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Mitsubishi Lancer Evolution 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Generation: VIII Model Code: CT9A (JDM), VIII (Global) Codes Chassis Code: CT9A Engine Code: 4G63 (MIVEC) 👋 Introduction Market Position Market Position: Performance rally-bred homologation special, enthusiast-focused sports sedan Competitive Analysis Competitors: Subaru WRX STI, Lancia Delta Integrale, Ford Focus RS, Audi S3 Key Features Key Features: Symmetrical All-Wheel Drive (SAWD), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), potent turbocharged engine, robust chassis Target Audience Target Audience: Enthusiasts, DIY mechanics, performance tuners, owners seeking in-depth technical understanding Unique Selling Proposition Usp: Unrivaled all-wheel-drive system and rally heritage translated to a road-going performance icon. 📋 Manual Details Coverage Areas Coverage: Complete Service and Repair Page Count Page Count: Likely 1000+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Official Factory Service Manual (FSM) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: 4G63 MIVEC Turbocharged, lubrication, cooling, fuel, ignition, emissions control, starting, charging Transmission: 6-speed manual (Getrag), drivetrain components, propeller shaft, rear differential, driveshafts Brakes: ABS, EBD, front Brembo 4-piston calipers, rear Brembo 2-piston calipers, brake fluid, bleeding procedures Suspension: Front MacPherson struts, rear multi-link, springs, shock absorbers, sway bars, alignment procedures Steering: Power assisted rack and pinion, steering column, tie rods Electrical: Battery, alternator, starter, lighting, ignition system, CAN bus, ECU, sensors, wiring diagrams, fuses, relays Bodywork: Exterior panels, interior trim, doors, windows, locks, glass, bumpers, aerodynamics HVAC: Heating, Ventilation, and Air Conditioning system components, refrigerant, troubleshooting Safety Systems: SRS airbags, seatbelts, seatbelt pretensioners Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and replacements Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, fault diagnosis for all major systems Repair: Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component repair Disassembly Assembly: Step-by-step instructions for removing, installing, and reassembling all major components Diagnostics: OBD-II diagnostics, ECU data interpretation, sensor testing, actuator testing Specifications: Torque specifications for all fasteners, engine clearances, fluid capacities, pressure specifications Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics) 📊 Manual Specifications File Format File Format: PDF Searchable: Yes (if OCR processed) Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63 MIVEC Inline-4 DOHC Turbocharged Displacement: 2.0 Liters (1997 cc) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Power Output Hp: 275 hp (205 kW) @ 6500 rpm (JDM Spec), 276 hp (206 kW) @ 6500 rpm (US Spec) Torque Output Lb Ft: 273 lb-ft (370 Nm) @ 3500 rpm (JDM Spec), 286 lb-ft (388 Nm) @ 3500 rpm (US Spec) Performance Redline: 7000 rpm Fuel System Fuel Type: Premium Unleaded Gasoline (91+ Octane) Fuel Delivery: Electronic Fuel Injection (EFI) with Turbocharger Turbocharger: Mitsubishi TD05H-16G (Single Scroll) Engine Management ECU: Multi-point Fuel Injection, Electronic Ignition Control 🔧 Transmission Standard Transmission Type: 6-speed Manual (Getrag Type D) Optional Optional Transmission: None (Manual was standard) Features Drivetrain: All-Wheel Drive (SAWD) with Active Center Differential (ACD) Differential Control: ACD with tarmac, gravel, and snow modes; Super AYC (Active Yaw Control) for rear differential torque vectoring Fluid Specs Transmission Fluid Type: API GL-4 or GL-5 (check specific manual for exact spec, often synthetic) 📐 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) Ground Clearance: 135 mm (5.3 in) Weights Curb Weight: Approx. 1450 kg (3197 lbs) Gross Vehicle Weight Rating: Approx. 1800 kg (3968 lbs) Wheels Tires Wheel Size: 17 x 8.0 inches (standard GSR/MR) Tire Size: 235/45R17 (standard) Bolt Pattern: 5x114.3 mm (5x4.5 inch) Offset: ET38 (standard) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated by NHTSA for this specific model year, but generally good for its class. IIHS Side Impact: Not explicitly rated by IIHS for this specific model year, but generally good for its class. Active Features ABS: Standard (Bosch 5.3 ABS) Ebd: Standard (Electronic Brake-force Distribution) Acd: Standard (Active Center Differential) Sayc: Standard on MR trim, optional/integrated with ACD on GSR Passive Features Airbags: Driver and Passenger Airbags (SRS) Seatbelts: 3-point front and rear seatbelts with pretensioners Roll Cage: Reinforced chassis structure, often referred to as a 'safety cage' for rally homologation 💡 Technology Features Infotainment Infotainment System: Basic factory CD player with AM/FM radio. Later models might have options for upgraded head units. Speakers: Typically 6-speaker system. Driver Assistance Driver Assistance Features: ABS, EBD, ACD, S-AYC (on MR trim). Connectivity Connectivity Options: Limited. Primarily basic audio inputs. Aftermarket solutions for Bluetooth/USB. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 - 5,000 miles or 6 months, whichever comes first (depending on driving conditions; severe use requires more frequent...
