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Mitsubishi 2004 Lancer Evo 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 Segment: Performance Compact Sedan (rally homologation special) Target Audience: Enthusiasts, professional mechanics, owners seeking in-depth DIY knowledge and repair capabilities. Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (other generations), Ford Focus RS, Volkswagen Golf R, Honda Civic Type R. Key Features Performance Focus: Designed for a vehicle renowned for its motorsport heritage and advanced AWD system. Documentation Type: Official factory workshop manual content, providing accurate and detailed repair information. 📋 Manual Details Coverage Areas Systems Covered: General Information, Service Specifications, Emission Control, Electrical Systems, Body (Bumpers, Hood, Fenders, Grille, Accessories), Suspension, Steering, Lubrication, Propeller Shaft, Differential, Brakes, Engine Maintenance & Troubleshooting, Instrument Panel, Front Axle, Rear Axle, Transmission, Drive Configuration, Clutch System, Index. Page Count Page Count: Estimated 1000+ pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: 4G63T (MIVEC DOHC Turbocharged Intercooled) Transmission: 6-speed manual (Getrag) with ACD (Active Center Differential) Drivetrain: All-Wheel Drive (AWD) with ACD, Front Helical LSD, Rear Active LSD Brakes: Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, ABS, EBD Suspension: MacPherson strut front, Multi-link rear, Bilstein shock absorbers, Eibach springs (MR specific) Steering: Power-assisted rack and pinion Electrical: Wiring diagrams, ECU, sensors, lighting, body control modules, audio system Procedures Included Maintenance: Routine scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, belt inspections and replacements. Troubleshooting: Diagnostic procedures for common and uncommon issues across all major systems, fault code interpretation. Repair: Engine disassembly and reassembly, transmission overhaul, brake component replacement, suspension component replacement, body panel repair, electrical component repair. Diagnostics: Detailed diagnostic flowcharts, component testing procedures, ECU parameter checks. Installation: Procedures for installing common replacement parts and accessories as per factory specifications. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component alignment. 📊 Manual Specifications File Format PDF Quality: High resolution, fully searchable text, allowing for easy navigation and keyword searches. Print Quality Printable Pages: All pages are printable, allowing users to create physical copies for workshop use. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (Evolution VIII variant) Configuration: Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled Displacement: 1997 cc (2.0 Liters) Performance Horsepower Usdm: 276 hp @ 6500 rpm Torque Usdm: 286 lb-ft @ 3500 rpm Horsepower Jdm: 280 PS (276 hp) @ 6500 rpm (net) Torque Jdm: 333 Nm (246 lb-ft) @ 3500 rpm (net) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI - Multi-Point Injection) with high-flow injectors Fuel Type: Unleaded Premium Unleaded Gasoline (91 octane or higher recommended) Cooling System Coolant Capacity: Approx. 6.8 Liters (14.4 US Quarts) 🔧 Transmission Standard Type: 6-speed Manual Transmission (Getrag MD742) Gear Ratios 1St: 3.143 Gear Ratios 2Nd: 2.105 Gear Ratios 3Rd: 1.429 Gear Ratios 4Th: 1.034 Gear Ratios 5Th: 0.763 Gear Ratios 6Th: 0.616 Final Drive Ratio: 4.529 Features Acd: Active Center Differential (ACD) for variable torque split Lsd: Helical LSD front, Active LSD rear (part of AYC system) Fluid Specifications Manual Transmission Fluid: Mitsubishi Diaqueen Gear Oil GL-5 75W-85 (or equivalent) Acd Fluid: Mitsubishi Diaqueen LSD Gear Oil GL-5 75W-85 (or equivalent) Rear Diff Fluid: Mitsubishi Diaqueen LSD Gear Oil GL-5 75W-85 (or equivalent) 📐 Dimensions Exterior Length: 4435 mm (174.6 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2600 mm (102.4 in) Weights Curb Weight: Approx. 