2004 Mitsubishi LANCER EVO 8 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Designation: Evolution VIII (Evo 8) Model Code: CT9A Model Generation: Seventh Generation Year: 2004 Codes Chassis Code: CT9A Engine Code Primary: 4G63T (2.0L DOHC MIVEC Turbocharged Inline-4) 👋 Introduction Market Position Segment: Performance Compact Sedan, Rally Homologation Special Positioning: High-performance, driver-focused vehicle known for its rally heritage and advanced drivetrain technology. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Honda Civic Type R (in relevant markets), Ford Focus RS. Key Features Drivetrain: Advanced Super All-Wheel Control (S-AWC) with Active Center Differential (ACD) and Active Yaw Control (AYC). Engine: Powerful 4G63T 2.0L MIVEC turbocharged inline-four engine. Braking: High-performance Brembo braking system. Aerodynamics: Aggressive body kit, large rear wing, functional hood vents for cooling. 📋 Manual Details Coverage Areas Coverage Scope: Complete repair and service for the 2004 Mitsubishi Lancer Evolution VIII. Region Applicability: Primarily North American specifications, with potential for international variations noted where significant. Page Count Estimated Pages: Over 2000 Manual Type Type: Factory Authorized Service Repair Manual Distinction: Distinct from Owner's Manual; designed for professional technicians and advanced DIYers. Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63T MIVEC Turbo), Fuel System, Exhaust System, Cooling System, Lubrication System. Drivetrain: Manual Transmission (Getrag 5-speed or optional 6-speed depending on market/trim), All-Wheel Drive (AYC/ACD) System, Differentials, Driveshafts, Axles. Chassis: Suspension (Front MacPherson Strut, Rear Multi-link), Steering System, Braking System (Front Brembo 4-piston, Rear Brembo 2-piston). Electrical: ECU, Engine Control, Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio Systems, Body Electrical, Power Accessories. Body: Body Panels, Interior Trim, Exterior Trim, Glass, Doors, Hood, Trunk, Sealing Systems. HVAC: Heating, Ventilation, and Air Conditioning System. Safety Systems: Airbag System, ABS (Anti-lock Braking System). Procedures Included Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), circuit diagrams, component testing procedures. Maintenance: Scheduled maintenance intervals, fluid changes, filter replacements, inspections. Repair: Detailed step-by-step repair instructions for all major components and systems, including engine rebuild, transmission overhaul, suspension component replacement. Adjustment: Component adjustments (e.g., clutch, brakes), alignment specifications. Installation: Procedures for installing and removing components, including specialized parts. Specifications: Torque specifications for all fasteners, clearances, measurements. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic procedures, including use of scan tools and interpretation of sensor data. Special Tools: Identification and usage instructions for specialized tools required for specific repairs. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick access to information. Print Quality Quality: High-resolution digital scans for clear text and sharp illustrations. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L (1997 cc) DOHC Turbocharged Inline-4 with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) Performance Horsepower Std: 271 hp @ 6500 RPM (US Market) Torque Std: 273 lb-ft @ 3500 RPM (US Market) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Redline: 7000 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Port Injection Fuel Type: Premium Unleaded (91 octane or higher recommended) Turbocharger: Mitsubishi TD05H-16G (or similar variant) Intercooler: Air-to-Air Front-Mounted Intercooler 🔧 Transmission Standard Type: 5-speed Manual (MGN-101) Optional Type: 6-speed Manual (MGN-201) available on certain higher trims/markets Features AWD System: Super All-Wheel Control (S-AWC) including Active Center Differential (ACD) and Active Yaw Control (AYC). Clutch Type: Hydraulically Actuated, Single Dry Plate Gear Ratios: Specific ratios detailed in manual (vary by 5-speed/6-speed and market). Differential Type: Front Helical LSD, Rear Helical LSD (integrated with AYC). 📐 Dimensions Exterior Length: 4490 mm (176.8 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2630 mm (103.5 in) Track Width Front: 1515 mm (59.6 in) Track Width Rear: 1510 mm (59.4 in) Weights Curb Weight Std: Approximately 1420 kg (3130 lbs) for GSR, 1385 kg (3053 lbs) for RS (US Spec) Gross Vehicle Weight Rating: 1800 kg (3968 lbs) (Approximate) Towing Capacity: Not Recommended/Specified 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (for 2004 model year, standard Lancer) IIHS Side Impact: Good (for 2004 model year, standard Lancer) Active Features ABS: Standard Anti-lock Braking System with Electronic Brake-force Distribution (EBD). Traction Control: Active Stability Control (ASC) available on some trims. Driving Dynamics: AYC (Active Yaw Control) and ACD (Active Center Differential) contribute to stability and cornering grip. Passive Features Airbags: Driver and Front Passenger Airbags. Seatbelts: 3-point Front and Rear Seatbelts with pretensioners and force limiters. Body Structure: Reinforced Body Structure for crash energy absorption. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional Rockford Fosgate premium audio system on some trims. Display: Digital Odometer, Trip Computer, Exterior Temperature Gauge, ACD/AYC Mode Display. Driver Assistance ABS: Standard ABS. Asc: Optional Active Stability Control (ASC). Connectivity Oem Features: Limited by era; focus on...
