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...
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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