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Mitsubishi Lancer Evo 8 2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Year: 2003 Codes Chassis Code: CT9A Engine Code Primary: 4G63T 👋 Introduction Market Position Vehicle Segment: Performance compact sedan / Rally homologation special Target Audience: Enthusiasts, tuners, professional mechanics specializing in performance vehicles Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (later generations) Key Features Performance Focus: Designed for high-performance driving and motorsport capabilities Technical Innovation: Features advanced technologies like ACD, AYC, and powerful turbocharged engines 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service and repair Page Count Estimated Pages: Approximately 1500+ Manual Type Manual Classification: Factory Service Manual (FSM) / Workshop Manual Language Language Offered: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system Engine Electrical: Ignition system, fuel injection system (ECI-Multi), sensors (MAP, TPS, O2, Crank Angle, Cam Angle), actuators, ECU (Engine Control Unit) diagnostics, starting system, charging system Transmission: 6-speed manual transmission (Getrag 233), clutch system, differential (front, center, rear ACD - Active Center Differential), torque transfer system Drivetrain: Drive shafts, axles, transfer case, wheel hubs Suspension: Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, anti-roll bars, bushings Steering: Power steering system (hydraulic), steering rack, tie rods, steering column Brakes: Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, vented discs, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, bleeding procedures Electrical System: Wiring diagrams, fuse boxes, relays, lighting (headlights, taillights, interior), power windows, mirrors, central locking, wipers, horn, audio system Body And Interior: Exterior panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning) Body And Chassis: Chassis structure, body mounting, rust prevention, corrosion protection Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement Engine Repair: Head gasket replacement, piston ring replacement, bearing replacement, valve adjustment, turbocharger diagnosis and repair/replacement Transmission Repair: Clutch replacement, transmission fluid change, seal replacement, internal component inspection and repair Brake Service: Brake pad and rotor replacement, brake caliper service, brake line replacement, ABS component testing Suspension And Steering Service: Shock/strut replacement, bushing replacement, wheel alignment procedures, power steering fluid flush Electrical Troubleshooting: Diagnostic procedures for common electrical faults, wiring harness repair, component testing using multimeter and oscilloscope Troubleshooting Guides: Systematic diagnostic flowcharts for common symptoms (e.g., no-start, rough running, poor performance) Body And Trim Repair: Panel alignment, trim piece removal and installation, bumper repair Technical Depth Depth Of Information: Comprehensive, suitable for professional technicians and experienced DIY enthusiasts Diagnostic Tools Required: Specifies required diagnostic tools (e.g., MUT-III, scan tools, multimeters, oscilloscopes, specialized engine tools) Torque Specifications: Detailed torque specifications for all critical fasteners Clearances And Tolerances: Engine internal clearances (bearing play, piston-to-cylinder wall), valve lash settings Wiring Diagrams: Full electrical system schematics with component identification and wiring colors Special Tools: Lists and describes Mitsubishi-specific or specialized tools needed for certain procedures 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text Print Quality Diagram Clarity: Top quality diagrams, illustrations, and exploded views Binding Type Digital Format Type: Downloadable PDF Paper Type Digital Accessibility: Accessible on computers, tablets, and smartphones ⚙️ Engine Specifications Primary Engine Engine Type: 4G63T Inline-4, DOHC, 16-valve, turbocharged and intercooled Displacement: 1997 cc (2.0 Liters) Performance Horsepower Us Spec: 271 hp @ 6500 rpm Torque Us Spec: 273 lb-ft @ 3500 rpm Turbocharger: Mitsubishi TD05HR-16G (or similar variant) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) with electronic control Fuel Type: Premium Unleaded Gasoline (91+ Octane) 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission (Getrag 233) Optional Optional Transmission: Not available for Evo VIII Features Drivetrain Configuration: All-Wheel Drive (AWD) Center Differential: Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow) Rear Differential: Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC) depending on market/trim 📐 Dimensions Exterior Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2625 mm (103.3 in) Weights Curb Weight: Approximately 1450 kg (3197 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated by NHTSA for 2003 model year in many markets, but designed with safety in mind. IIHS Frontal Offset: Typically performed well in tests for its class, but specific ratings may vary by region. Active Features Active Safety Systems: ABS, EBD, ACD, AYC/S-AYC Passive Features Airbags: Driver and front passenger airbags, optional side airbags (market dependent) Body Structure: Reinforced chassis and safety cage structure for rally homologation 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD stereo system, typically with speaker upgrades for performance models. Climate Control: Manual or automatic climate control (market dependent), with A/C. Driver Assistance Traction Control: Integrated into AWD system (ACD) and AYC. Performance Monitoring: Gauges for boost pressure, oil...
