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2004 Mitsubishi Evolution 8 Mr Workshop & Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII MR Year: 2004 Codes Chassis Code: CT9A 👋 Introduction Market Position Market Position: The Lancer Evolution VIII MR represents the pinnacle of Mitsubishi's rally-bred performance sedans for its era, targeting driving enthusiasts and track day participants. Competitive Analysis Competitors: Competed against other high-performance, all-wheel-drive sports sedans such as the Subaru Impreza WRX STI and certain models from BMW M Division and Audi Sport. Key Features Mr Specific Features: Exclusive MR designation signifies a higher performance trim, featuring BBS alloy wheels, Bilstein shock absorbers, and an aluminum roof for weight reduction. Diy Benefit Benefit 1: Enables DIY servicing and repairs, fostering a deeper understanding of the vehicle's mechanics. Benefit 2: Encourages the acquisition of specialized tools for performance vehicle maintenance. Benefit 3: Potential for significant cost savings compared to professional dealership service. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive workshop and service repair for the 2004 Mitsubishi Lancer Evolution VIII MR Page Count Page Count: Not specified, but implied to be extensive given 'detailed instructions and step by step diagrams for all workshop procedures'. Manual Type Manual Type: Workshop & Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul of the 4G63T engine, including turbocharger system, fuel injection, ignition, cooling, and lubrication. Drivetrain: Complete coverage of the 6-speed manual transmission (GSE64), Active Yaw Control (AYC) system, Super Active Yaw Control (SAYC), and all-wheel-drive components. Suspension Steering: In-depth information on Bilstein shock absorbers, front and rear suspension components, steering system, alignment specifications, and wheel bearing service. Brakes: Detailed procedures for hydraulic brake system maintenance, caliper and rotor replacement, ABS system diagnosis, and brake fluid specifications. Electrical: Comprehensive wiring diagrams, fuse box locations, component testing, diagnosis of electrical systems including ECU, lighting, and comfort features. Body Chassis: Information on body panel repair, aluminum roof installation/removal, interior trim, and chassis structural integrity. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, coolant flushes, brake fluid replacement, and tire rotation. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for engine, transmission, electrical, and chassis issues. Repair Overhaul: Step-by-step instructions for engine rebuilds, transmission disassembly and reassembly, clutch replacement, brake component replacement, and turbocharger service. Technical Data Specs: Torque specifications for all fasteners, engine timing procedures, component clearances, and diagnostic trouble codes (DTCs). Technical Depth Depth: Advanced diagnostic capabilities, complete engine and transmission rebuild procedures, and detailed component-level repair instructions. 📊 Manual Specifications File Format File Format: PDF Compatibility Compatibility: Compatible with all versions of Windows and Mac operating systems. Requirements Software Requirements: Adobe Acrobat Reader or compatible PDF viewer. Print Quality Print Quality: High-resolution digital format, suitable for printing individual pages or the entire manual. Binding Type Binding Type: Digital download (not a physical book, thus no binding). Paper Type Paper Type: Digital (N/A) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: DOHC, 16-valve, turbocharged, intercooled inline-4 cylinder Displacement: 2.0 Liters (1997 cc) Performance Horsepower: Approx. 270-280 HP (varies slightly by market and tune) Torque: Approx. 286-295 lb-ft (varies slightly by market and tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with high-flow injectors and Denso fuel pump. Recommended Fuel: Premium Unleaded (91 Octane or higher) Turbocharger Turbo Type: Mitsubishi Heavy Industries (MHI) TD05HR-16G turbocharger with twin-scroll design. 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (Getrag ASN, Model GSE64) Optional Optional Transmission: N/A for MR model (only manual was offered) Features Drivetrain Features: Advanced All-Wheel-Drive (AWD) system with Active Yaw Control (AYC) or Super Active Yaw Control (SAYC) depending on specific market/variant. Fluid Specs Manual Transmission Fluid: Refer to manual for specific GL-3 or GL-4 rated gear oil, typically SAE 75W-90. 📐 Dimensions Exterior Length: Approx. 4,445 mm (175.0 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight: Approx. 1,450 kg (3,197 lbs) - MR variant due to aluminum roof and other features. 🛡️ Safety Features Ratings NHTSA Rating: Specific NHTSA ratings for the 2004 MR may vary; however, similar models received good ratings in frontal impacts. Refer to specific country's safety databases. Active Features Traction Control: Active All-Wheel Drive (AWD) system with AYC/SAYC, driver-selectable modes (Tarmac, Gravel, Snow). ABS: Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD). Passive Features Airbags: Frontal airbags for driver and passenger; side airbags may be optional or standard depending on market. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Infotainment System: Basic factory stereo systems with CD player; higher trims may have premium audio options. Limited by 2004 standards. Driver Assistance Driver Assistance Features: ABS, EBD, and the electronically controlled AWD system with AYC/SAYC are the primary driver assistance features. Connectivity Connectivity Options: Limited by 2004 standards; primarily analog systems. No Bluetooth or USB connectivity as standard....
