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2004 Mitsubushi LANCER EVO 8 VIII CAR Service/Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII (Evo 8) Year: 2004 Codes Chassis Code: CT9A Engine Code Prefix: 4G63 👋 Introduction Market Position Vehicle Segment: High-performance compact sedan (rally homologation special) Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS, Volkswagen Golf GTI/R32 Key Features Performance Focus: All-wheel drive, turbocharged engine, advanced differential systems, performance-oriented chassis Manual Value Proposition: Provides in-depth, factory-spec information for DIY repairs and maintenance, enabling cost savings and proper upkeep of a complex performance vehicle. Manual Type Distinction Distinction From Chiltens: Factory Service Manual (FSM) offering OEM-level detail, unlike aftermarket repair guides which are often less comprehensive and may lack specific technical nuances. 📋 Manual Details Coverage Areas Manual Coverage: Complete vehicle service and repair Page Count Total Pages: 859 Manual Type Manual Type: Factory Service Manual (FSM) Manual Content Source: Official Mitsubishi Factory Service Manual Language Language: English Format File Format: PDF Compatibility: Windows & macOS 📖 Manual Coverage Systems Covered Engine Systems: General information, lubrication, fuel, cooling, intake/exhaust, electrical, emission control, engine mounts Drivetrain Systems: Clutch, manual transaxle, propeller shaft, front axle, rear axle, wheel & tire Suspension Steering: Front suspension, rear suspension, steering system Braking Systems: Service brakes, parking brake Body Interior: Body structure, interior components, Supplemental Restraint System (SRS), exterior panels, glass Electrical HVAC: Chassis electrical, component locations, configuration diagrams, splice locations, circuit diagrams, HVAC (Heating, Air Conditioning, Ventilation) Chassis Systems: Integrated coverage of chassis, suspension, brakes, and steering for optimal performance and safety. Procedures Included Diagnostic Procedures: Troubleshooting guides for all major systems Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, tune-ups Repair Procedures: Detailed step-by-step instructions for component removal, installation, and overhaul Specification Settings: Torque specifications, alignment settings, electrical parameters Wiring Diagrams: Comprehensive circuit diagrams for all vehicle electrical systems. Component Locations: Detailed diagrams showing the placement of all major and minor components. Technical Depth Depth Of Coverage: Comprehensive, from basic diagnostics to complete engine and transmission rebuilds Detail Level: Factory-level detail, including exploded views, schematics, and wiring diagrams 📊 Manual Specifications File Format Searchability: Typically searchable text within PDF for efficient information retrieval Print Quality Readability: High-resolution PDF ensuring clear text and diagrams Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63T (MIVEC version in some markets, though typically the non-MIVEC version for the Evo VIII) Configuration: Inline-4, turbocharged, intercooled Displacement: 2.0 Liters (1997 cc) Performance Horsepower: Approx. 261-271 hp (varies by market and specific tune) Torque: Approx. 257-260 lb-ft (varies by market and specific tune) Fuel System Fuel Delivery: Multi-point fuel injection (MPI), Electronic Throttle Control Engine Management ECU Type: ECU (Engine Control Unit) with OBD-II diagnostics Cooling System Coolant Type: Ethylene Glycol based coolant (refer to manual for specific Mitsubishi specification, e.g., DiaQueen Super Long Life Coolant) Lubrication Oil Type: Synthetic 5W-30 or 10W-30 (API SG/SH/SJ/SL, ACEA A3/B3 or higher - consult manual for precise recommendations) Oil Capacity: Approx. 4.5-4.7 Liters (with filter change) Engine Electrical Ignition System: Distributorless ignition system (DIS) with coil-on-plug or coil-pack technology 🔧 Transmission Standard Transmission Type: 6-speed Manual Transaxle Features Drive System: All-Wheel Drive (AWD) with Active Center Differential (ACD) and optional Active Yaw Control (AYC) on some models Fluid Specification Gear Oil Type: GL-4 or GL-5 rated gear oil (specific viscosity recommended by Mitsubishi, often 75W-90) 📐 Dimensions Exterior Length: Approx. 