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Sku: 428065
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Mitsubishi Lancer Evolution 8 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII
Generation:
VIII
Model Code:
CT9A (JDM), VIII (Global)
Codes
Chassis Code:
CT9A
Engine Code:
4G63 (MIVEC)
👋 Introduction
Market Position
Market Position:
Performance rally-bred homologation special, enthusiast-focused sports sedan
Competitive Analysis
Competitors:
Subaru WRX STI, Lancia Delta Integrale, Ford Focus RS, Audi S3
Key Features
Key Features:
Symmetrical All-Wheel Drive (SAWD), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), potent turbocharged engine, robust chassis
Target Audience
Target Audience:
Enthusiasts, DIY mechanics, performance tuners, owners seeking in-depth technical understanding
Unique Selling Proposition
Usp:
Unrivaled all-wheel-drive system and rally heritage translated to a road-going performance icon.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service and Repair
Page Count
Page Count:
Likely 1000+ pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Official Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
4G63 MIVEC Turbocharged, lubrication, cooling, fuel, ignition, emissions control, starting, charging
Transmission:
6-speed manual (Getrag), drivetrain components, propeller shaft, rear differential, driveshafts
Brakes:
ABS, EBD, front Brembo 4-piston calipers, rear Brembo 2-piston calipers, brake fluid, bleeding procedures
Suspension:
Front MacPherson struts, rear multi-link, springs, shock absorbers, sway bars, alignment procedures
Steering:
Power assisted rack and pinion, steering column, tie rods
Electrical:
Battery, alternator, starter, lighting, ignition system, CAN bus, ECU, sensors, wiring diagrams, fuses, relays
Bodywork:
Exterior panels, interior trim, doors, windows, locks, glass, bumpers, aerodynamics
HVAC:
Heating, Ventilation, and Air Conditioning system components, refrigerant, troubleshooting
Safety Systems:
SRS airbags, seatbelts, seatbelt pretensioners
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and replacements
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, fault diagnosis for all major systems
Repair:
Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component repair
Disassembly Assembly:
Step-by-step instructions for removing, installing, and reassembling all major components
Diagnostics:
OBD-II diagnostics, ECU data interpretation, sensor testing, actuator testing
Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, pressure specifications
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics)
📊 Manual Specifications
File Format
File Format:
PDF
Searchable:
Yes (if OCR processed)
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63 MIVEC Inline-4 DOHC Turbocharged
Displacement:
2.0 Liters (1997 cc)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Power Output Hp:
275 hp (205 kW) @ 6500 rpm (JDM Spec), 276 hp (206 kW) @ 6500 rpm (US Spec)
Torque Output Lb Ft:
273 lb-ft (370 Nm) @ 3500 rpm (JDM Spec), 286 lb-ft (388 Nm) @ 3500 rpm (US Spec)
Performance
Redline:
7000 rpm
Fuel System
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Turbocharger
Turbocharger:
Mitsubishi TD05H-16G (Single Scroll)
Engine Management
ECU:
Multi-point Fuel Injection, Electronic Ignition Control
🔧 Transmission
Standard
Transmission Type:
6-speed Manual (Getrag Type D)
Optional
Optional Transmission:
None (Manual was standard)
Features
Drivetrain:
All-Wheel Drive (SAWD) with Active Center Differential (ACD)
Differential Control:
ACD with tarmac, gravel, and snow modes; Super AYC (Active Yaw Control) for rear differential torque vectoring
Fluid Specs
Transmission Fluid Type:
API GL-4 or GL-5 (check specific manual for exact spec, often synthetic)
📐 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)
Ground Clearance:
135 mm (5.3 in)
Weights
Curb Weight:
Approx. 1450 kg (3197 lbs)
Gross Vehicle Weight Rating:
Approx. 1800 kg (3968 lbs)
Wheels Tires
Wheel Size:
17 x 8.0 inches (standard GSR/MR)
Tire Size:
235/45R17 (standard)
Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Offset:
ET38 (standard)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated by NHTSA for this specific model year, but generally good for its class.