1400 kg (3086 lbs) Gross Vehicle Weight Rating: Approx. 1815 kg (3999 lbs) 🛡️ Safety Features Ratings NHTSA Frontal Crash: 5-Star (for driver and front passenger) Active Features ABS: Anti-lock Braking System Ebd: Electronic Brakeforce Distribution Ayc: Active Yaw Control (integrated with ACD) Passive Features Airbags: Driver and front passenger airbags, side curtain airbags (optional/standard depending on market) Seatbelts: 3-point front seatbelts with pre-tensioners and force limiters, 3-point rear seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM CD player with 6 speakers, optional Rockford Fosgate audio upgrade. Driver Assistance Acd Modes: Driver-selectable modes for ACD (Tarmac, Gravel, Snow) affecting torque distribution. Ayc: Active Yaw Control (AYC) system actively distributes torque to the rear wheels for improved cornering. Connectivity Gauge Cluster: Multi-function gauge cluster including boost gauge and ACD status display. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 miles or 6 months (whichever comes first) for normal use; 3,000 miles or 3 months for severe use (e.g., track driving, frequent short trips). Engine Oil Filter: Replace with every oil change. Spark Plugs: Replace every 60,000 miles (standard plugs) or 105,000 miles (iridium plugs). Timing Belt: Replace every 96,000 miles or 8 years. Fluid Specifications...
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Mitsubishi 2004 Lancer Evo 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
Segment:
Performance Compact Sedan (rally homologation special)
Target Audience:
Enthusiasts, professional mechanics, owners seeking in-depth DIY knowledge and repair capabilities.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (other generations), Ford Focus RS, Volkswagen Golf R, Honda Civic Type R.
Key Features
Performance Focus:
Designed for a vehicle renowned for its motorsport heritage and advanced AWD system.
Documentation Type:
Official factory workshop manual content, providing accurate and detailed repair information.
📋 Manual Details
Coverage Areas
Systems Covered:
General Information, Service Specifications, Emission Control, Electrical Systems, Body (Bumpers, Hood, Fenders, Grille, Accessories), Suspension, Steering, Lubrication, Propeller Shaft, Differential, Brakes, Engine Maintenance & Troubleshooting, Instrument Panel, Front Axle, Rear Axle, Transmission, Drive Configuration, Clutch System, Index.
Page Count
Page Count:
Estimated 1000+ pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
4G63T (MIVEC DOHC Turbocharged Intercooled)
Transmission:
6-speed manual (Getrag) with ACD (Active Center Differential)
Drivetrain:
All-Wheel Drive (AWD) with ACD, Front Helical LSD, Rear Active LSD
Brakes:
Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, ABS, EBD
Suspension:
MacPherson strut front, Multi-link rear, Bilstein shock absorbers, Eibach springs (MR specific)
Steering:
Power-assisted rack and pinion
Electrical:
Wiring diagrams, ECU, sensors, lighting, body control modules, audio system
Procedures Included
Maintenance:
Routine scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, belt inspections and replacements.
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all major systems, fault code interpretation.
Repair:
Engine disassembly and reassembly, transmission overhaul, brake component replacement, suspension component replacement, body panel repair, electrical component repair.
Diagnostics:
Detailed diagnostic flowcharts, component testing procedures, ECU parameter checks.
Installation:
Procedures for installing common replacement parts and accessories as per factory specifications.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component alignment.
📊 Manual Specifications
File Format
PDF Quality:
High resolution, fully searchable text, allowing for easy navigation and keyword searches.