4,490 mm (176.8 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight: Approx. 1,450-1,500 kg (3,197-3,307 lbs) depending on specification 🛡️ Safety Features Ratings NHTSA Front Impact: Not specifically rated for 2004 model year in all markets, but generally considered robust for its class. Passive Features Airbags: Driver and passenger front airbags, side airbags (optional/standard depending on trim) Seatbelts: 3-point seatbelts with pretensioners Active Features ABS: Anti-lock Braking System (ABS) Traction Control: Active Skid Prevention (ASP) / Traction Control System (TCS) AWD System: Advanced Symmetrical All-Wheel Drive with Active Center Differential (ACD) 💡 Technology Features Infotainment Audio System: Factory CD player with AM/FM radio, often with premium sound system options (e.g., Rockford Fosgate). Display: Basic LCD display for radio and climate control. Driver Assistance Performance Aids: ACD (Active Center Differential), AYC (Active Yaw Control - optional), Helical Limited Slip Differential (front), Mechanical Limited Slip Differential (rear) Connectivity Oem Connectivity: Limited by modern standards; typically no Bluetooth or USB integration from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,750-7,500 miles (6,000-12,000 km) or 6-12 months, depending on driving conditions. Refer to manual for severe vs. normal use. Transmission Fluid Interval: Recommended replacement every 30,000-60,000 miles (48,000-96,000 km). Check manual for specific ACD and AYC fluid changes. Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 (check manual for precise specification)...
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2004 Mitsubushi LANCER EVO 8 VIII CAR Service/Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII (Evo 8)
Year:
2004
Codes
Chassis Code:
CT9A
Engine Code Prefix:
4G63
👋 Introduction
Market Position
Vehicle Segment:
High-performance compact sedan (rally homologation special)
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS, Volkswagen Golf GTI/R32
Key Features
Performance Focus:
All-wheel drive, turbocharged engine, advanced differential systems, performance-oriented chassis
Manual Value Proposition:
Provides in-depth, factory-spec information for DIY repairs and maintenance, enabling cost savings and proper upkeep of a complex performance vehicle.
Manual Type Distinction
Distinction From Chiltens:
Factory Service Manual (FSM) offering OEM-level detail, unlike aftermarket repair guides which are often less comprehensive and may lack specific technical nuances.
📋 Manual Details
Coverage Areas
Manual Coverage:
Complete vehicle service and repair
Page Count
Total Pages:
859
Manual Type
Manual Type:
Factory Service Manual (FSM)
Manual Content Source:
Official Mitsubishi Factory Service Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility:
Windows & macOS
📖 Manual Coverage
Systems Covered
Engine Systems:
General information, lubrication, fuel, cooling, intake/exhaust, electrical, emission control, engine mounts
Drivetrain Systems:
Clutch, manual transaxle, propeller shaft, front axle, rear axle, wheel & tire
Suspension Steering:
Front suspension, rear suspension, steering system
Braking Systems:
Service brakes, parking brake
Body Interior:
Body structure, interior components, Supplemental Restraint System (SRS), exterior panels, glass
Electrical HVAC:
Chassis electrical, component locations, configuration diagrams, splice locations, circuit diagrams, HVAC (Heating, Air Conditioning, Ventilation)
Chassis Systems:
Integrated coverage of chassis, suspension, brakes, and steering for optimal performance and safety.
Procedures Included
Diagnostic Procedures:
Troubleshooting guides for all major systems
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and overhaul
Specification Settings:
Torque specifications, alignment settings, electrical parameters
Wiring Diagrams:
Comprehensive circuit diagrams for all vehicle electrical systems.