Detailed step-by-step repair instructions for all major components and systems, including engine rebuild, transmission overhaul, suspension component replacement.
Electronic Fuel Injection (EFI) with Sequential Port Injection
Fuel Type:
Premium Unleaded (91 octane or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G (or similar variant)
Intercooler:
Air-to-Air Front-Mounted Intercooler
🔧 Transmission
Standard
Type:
5-speed Manual (MGN-101)
Optional
Type:
6-speed Manual (MGN-201) available on certain higher trims/markets
Features
AWD System:
Super All-Wheel Control (S-AWC) including Active Center Differential (ACD) and Active Yaw Control (AYC).
Clutch Type:
Hydraulically Actuated, Single Dry Plate
Gear Ratios:
Specific ratios detailed in manual (vary by 5-speed/6-speed and market).
Differential Type:
Front Helical LSD, Rear Helical LSD (integrated with AYC).
📐 Dimensions
Exterior
Length:
4490 mm (176.8 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2630 mm (103.5 in)
Track Width Front:
1515 mm (59.6 in)
Track Width Rear:
1510 mm (59.4 in)
Weights
Curb Weight Std:
Approximately 1420 kg (3130 lbs) for GSR, 1385 kg (3053 lbs) for RS (US Spec)
Gross Vehicle Weight Rating:
1800 kg (3968 lbs) (Approximate)
Towing Capacity:
Not Recommended/Specified
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for 2004 model year, standard Lancer)
IIHS Side Impact:
Good (for 2004 model year, standard Lancer)
Active Features
ABS:
Standard Anti-lock Braking System with Electronic Brake-force Distribution (EBD).
Traction Control:
Active Stability Control (ASC) available on some trims.
Driving Dynamics:
AYC (Active Yaw Control) and ACD (Active Center Differential) contribute to stability and cornering grip.
Passive Features
Airbags:
Driver and Front Passenger Airbags.
Seatbelts:
3-point Front and Rear Seatbelts with pretensioners and force limiters.
Body Structure:
Reinforced Body Structure for crash energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional Rockford Fosgate premium audio system on some trims.
Display:
Digital Odometer, Trip Computer, Exterior Temperature Gauge, ACD/AYC Mode Display.
Driver Assistance
ABS:
Standard ABS.
Asc:
Optional Active Stability Control (ASC).
Connectivity
Oem Features:
Limited by era; focus on performance systems. No factory Bluetooth or USB typically.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first, especially under spirited driving conditions.
Air Filter Replacement:
Every 15,000-20,000 miles or as needed.
Spark Plug Replacement:
Every 30,000-45,000 miles (depending on plug type).
Timing Belt Replacement:
Every 60,000-90,000 miles or 5-7 years (critical item for 4G63T).
Coolant Flush:
Every 2 years or 30,000 miles.
Fluid Specifications
Engine Oil:
5W-30 Synthetic (API SG/SH/SJ or higher, ACEA A3/B3 or higher) - Capacity: 4.5 L (4.8 US qt)
Transmission Fluid Mt:
API GL-4 Hypoid Gear Oil (75W-90) - Capacity: 2.5 L (2.6 US qt)
Transfer Case Fluid:
API GL-5 Hypoid Gear Oil (75W-90) - Capacity: 0.8 L (0.8 US qt)
Rear Differential Fluid:
API GL-5 Hypoid Gear Oil (75W-90) - Capacity: 1.3 L (1.4 US qt)
Brake Fluid:
DOT 3 or DOT 4
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent silicate-free, ethylene glycol based antifreeze. (50/50 mix) - Capacity: 7.0 L (7.4 US qt)
Known Issues
Engine Internal:
Connecting rod failure (especially with aggressive tuning or poor maintenance), turbocharger failure, oil consumption.
Drivetrain:
AYC/ACD pump failure, clutch wear, differential issues if abused.
Suspension:
Worn bushings, strut failure over time.
Electrical:
Corrosion on wiring harnesses, ECU issues.
Body:
Rusting in common areas (fender arches, rocker panels), especially in regions with salt exposure.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation
Motorsport Roots:
Directly derived from Mitsubishi's successful World Rally Championship (WRC) Lancer Evolution models.