Print Quality
Printable Pages:
All pages are printable, allowing users to create physical copies for workshop use.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (Evolution VIII variant)
Configuration:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Usdm:
276 hp @ 6500 rpm
Torque Usdm:
286 lb-ft @ 3500 rpm
Horsepower Jdm:
280 PS (276 hp) @ 6500 rpm (net)
Torque Jdm:
333 Nm (246 lb-ft) @ 3500 rpm (net)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI - Multi-Point Injection) with high-flow injectors
Fuel Type:
Unleaded Premium Unleaded Gasoline (91 octane or higher recommended)
Cooling System
Coolant Capacity:
Approx. 6.8 Liters (14.4 US Quarts)
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (Getrag MD742)
Gear Ratios 1St:
3.143
Gear Ratios 2Nd:
2.105
Gear Ratios 3Rd:
1.429
Gear Ratios 4Th:
1.034
Gear Ratios 5Th:
0.763
Gear Ratios 6Th:
0.616
Final Drive Ratio:
4.529
Features
Acd:
Active Center Differential (ACD) for variable torque split
Lsd:
Helical LSD front, Active LSD rear (part of AYC system)
Fluid Specifications
Manual Transmission Fluid:
Mitsubishi Diaqueen Gear Oil GL-5 75W-85 (or equivalent)
Acd Fluid:
Mitsubishi Diaqueen LSD Gear Oil GL-5 75W-85 (or equivalent)
Rear Diff Fluid:
Mitsubishi Diaqueen LSD Gear Oil GL-5 75W-85 (or equivalent)
📐 Dimensions
Exterior
Length:
4435 mm (174.6 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1400 kg (3086 lbs)
Gross Vehicle Weight Rating:
Approx. 1815 kg (3999 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash:
5-Star (for driver and front passenger)
Active Features
ABS:
Anti-lock Braking System
Ebd:
Electronic Brakeforce Distribution
Ayc:
Active Yaw Control (integrated with ACD)
Passive Features
Airbags:
Driver and front passenger airbags, side curtain airbags (optional/standard depending on market)
Seatbelts:
3-point front seatbelts with pre-tensioners and force limiters, 3-point rear seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player with 6 speakers, optional Rockford Fosgate audio upgrade.
Driver Assistance
Acd Modes:
Driver-selectable modes for ACD (Tarmac, Gravel, Snow) affecting torque distribution.
Ayc:
Active Yaw Control (AYC) system actively distributes torque to the rear wheels for improved cornering.
Connectivity
Gauge Cluster:
Multi-function gauge cluster including boost gauge and ACD status display.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles or 6 months (whichever comes first) for normal use; 3,000 miles or 3 months for severe use (e.g., track driving, frequent short trips).
Engine Oil Filter:
Replace with every oil change.
Spark Plugs:
Replace every 60,000 miles (standard plugs) or 105,000 miles (iridium plugs).
Timing Belt:
Replace every 96,000 miles or 8 years.
Fluid Specifications
Engine Oil:
API SG, SH, or SJ classification, SAE 5W-30 viscosity (check owner's manual for precise recommendation).
Engine Coolant:
Mitsubishi Super Long Life Coolant (Zebra Green) or equivalent OAT/HOAT coolant (50/50 mix with distilled water).
Brake Fluid:
DOT 3 or DOT 4 High-Temperature Brake Fluid.
Known Issues
Engine Internal:
Ringland failure in early 4G63 engines under extreme stress, valve seal wear, turbocharger oil feed issues if maintenance is neglected.
Drivetrain:
ACD pump failure, AYC pump failure, differential wear with aggressive use.
Clutch:
Clutch wear can be accelerated by aggressive driving; hydraulic system leaks.
Body Electrical:
Corrosion on strut towers, minor electrical gremlins if water ingress occurs.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Direct lineage from Mitsubishi's WRC (World Rally Championship) success, built as a homologation special.
Model Evolution
Evo Viii Introduction:
Introduced in 2003 as the Evolution VIII, building on the success of the Evolution VII.
Mr Variant:
The 'MR' (Mitsubishi Racing) designation signifies a more performance-oriented package, often including specific suspension tuning, lighter components, and premium interior features compared to the standard GSR or RS trims.
Production
Production Location:
Japan
Production Years Evo Viii:
2003-2005
🏆 Awards & Recognition
Recognitions
General Reputation:
Consistently lauded by automotive journalists and enthusiasts as one of the greatest performance sedans of its era, often appearing on 'best of' lists.
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