Rally Championship) Lancer Evolution program.
Model Evolution
Evo Viii Mr Distinction:
The 'MR' designation signifies 'Mitsubishi Racing' and denotes specific upgrades over the standard Evo VIII, including Bilstein suspension, specific Enkei wheels, and sometimes revised engine tuning.
Generation Placement:
Eighth generation Lancer Evolution, bridging the gap before the Evo IX.
Production
Production Years:
Evo VIII produced from 2003-2005, MR variant specifically for 2004-2005.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Titles:
Lancer Evolution models have numerous WRC and national rally championships to their name, solidifying its performance pedigree.
Automotive Press:
Consistently praised by automotive journalists for its handling, acceleration, and track capability.
Ratings
Enthusiast Following:
Strong and dedicated enthusiast base, making it a highly sought-after vehicle.