Mitsubishi Lancer Evolution 8 2003-2005 WSM Service Manual

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The Lancer Evolution VIII, also known as the Evo VIII, is a performance-oriented compact sedan produced from 2003 to 2005. Built on a rally-bred chassis (CT9A), this model is distinguished by its potent 4G63T turbocharged engine, advanced Active Center Differential (ACD) system offering selectable modes for various terrains, and robust Brembo braking system. Engineered for exceptional handling and exhilarating driving dynamics, the Evo VIII represents a significant iteration in the storied performance vehicle lineage, known for its sophisticated all-wheel-drive capabilities and direct connection to motorsport success. This comprehensive workshop service manual provides in-depth technical information and procedures for the Lancer Evolution VIII. It covers all major systems, including the powertrain, transmission, drivetrain, suspension, steering, brakes, and electrical components. Detailed maintenance schedules, repair instructions, troubleshooting guides, and diagnostic procedures are included to assist owners and technicians in maintaining and repairing the vehicle. The manual is designed to offer professional-level guidance, ensuring the optimal performance and longevity of your Evo VIII. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo VIII Production Years Covered: 2003, 2004, 2005 Codes Chassis Code: CT9A Engine Code Primary: 4G63 Engine Code Variant: 4G63T (DOHC, turbocharged, MIVEC) 👋 Introduction Market Position Market Segment: Performance Compact Sedan / Rally Homologation Special Competitor Set: Subaru Impreza WRX STI, Mitsubishi Lancer (non-Evolution variants), Ford Focus RS (later generations), Honda Civic Type R (later generations) Competitive Analysis Key Differentiators: Advanced AWD system (ACD), powerful turbocharged engine, rally-bred chassis, performance braking (Brembo), aggressive styling, homologation pedigree. Key Features Performance Focus: Designed for high-performance driving, track use, and rallying. Emphasizes handling, acceleration, and braking capabilities. Technical Sophistication: Features advanced drivetrain management (ACD, AYC - Active Yaw Control, although AYC was more prominent in prior generations, ACD is key for Evo VIII), powerful MIVEC engine technology, and robust chassis engineering. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Specific Regions Covered: Global (technical specifications applicable across markets) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service Manual (WSM) Additional Manual Types Indicated: Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Cooling System, Fuel System, Lubrication System, Ignition System, Exhaust System, Engine Management System (ECU/ECM) Transmission Drivetrain: Manual Transmission (Getrag 5-speed), Transfer Case, ACD (Active Center Differential), Rear Differential, Driveshafts, Axles Suspension Steering: Front Suspension (MacPherson Strut), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Wheels, Tires Brakes: Front Brakes (Brembo 4-piston calipers), Rear Brakes (Brembo 2-piston calipers), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Parking Brake Electrical: Battery, Charging System (Alternator), Starting System (Starter Motor), Lighting System, Instrumentation, Audio System, Power Accessories, SRS (Supplemental Restraint System) / Airbags Body Chassis: Body Exterior Panels, Doors, Hood, Trunk, Bumpers, Chassis Frame, Interior Trim, Seats Climate Control: HVAC (Heating, Ventilation, Air Conditioning) System Diagnostics: OBD-II (On-Board Diagnostics II) System, DTC (Diagnostic Trouble Codes) listing and troubleshooting Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection/Replacement Repair: Engine Overhaul/Rebuild, Transmission Rebuild, Clutch Replacement, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues Diagnostics Programming: ECU/ECM diagnostics, sensor testing, actuator testing, immobilizer system checks Installation Adjustment: Component installation and removal procedures, alignment specifications, timing belt adjustment Technical Depth Depth: Professional Level - Covers detailed disassembly, assembly, inspection, measurement, and repair procedures for all major vehicle systems. Diagnostic Capabilities: Advanced diagnostic procedures, wiring diagrams, component testing specifications, and diagnostic trouble code explanations. Rebuild Specifications: Includes critical torque specifications, clearances, and tolerances for engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text content (assuming professional quality scan/creation) Print Quality Print Quality Recommendation: Printable on standard office printers Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Engine Code Specific: 4G63T (Evo VIII specific tuning) Performance Horsepower Hp Approx: 271 hp @ 6500 rpm (JDM/European spec), 265 hp @ 6500 rpm (USDM spec) Torque Lb-Ft Approx: 273 lb-ft @ 3500 rpm (JDM/European spec), 275 lb-ft @ 3500 rpm (USDM spec) Redline: 7,000 rpm Fuel System Fuel Type: Unleaded Gasoline (Premium Unleaded Recommended, 91+ Octane) Fuel Delivery: Multi-Point Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G (or similar variant depending on market) Intercooler: Air-to-Air Front-Mounted Intercooler 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Transmission Manufacturer Standard: Getrag (Model 232) Optional Transmission Type Optional: None (Manual transmission only for Evolution VIII) Features Drivetrain Configuration: All-Wheel Drive (AWD) Transfer Case: Center Differential with ACD (Active Center Differential) Rear Differential: Helical...