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2004 Mitsubishi Evolution 8 Mr Workshop & Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII MR
Year:
2004
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Market Position:
The Lancer Evolution VIII MR represents the pinnacle of Mitsubishi's rally-bred performance sedans for its era, targeting driving enthusiasts and track day participants.
Competitive Analysis
Competitors:
Competed against other high-performance, all-wheel-drive sports sedans such as the Subaru Impreza WRX STI and certain models from BMW M Division and Audi Sport.
Key Features
Mr Specific Features:
Exclusive MR designation signifies a higher performance trim, featuring BBS alloy wheels, Bilstein shock absorbers, and an aluminum roof for weight reduction.
Diy Benefit
Benefit 1:
Enables DIY servicing and repairs, fostering a deeper understanding of the vehicle's mechanics.
Benefit 2:
Encourages the acquisition of specialized tools for performance vehicle maintenance.
Benefit 3:
Potential for significant cost savings compared to professional dealership service.
📋 Manual Details
Coverage Areas
Manual Coverage:
Comprehensive workshop and service repair for the 2004 Mitsubishi Lancer Evolution VIII MR
Page Count
Page Count:
Not specified, but implied to be extensive given 'detailed instructions and step by step diagrams for all workshop procedures'.
Manual Type
Manual Type:
Workshop & Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul of the 4G63T engine, including turbocharger system, fuel injection, ignition, cooling, and lubrication.
Drivetrain:
Complete coverage of the 6-speed manual transmission (GSE64), Active Yaw Control (AYC) system, Super Active Yaw Control (SAYC), and all-wheel-drive components.
Suspension Steering:
In-depth information on Bilstein shock absorbers, front and rear suspension components, steering system, alignment specifications, and wheel bearing service.
Brakes:
Detailed procedures for hydraulic brake system maintenance, caliper and rotor replacement, ABS system diagnosis, and brake fluid specifications.
Electrical:
Comprehensive wiring diagrams, fuse box locations, component testing, diagnosis of electrical systems including ECU, lighting, and comfort features.
Body Chassis:
Information on body panel repair, aluminum roof installation/removal, interior trim, and chassis structural integrity.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, coolant flushes, brake fluid replacement, and tire rotation.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for engine, transmission, electrical, and chassis issues.
Repair Overhaul:
Step-by-step instructions for engine rebuilds, transmission disassembly and reassembly, clutch replacement, brake component replacement, and turbocharger service.
Technical Data Specs:
Torque specifications for all fasteners, engine timing procedures, component clearances, and diagnostic trouble codes (DTCs).
Technical Depth
Depth:
Advanced diagnostic capabilities, complete engine and transmission rebuild procedures, and detailed component-level repair instructions.
📊 Manual Specifications
File Format
File Format:
PDF
Compatibility
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Requirements
Software Requirements:
Adobe Acrobat Reader or compatible PDF viewer.
Print Quality
Print Quality:
High-resolution digital format, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
Digital download (not a physical book, thus no binding).
Paper Type
Paper Type:
Digital (N/A)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
DOHC, 16-valve, turbocharged, intercooled inline-4 cylinder
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower:
Approx. 270-280 HP (varies slightly by market and tune)
Torque:
Approx. 286-295 lb-ft (varies slightly by market and tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with high-flow injectors and Denso fuel pump.