IIHS Side Impact:
Not explicitly rated by IIHS for this specific model year, but generally good for its class.
Active Features
ABS:
Standard (Bosch 5.3 ABS)
Ebd:
Standard (Electronic Brake-force Distribution)
Acd:
Standard (Active Center Differential)
Sayc:
Standard on MR trim, optional/integrated with ACD on GSR
Passive Features
Airbags:
Driver and Passenger Airbags (SRS)
Seatbelts:
3-point front and rear seatbelts with pretensioners
Roll Cage:
Reinforced chassis structure, often referred to as a 'safety cage' for rally homologation
💡 Technology Features
Infotainment
Infotainment System:
Basic factory CD player with AM/FM radio. Later models might have options for upgraded head units.
Speakers:
Typically 6-speaker system.
Driver Assistance
Driver Assistance Features:
ABS, EBD, ACD, S-AYC (on MR trim).
Connectivity
Connectivity Options:
Limited. Primarily basic audio inputs. Aftermarket solutions for Bluetooth/USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 5,000 miles or 6 months, whichever comes first (depending on driving conditions; severe use requires more frequent changes).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (depending on plug type and manufacturer recommendation).
Timing Belt Replacement:
Crucial: Every 60,000 - 90,000 miles or 5-7 years. Failure is catastrophic.
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years.
Transmission Fluid Change:
Every 30,000 - 60,000 miles, especially for spirited driving.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 - 5.0 Liters (with filter)
Engine Oil Recommendation:
0W-30, 5W-30, or 5W-40 Synthetic (API SN or higher, ACEA A3/B4 recommended for performance).
Coolant Type:
Mitsubishi Super Long Life Coolant (DIA-QUEEN SUPER LONG LIFE COOLANT) or equivalent OAT/HOAT coolant, typically red or pink.
Brake Fluid Type:
DOT 3 or DOT 4 (preferably DOT 4 for higher performance).
Known Issues
Engine:
Head gasket failures (especially on modified engines), turbocharger wear, piston ring wear, connecting rod bearing failures (high mileage/abuse).
Drivetrain:
ACD/AYC pump failures, manual transmission synchro wear, rear differential issues.
Electrical:
Faulty ACD/AYC pump relays, ABS sensor failures, ECU failures.
Suspension Steering:
Worn suspension bushings, strut mounts, power steering pump leaks.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long and storied history in the World Rally Championship (WRC), with the Lancer Evolution series being its flagship rally homologation model.
Model Evolution
Evolution Lineage:
The Evo VIII (CT9A) followed the Evo VII and was part of a continuous development cycle driven by rally success. It introduced significant chassis and drivetrain improvements.
Production
Production Years:
2003-2005
Assembly Location:
Japan
Variants
Notable Variants:
GSR (standard, often more creature comforts), RS (lighter, stripped-down, rally-focused), MR (premium trim, Bilstein suspension, Recaro seats, usually a more aggressive ACD/AYC setup)
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently recognized by automotive media for its handling, performance, and rally-inspired driving dynamics. Often praised as one of the best affordable performance cars of its era.
Ratings
Enthusiast Ratings:
Highly rated by enthusiasts for its tuning potential and engaging driving experience.
Certifications
Homologation Status:
Rally homologation special, built to meet FIA regulations for Group A rallying.
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