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Sku: 83479

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Disponibilidade: Em estoque

Tag: 2003 2004 2005 Car Cars Lancer Evolution 8 Misc Mitsubishi

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo VIII

Production Years Covered:

2003, 2004, 2005

Codes

Chassis Code:

Engine Code Primary:

Engine Code Variant:

4G63T (DOHC, turbocharged, MIVEC)

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Competitor Set:

Subaru Impreza WRX STI, Mitsubishi Lancer (non-Evolution variants), Ford Focus RS (later generations), Honda Civic Type R (later generations)

Competitive Analysis

Key Differentiators:

Advanced AWD system (ACD), powerful turbocharged engine, rally-bred chassis, performance braking (Brembo), aggressive styling, homologation pedigree.

Key Features

Performance Focus:

Designed for high-performance driving, track use, and rallying. Emphasizes handling, acceleration, and braking capabilities.

Technical Sophistication:

Features advanced drivetrain management (ACD, AYC - Active Yaw Control, although AYC was more prominent in prior generations, ACD is key for Evo VIII), powerful MIVEC engine technology, and robust chassis engineering.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive

Specific Regions Covered:

Global (technical specifications applicable across markets)

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Service Manual (WSM)

Additional Manual Types Indicated:

Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Cooling System, Fuel System, Lubrication System, Ignition System, Exhaust System, Engine Management System (ECU/ECM)

Transmission Drivetrain:

Manual Transmission (Getrag 5-speed), Transfer Case, ACD (Active Center Differential), Rear Differential, Driveshafts, Axles

Suspension Steering:

Front Suspension (MacPherson Strut), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Wheels, Tires

Brakes:

Front Brakes (Brembo 4-piston calipers), Rear Brakes (Brembo 2-piston calipers), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Parking Brake

Electrical:

Battery, Charging System (Alternator), Starting System (Starter Motor), Lighting System, Instrumentation, Audio System, Power Accessories, SRS (Supplemental Restraint System) / Airbags

Body Chassis:

Body Exterior Panels, Doors, Hood, Trunk, Bumpers, Chassis Frame, Interior Trim, Seats

Climate Control:

HVAC (Heating, Ventilation, Air Conditioning) System

Diagnostics:

OBD-II (On-Board Diagnostics II) System, DTC (Diagnostic Trouble Codes) listing and troubleshooting

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Fuel), Spark Plug Replacement, Belt Inspection/Replacement

Repair:

Engine Overhaul/Rebuild, Transmission Rebuild, Clutch Replacement, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues

Diagnostics Programming:

ECU/ECM diagnostics, sensor testing, actuator testing, immobilizer system checks

Installation Adjustment:

Component installation and removal procedures, alignment specifications, timing belt adjustment

Technical Depth

Depth:

Professional Level - Covers detailed disassembly, assembly, inspection, measurement, and repair procedures for all major vehicle systems.

Diagnostic Capabilities:

Advanced diagnostic procedures, wiring diagrams, component testing specifications, and diagnostic trouble code explanations.

Rebuild Specifications:

Includes critical torque specifications, clearances, and tolerances for engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely searchable text content (assuming professional quality scan/creation)

Print Quality

Print Quality Recommendation:

Printable on standard office printers

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Engine Code Specific:

4G63T (Evo VIII specific tuning)

Performance

Horsepower Hp Approx:

271 hp @ 6500 rpm (JDM/European spec), 265 hp @ 6500 rpm (USDM spec)

Torque Lb-Ft Approx:

273 lb-ft @ 3500 rpm (JDM/European spec), 275 lb-ft @ 3500 rpm (USDM spec)

Redline:

7,000 rpm

Fuel System

Fuel Type:

Unleaded Gasoline (Premium Unleaded Recommended, 91+ Octane)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Turbocharger:

Mitsubishi TD05HR-16G (or similar variant depending on market)

Intercooler:

Air-to-Air Front-Mounted Intercooler

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Transmission Manufacturer Standard:

Getrag (Model 232)

Optional

Transmission Type Optional:

None (Manual transmission only for Evolution VIII)

Features

Drivetrain Configuration:

All-Wheel Drive (AWD)

Transfer Case:

Center Differential with ACD (Active Center Differential)

Rear Differential:

Helical Limited-Slip Differential (LSD)

Front Differential:

Open Differential

Acd Modes:

Tarmac, Gravel, Snow

📐 Dimensions

Exterior

Length Mm:

4490 mm

Width Mm:

1770 mm

Height Mm:

1415 mm

Wheelbase Mm:

2625 mm

Track Width Front Mm:

1510 mm

Track Width Rear Mm:

1505 mm

Weights

Curb Weight Kg Approx:

1400 - 1450 kg (depending on market and options)

Gross Vehicle Weight Rating Kg Approx:

1850 kg

Cargo

Trunk Volume Liters Approx:

280 Liters

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

4 Stars (for driver and passenger, based on available data for similar models)

IIHS Crash Test Ratings:

Good (for frontal offset, based on similar models/generations)

Active Features

Standard (Anti-lock Braking System)

Standard (Electronic Brake-force Distribution)

Traction Control:

Standard (TC-SST not applicable to this manual transmission model)

AWD System:

ACD (Active Center Differential) with driver-selectable modes enhances traction and stability.

Passive Features

Airbags:

Driver and Front Passenger Airbags (SRS)

Seatbelts:

Three-point front and rear seatbelts with pre-tensioners and force limiters

Rollover Protection:

Reinforced body structure

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, often with premium speaker options (e.g., Rockford Fosgate).

Display Type:

Analog gauges, basic LCD trip computer and climate controls.

Driver Assistance

Standard ABS system is a key driver assistance feature.

Traction Control:

Standard traction control system complements the AWD.

Torque Vectoring:

While not explicitly electronic torque vectoring in the modern sense, the ACD system allows for variable torque distribution to enhance cornering.

Connectivity

Connectivity Features:

Limited by era; typically no Bluetooth, USB, or smartphone integration. May have power antenna and basic speaker outputs.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval Km Miles:

7,500 km or 6 months (whichever comes first), or 3,750 km / 3 months for severe driving conditions.

Oil Filter Replacement Interval:

At every oil change

Air Filter Replacement Interval:

15,000 km or 12 months, inspect more frequently

Spark Plug Replacement Interval:

45,000 km for standard spark plugs, 90,000 km for iridium-tipped plugs (check specific plug type)

Timing Belt Replacement Interval:

105,000 km or 7 years (critical component, inspect regularly)

Fluid Specifications

Engine Oil Type:

API SG or SH, ILSAC GF-II or GF-III, Viscosity SAE 5W-30 or 10W-40 (check manual for specific climate recommendations)

Engine Oil Capacity Liters:

4.5 Liters (with filter)

Transmission Fluid Type:

API GL-4, SAE 75W-90 Hypoid Gear Oil (for manual transmission)

Transfer Case Fluid Type:

API GL-5, SAE 75W-90 Hypoid Gear Oil

Rear Differential Fluid Type:

API GL-5, SAE 75W-90 Hypoid Gear Oil (consider LSD additive if specified)

Coolant Type:

Ethylene Glycol based coolant (Mitsubishi Genuine Super Long Life Coolant or equivalent)

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific recommendation)

Power Steering Fluid Type:

ATF Dexron II or III (check manual for exact specification)

Known Issues

Engine:

Head gasket failures (especially on heavily modified engines), turbocharger wear, piston ring issues (less common on stock), valve seat wear.

Transmission:

Grinding gears (especially 2nd and 5th), worn synchros, clutch wear.

Acd System:

ACD pump failures, sensor issues, fluid leaks.

Suspension Steering:

Worn control arm bushings, premature wear on ball joints and tie rod ends due to aggressive driving.

Electrical:

Alternator failures, power window motor issues, SRS warning light illumination.

Rust Corrosion:

Can be susceptible to rust in common areas like wheel wells, rocker panels, and subframes, especially in regions with road salt.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mitsubishi Motors, known for its engineering prowess, particularly in rallying and performance vehicles.

Model Evolution

Evolution Series Origin:

The Lancer Evolution lineage began in 1992 as a homologation special for the World Rally Championship (WRC).

Evo Viii Introduction:

The Evolution VIII was launched in 2003, marking a significant evolution in performance and technology for the series.

Key Changes From Evo Vii:

Updated turbocharger (TD05HR-16G), revised ACD system, stronger chassis, and improved aerodynamic elements. Introduction of the 'F' designation for some models indicating engine enhancements.

Production

Production Start Year:

Production End Year For Model:

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Rally Connection:

The Evo VIII was developed with rally homologation in mind, directly influencing its chassis, drivetrain, and engine design.

🏆 Awards & Recognition

Recognitions

Sport Compact Car Of The Year:

Often cited by automotive publications as a benchmark performance car.

Wrc Legacy:

Continues the highly successful WRC heritage of the Lancer Evolution line, recognized for its motorsport pedigree.

Ratings

Handling Performance Rankings:

Consistently ranked among the best-handling cars of its era by automotive journalists.

Certifications

Emissions Compliance:

Complies with relevant emissions standards for the model year and market of sale.