Component Locations:
Detailed diagrams showing the placement of all major and minor components.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic diagnostics to complete engine and transmission rebuilds
Detail Level:
Factory-level detail, including exploded views, schematics, and wiring diagrams
📊 Manual Specifications
File Format
Searchability:
Typically searchable text within PDF for efficient information retrieval
Print Quality
Readability:
High-resolution PDF ensuring clear text and diagrams
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T (MIVEC version in some markets, though typically the non-MIVEC version for the Evo VIII)
Configuration:
Inline-4, turbocharged, intercooled
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower:
Approx. 261-271 hp (varies by market and specific tune)
Torque:
Approx. 257-260 lb-ft (varies by market and specific tune)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI), Electronic Throttle Control
Engine Management
ECU Type:
ECU (Engine Control Unit) with OBD-II diagnostics
Cooling System
Coolant Type:
Ethylene Glycol based coolant (refer to manual for specific Mitsubishi specification, e.g., DiaQueen Super Long Life Coolant)
Lubrication
Oil Type:
Synthetic 5W-30 or 10W-30 (API SG/SH/SJ/SL, ACEA A3/B3 or higher - consult manual for precise recommendations)
Oil Capacity:
Approx. 4.5-4.7 Liters (with filter change)
Engine Electrical
Ignition System:
Distributorless ignition system (DIS) with coil-on-plug or coil-pack technology
🔧 Transmission
Standard
Transmission Type:
6-speed Manual Transaxle
Features
Drive System:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and optional Active Yaw Control (AYC) on some models
Fluid Specification
Gear Oil Type:
GL-4 or GL-5 rated gear oil (specific viscosity recommended by Mitsubishi, often 75W-90)
📐 Dimensions
Exterior
Length:
Approx. 4,490 mm (176.8 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase
Wheelbase:
Approx. 2,630 mm (103.5 in)
Weights
Curb Weight:
Approx. 1,450-1,500 kg (3,197-3,307 lbs) depending on specification
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not specifically rated for 2004 model year in all markets, but generally considered robust for its class.
Passive Features
Airbags:
Driver and passenger front airbags, side airbags (optional/standard depending on trim)
Seatbelts:
3-point seatbelts with pretensioners
Active Features
ABS:
Anti-lock Braking System (ABS)
Traction Control:
Active Skid Prevention (ASP) / Traction Control System (TCS)
AWD System:
Advanced Symmetrical All-Wheel Drive with Active Center Differential (ACD)
💡 Technology Features
Infotainment
Audio System:
Factory CD player with AM/FM radio, often with premium sound system options (e.g., Rockford Fosgate).
Display:
Basic LCD display for radio and climate control.
Driver Assistance
Performance Aids:
ACD (Active Center Differential), AYC (Active Yaw Control - optional), Helical Limited Slip Differential (front), Mechanical Limited Slip Differential (rear)
Connectivity
Oem Connectivity:
Limited by modern standards; typically no Bluetooth or USB integration from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,750-7,500 miles (6,000-12,000 km) or 6-12 months, depending on driving conditions. Refer to manual for severe vs. normal use.
Transmission Fluid Interval:
Recommended replacement every 30,000-60,000 miles (48,000-96,000 km). Check manual for specific ACD and AYC fluid changes.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for precise specification)
Power Steering Fluid:
Refer to manual for specific Mitsubishi specification (often ATF Dexron II/III or a dedicated power steering fluid)
Known Issues
Common Wear Items:
Clutch wear, turbocharger longevity (due to heat), spark plugs, fuel injectors, differential wear (especially with aggressive use).
Electrical Quirks:
Can include ABS sensor issues, SRS warning lights, or electrical connector corrosion in certain environments.
Engine Management:
Potential for turbo failure if not properly maintained (oil changes, cool-down periods), ignition coil issues.
📚 Vehicle History
Brand Heritage
Brand Origin:
Mitsubishi Motors Corporation, Japan
Model Evolution
Evolution Series:
Part of the legendary Lancer Evolution series, born from rally racing homologation requirements.
Production
Production Years:
Evo VIII production ran from 2003 to 2005.
Key Markets:
Japan, North America, Europe, Australia
🏆 Awards & Recognition
Recognitions
Motorsport Legacy:
The Evo VIII shares its DNA with rally-winning cars and is celebrated for its motorsport heritage and performance capabilities.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its handling, acceleration, and driver engagement.
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