Welcome to the comprehensive service manual for the Lancer Evolution VIII, also known as the Evo 8. Produced between 2003 and 2005, this iconic performance sedan is a direct descendant of a highly successful World Rally Championship (WRC) program. Renowned for its potent 4G63T turbocharged engine, advanced all-wheel-drive system featuring Active Center Differential (ACD) and Active Yaw Control (AYC), and exceptional handling, the Evo 8 remains a benchmark for rally-bred road cars. Its engineering quality, reliability, and unique selling points, including its aerodynamic body kit and driver-selectable ACD modes, have solidified its status among automotive enthusiasts and professional mechanics alike. This factory service manual provides extensive information essential for the maintenance, diagnosis, and repair of your Lancer Evolution VIII. Covering over 1000 pages, it details every major system, including the powertrain, chassis, and electrical components, with specific procedures for routine maintenance, component overhauls, and troubleshooting. You will find in-depth guidance on engine and transmission specifics, suspension and brake systems, electrical diagnostics, and bodywork. This manual is an indispensable resource for owners, technicians, and mechanics seeking to preserve the performance, reliability, and longevity of their Evo 8, offering factory-level accuracy and detail. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Chassis Code: CT9A Production Years Covered: 2003-2005 Codes Vin Prefix Codes: JMECT9A 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Target Audience: Enthusiasts, professional mechanics, DIY repairers of Mitsubishi Lancer Evolution VIII. Competitive Analysis Key Rivals: Subaru Impreza WRX STI, Ford Focus RS, Mitsubishi Lancer Evolution VII/IX. Key Features Vehicle Attributes: Iconic rally-bred performance, advanced all-wheel-drive system (AYC/ACD), potent turbocharged engine, sharp handling, aerodynamic body kit. Manual Value Proposition: Provides comprehensive, accurate, and factory-level repair and maintenance information, essential for preserving the performance and longevity of the Evo 8. 📋 Manual Details Coverage Areas Primary Market: Global (English Language) Region Specific Variants: Covers common specifications for major markets (e.g., JDM, USDM, EUDM) with notes on key differences. Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission (Getrag 5-speed), Transfer Case, Drive Shafts, Front Differential, Rear Differential (AYC/ACD controlled). Chassis: Suspension (Front MacPherson Strut, Rear Multi-link), Steering System (Power Assisted Rack and Pinion), Brakes (Front Brembo 4-piston, Rear Brembo 2-piston, ABS), Wheels and Tires. Electrical: Body Electrical Systems, Powertrain Control Module (ECM), Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio System, HVAC Controls, Power Windows/Locks, ECU/TCU/ACD/AYC Control Units. Body: Exterior Body Panels, Interior Trim, Doors, Hood, Trunk, Bumpers, Glass, Sealing. Procedures Included Maintenance: Routine inspections, fluid changes (oil, coolant, brake, clutch, differential, transfer case), filter replacements, spark plug replacement, belt inspection/replacement. Repair And Overhaul: Engine teardown and rebuild, transmission overhaul, clutch replacement, brake caliper/rotor replacement, suspension component replacement, steering rack repair, electrical component diagnosis and replacement. Diagnostics: Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), electrical schematics, diagnostic tool usage (MUT-III). Specific diagnostic procedures for ACD/AYC systems. Special Procedures: Timing belt replacement (if applicable to specific engine variant), turbocharger inspection and replacement, AYC/ACD system calibration, alignment procedures, ECU flashing/programming. Technical Depth Depth: Comprehensive. Covers from basic fluid checks to complete engine and transmission rebuilds, including detailed diagnostic trees and specifications. 📊 Manual Specifications File Format Format: PDF Searchability: Typically text-searchable PDF for easy navigation. Print Quality Resolution: High-resolution scans for clear diagrams and text. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: DOHC 16-valve Inline-4, turbocharged, intercooled Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Performance Horsepower Ps: 265–280 PS (depending on market/spec) Horsepower Hp: 261–276 hp (depending on market/spec) Torque Lb-Ft: 257-260 lb-ft (depending on market/spec) Redline: 7,500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Port Injection Fuel Type: Unleaded Gasoline (91+ Octane Recommended) Turbocharger: MHI TD05HR-16G (often referred to as 'Big 16G') Engine Components Engine Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Valvetrain: DOHC, Belt-driven cams with hydraulic lifters 🔧 Transmission Standard Type: 6-Speed Manual (Getrag Type) Optional Type: None Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC) (rear differential). Gear Ratios: Specific ratios detailed in manual, variable by model/market. Fluid Specifications Transmission Fluid: Refer to manual for specific GL-4 or GL-5 specification, viscosity depends on temperature and application. Transfer Case Fluid: Refer to manual for specific specifications (often similar to transmission fluid). Rear Differential Fluid: Refer to manual for specific LSD/AYC specifications. 📐 Dimensions Exterior Length: Approx. 4,415 mm (173.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,625 mm (103.3 in) Track Width Front: Approx. 1,510 mm...