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Mitsubishi Lancer Evo 8 2003 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII
Year:
2003
Codes
Chassis Code:
CT9A
Engine Code Primary:
4G63T
👋 Introduction
Market Position
Vehicle Segment:
Performance compact sedan / Rally homologation special
Target Audience:
Enthusiasts, tuners, professional mechanics specializing in performance vehicles
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (later generations)
Key Features
Performance Focus:
Designed for high-performance driving and motorsport capabilities
Technical Innovation:
Features advanced technologies like ACD, AYC, and powerful turbocharged engines
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair
Page Count
Estimated Pages:
Approximately 1500+
Manual Type
Manual Classification:
Factory Service Manual (FSM) / Workshop Manual
Language
Language Offered:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system
Engine Electrical:
Ignition system, fuel injection system (ECI-Multi), sensors (MAP, TPS, O2, Crank Angle, Cam Angle), actuators, ECU (Engine Control Unit) diagnostics, starting system, charging system
Transmission:
6-speed manual transmission (Getrag 233), clutch system, differential (front, center, rear ACD - Active Center Differential), torque transfer system
Drivetrain:
Drive shafts, axles, transfer case, wheel hubs
Suspension:
Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, anti-roll bars, bushings
Steering:
Power steering system (hydraulic), steering rack, tie rods, steering column
Brakes:
Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, vented discs, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, bleeding procedures
Electrical System:
Wiring diagrams, fuse boxes, relays, lighting (headlights, taillights, interior), power windows, mirrors, central locking, wipers, horn, audio system
Body And Interior:
Exterior panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning)
Body And Chassis:
Chassis structure, body mounting, rust prevention, corrosion protection
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement
Engine Repair:
Head gasket replacement, piston ring replacement, bearing replacement, valve adjustment, turbocharger diagnosis and repair/replacement
Transmission Repair:
Clutch replacement, transmission fluid change, seal replacement, internal component inspection and repair
Brake Service:
Brake pad and rotor replacement, brake caliper service, brake line replacement, ABS component testing
Suspension And Steering Service:
Shock/strut replacement, bushing replacement, wheel alignment procedures, power steering fluid flush
Electrical Troubleshooting:
Diagnostic procedures for common electrical faults, wiring harness repair, component testing using multimeter and oscilloscope
Troubleshooting Guides:
Systematic diagnostic flowcharts for common symptoms (e.g., no-start, rough running, poor performance)
Body And Trim Repair:
Panel alignment, trim piece removal and installation, bumper repair
Technical Depth
Depth Of Information:
Comprehensive, suitable for professional technicians and experienced DIY enthusiasts
Diagnostic Tools Required:
Specifies required diagnostic tools (e.g., MUT-III, scan tools, multimeters, oscilloscopes, specialized engine tools)
Torque Specifications:
Detailed torque specifications for all critical fasteners
Clearances And Tolerances:
Engine internal clearances (bearing play, piston-to-cylinder wall), valve lash settings
Wiring Diagrams:
Full electrical system schematics with component identification and wiring colors
Special Tools:
Lists and describes Mitsubishi-specific or specialized tools needed for certain procedures
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text
Print Quality
Diagram Clarity:
Top quality diagrams, illustrations, and exploded views
Binding Type
Digital Format Type:
Downloadable PDF
Paper Type
Digital Accessibility:
Accessible on computers, tablets, and smartphones
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T Inline-4, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Us Spec:
271 hp @ 6500 rpm
Torque Us Spec:
273 lb-ft @ 3500 rpm
Turbocharger:
Mitsubishi TD05HR-16G (or similar variant)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with electronic control
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
🔧 Transmission
Standard
Transmission Type:
6-speed Manual Transmission (Getrag 233)
Optional
Optional Transmission:
Not available for Evo VIII
Features
Drivetrain Configuration:
All-Wheel Drive (AWD)
Center Differential:
Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow)
Rear Differential:
Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC) depending on market/trim
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Weights
Curb Weight:
Approximately 1450 kg (3197 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated by NHTSA for 2003 model year in many markets, but designed with safety in mind.
IIHS Frontal Offset:
Typically performed well in tests for its class, but specific ratings may vary by region.
Active Features
Active Safety Systems:
ABS, EBD, ACD, AYC/S-AYC
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags (market dependent)
Body Structure:
Reinforced chassis and safety cage structure for rally homologation
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, typically with speaker upgrades for performance models.
Climate Control:
Manual or automatic climate control (market dependent), with A/C.
Driver Assistance
Traction Control:
Integrated into AWD system (ACD) and AYC.
Performance Monitoring:
Gauges for boost pressure, oil pressure, and voltage.
Connectivity
Connectivity Features:
Limited by era; primarily focused on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles or 6 months, whichever comes first, depending on driving conditions.
Spark Plug Replacement:
Approx. 30,000-60,000 miles (refer to manual for specific plug type and gap).
Timing Belt Replacement:
Crucial: 60,000 - 90,000 miles or 5-7 years, depending on conditions. Critical component to prevent catastrophic engine failure.
Fluid Specifications
Engine Oil Type:
Synthetic SAE 5W-30 or 5W-40 (API SN or equivalent, consult manual for exact specification and capacity).
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (LLC) or equivalent (Green).
Transmission Fluid Type:
GL-4 SAE 75W-85 or GL-4 SAE 75W-90 (for manual gearbox). Check ACD and rear diff fluid type separately.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Clutch wear, rear differential bushings, turbocharger seals (if improperly maintained), suspension components (control arm bushings).
Engine Considerations:
Head gasket failures can occur under extreme stress or if cooling system is neglected. Proper tuning and maintenance are vital for the 4G63T's longevity.
Acd And Ayc System:
Sensors and hydraulic components can be prone to failure with age and mileage; requires proper fluid changes.
📚 Vehicle History
Brand Heritage
Rally Roots:
Directly derived from Mitsubishi's World Rally Championship (WRC) Lancer rally cars.
Model Evolution
Evo Lineage:
Eighth generation of the highly successful Lancer Evolution series.
Evo Vii To Viii Changes:
Introduction of the 6-speed transmission, revised ACD system, larger turbocharger (TD05HR-16G), improved intercooler, and stronger chassis reinforcements.
Production
Production Years:
2003-2005
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Automotive Press Acclaim:
Consistently lauded by automotive media for its handling, performance, and rally-inspired engineering.
Performance Magazine Awards:
Often featured in 'best handling car' or 'most thrilling car' lists from performance-oriented publications.
Ratings
Enthusiast Ratings:
Highly regarded within the enthusiast community as a benchmark for performance sedans.
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