Recommended Fuel:
Premium Unleaded (91 Octane or higher)
Turbocharger
Turbo Type:
Mitsubishi Heavy Industries (MHI) TD05HR-16G turbocharger with twin-scroll design.
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission (Getrag ASN, Model GSE64)
Optional
Optional Transmission:
N/A for MR model (only manual was offered)
Features
Drivetrain Features:
Advanced All-Wheel-Drive (AWD) system with Active Yaw Control (AYC) or Super Active Yaw Control (SAYC) depending on specific market/variant.
Fluid Specs
Manual Transmission Fluid:
Refer to manual for specific GL-3 or GL-4 rated gear oil, typically SAE 75W-90.
📐 Dimensions
Exterior
Length:
Approx. 4,445 mm (175.0 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,630 mm (103.5 in)
Weights
Curb Weight:
Approx. 1,450 kg (3,197 lbs) - MR variant due to aluminum roof and other features.
🛡️ Safety Features
Ratings
NHTSA Rating:
Specific NHTSA ratings for the 2004 MR may vary; however, similar models received good ratings in frontal impacts. Refer to specific country's safety databases.
Active Features
Traction Control:
Active All-Wheel Drive (AWD) system with AYC/SAYC, driver-selectable modes (Tarmac, Gravel, Snow).
ABS:
Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD).
Passive Features
Airbags:
Frontal airbags for driver and passenger; side airbags may be optional or standard depending on market.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory stereo systems with CD player; higher trims may have premium audio options. Limited by 2004 standards.
Driver Assistance
Driver Assistance Features:
ABS, EBD, and the electronically controlled AWD system with AYC/SAYC are the primary driver assistance features.
Connectivity
Connectivity Options:
Limited by 2004 standards; primarily analog systems. No Bluetooth or USB connectivity as standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 to 7,500 miles or 6 months, whichever comes first (refer to manual for exact specification and severe driving conditions).
Spark Plug Replacement:
Approximately 30,000 miles for standard iridium spark plugs.
Timing Belt Replacement:
Crucial! Typically 60,000 miles or 5 years for the timing belt and associated components (tensioner, idler pulleys).
Fluid Specifications
Engine Oil Type:
Refer to manual. Commonly 5W-30 or 10W-30 synthetic oil meeting API SN or similar specifications. High-performance oils recommended.
Coolant Type:
Mitsubishi Super Long Life Coolant (Zebra) or equivalent, typically a 50/50 mix of ethylene glycol and distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Common Issues:
Potential for turbocharger failure if oil changes are neglected, cracked cylinder heads under extreme heat, and wear on valve stem seals causing oil consumption.
Drivetrain Common Issues:
Clutch wear (especially with aggressive driving), occasional issues with the AYC pump or hydraulic system.
Suspension Common Issues:
Wear on suspension bushings, ball joints, and wheel bearings due to aggressive driving and high cornering forces.
📚 Vehicle History
Brand Heritage
Rally Heritage:
The Lancer Evolution line is directly descended from Mitsubishi's successful World Rally Championship (WRC) program, built to homologate rally components.
Model Evolution
Evolution Viii:
The Evolution VIII, launched in 2003, introduced significant upgrades including a stronger engine, improved transmission, and revised suspension. The MR variant was a special edition of the VIII.
Production
Production Location:
Japan
Production Years Viii:
2003-2005
Uk Variants
Uk Special Editions:
In the United Kingdom, the Evolution VIII was offered in various "FQ" (Flower Quality) variants, such as FQ300, FQ320, FQ340, and FQ400, denoting increased horsepower.
🏆 Awards & Recognition
Recognitions
Performance Accolades:
The Lancer Evolution VIII series, including the MR, was widely acclaimed by automotive journalists for its exceptional handling, performance, and rally-bred DNA.
Rally Dominance:
Continues the legacy of the Lancer Evolution in motorsport, particularly in WRC, which heavily influenced its design and engineering.
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