2004 Mitsubushi LANCER EVOLUTION Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Variant: Evolution VIII Year: 2004 Codes Chassis Code: CT9A 👋 Introduction Market Position Market Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (lesser trims) Key Features Performance Focus: All-Wheel Drive (AWD) with Active Center Differential (ACD), Twin-Scroll Turbocharged Engine, Performance-tuned Suspension, Powerful Braking System Rally Heritage: Direct lineage from World Rally Championship (WRC) cars, offering homologation-level performance and engineering for street use. Aerodynamics: Aggressive aerodynamic enhancements including a large rear wing, front splitter, and aerodynamic body kit. 📋 Manual Details Coverage Areas Primary Focus: Factory Service and Repair Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual (FSM) Purpose: Designed for use by certified Mitsubishi technicians and experienced DIY mechanics. Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Turbocharger, Cooling System, Fuel System, Exhaust System, Drivetrain (Manual Transmission, Transfer Case, Front Differential, Rear Differential) Chassis: Suspension (Front MacPherson Strut, Rear Multi-link), Steering System, Brake System (ABS, EBD), Wheels and Tires Electrical: Engine Control Module (ECM), Powertrain Control Module (PCM), Ignition System, Charging System, Starting System, Lighting, Instrumentation, Wiper/Washer System, HVAC Controls, Audio System, SRS (Airbag) System, Immobilizer Body: Exterior Body Panels, Interior Trim, Doors, Windows, Mirrors, Bumpers, Seats, Roof Panel Exhaust System: Catalytic converter, mufflers, exhaust manifold, oxygen sensors, catalytic converter replacement. Cooling System: Radiator, coolant hoses, water pump, thermostat, cooling fans, coolant flush and fill procedures. Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Service, Fluid Level Checks and Replenishments, Belt Inspections and Replacements Repair And Rebuild: Engine Overhaul, Turbocharger Replacement, Transmission Rebuild, Clutch Replacement, Suspension Component Replacement, Brake Caliper Overhaul, Electrical Component Diagnosis and Replacement Diagnostics: Troubleshooting Charts, Symptom-based Diagnostics, DTC (Diagnostic Trouble Code) Interpretation and Resolution, Wiring Diagrams Specifications: Torque Specifications, Clearances, Measurements, Component Dimensions Wiring Diagrams: Detailed electrical wiring diagrams for all major systems, crucial for troubleshooting electrical issues. Troubleshooting Guide: Extensive troubleshooting guides for common vehicle problems, broken down by system and symptom. Technical Depth Depth: Comprehensive; Covers from basic maintenance to full engine and transmission rebuilds, including detailed electrical system diagnostics. Diagnostic Tools And Software: Information on diagnostic connectors (OBD-II), trouble codes (DTCs), and potentially proprietary Mitsubishi diagnostic procedures. Emissions Control: Details on emissions control systems, components, and diagnostic procedures related to emissions. 📊 Manual Specifications File Format PDF Quality: High Resolution (scanned or native digital, typically searchable text) Print Quality Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged Displacement: 2.0 Liters (1997 cc) Performance Horsepower Usdm: 271 HP @ 6500 RPM Torque Usdm: 273 lb-ft @ 3500 RPM Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Multi-Port Injection Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Cooling System Coolant Capacity: Approximately 7.0 Liters (7.4 US Quarts) Turbocharger Turbocharger Model: Mitsubishi TD05H-16G (or similar Twin-Scroll) 🔧 Transmission Standard Transmission Type: 6-Speed Manual Transmission (Getrag) Optional Optional Transmission: N/A for Evolution VIII USDM Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Helical Limited-Slip Front Differential (LSD), Viscous Coupling Limited-Slip Rear Differential (VLSD) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (Refer to Manual for specific Mitsubishi recommendations, e.g., DiaQueen LSD Gear Oil) Fluid Capacity Manual Transmission Fluid Capacity: Approximately 2.0 Liters (2.1 US Quarts) 📐 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) Front Track: 1500 mm (59.1 in) Rear Track: 1500 mm (59.1 in) Weights Curb Weight Usdm: Approximately 1450 kg (3200 lbs) Gross Vehicle Weight Rating: Refer to vehicle placard Towing Capacity: Not Recommended / Not Specified 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star Driver, 5-Star Passenger (for 2004 Lancer, specific Evo VIII ratings may vary) IIHS Front Impact: Good (for 2004 Lancer, specific Evo VIII ratings may vary) Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Active Center Differential (ACD) Passive Features Passive Safety Systems: Driver and Front Passenger Airbags, Side-Impact Airbags (optional), Reinforced Body Structure, Front and Rear Crumple Zones 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with 6 speakers. Premium audio system (e.g., Rockford Fosgate) was optional on some trims. Navigation: Optional factory navigation system available on some models. Driver Assistance Driver Assistance Features: ABS, EBD, ACD (electronic center differential control). No electronic stability control (ESC) or traction control (except that provided by the AWD system) in the USDM Evolution VIII. Connectivity Connectivity Features: Limited by 2004 standards. May include basic antenna for radio. Aftermarket solutions common for Bluetooth/USB. 🔧 Maintenance Service Intervals...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Model Variant:

Evolution VIII

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart (lesser trims)

Key Features

Performance Focus:

All-Wheel Drive (AWD) with Active Center Differential (ACD), Twin-Scroll Turbocharged Engine, Performance-tuned Suspension, Powerful Braking System

Rally Heritage:

Direct lineage from World Rally Championship (WRC) cars, offering homologation-level performance and engineering for street use.

Aerodynamics:

Aggressive aerodynamic enhancements including a large rear wing, front splitter, and aerodynamic body kit.

📋 Manual Details

Coverage Areas

Primary Focus:

Factory Service and Repair

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual (FSM)

Purpose:

Designed for use by certified Mitsubishi technicians and experienced DIY mechanics.

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Turbocharger, Cooling System, Fuel System, Exhaust System, Drivetrain (Manual Transmission, Transfer Case, Front Differential, Rear Differential)

Chassis:

Suspension (Front MacPherson Strut, Rear Multi-link), Steering System, Brake System (ABS, EBD), Wheels and Tires

Electrical:

Engine Control Module (ECM), Powertrain Control Module (PCM), Ignition System, Charging System, Starting System, Lighting, Instrumentation, Wiper/Washer System, HVAC Controls, Audio System, SRS (Airbag) System, Immobilizer

Body:

Exterior Body Panels, Interior Trim, Doors, Windows, Mirrors, Bumpers, Seats, Roof Panel

Exhaust System:

Catalytic converter, mufflers, exhaust manifold, oxygen sensors, catalytic converter replacement.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, cooling fans, coolant flush and fill procedures.

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Spark Plug Service, Fluid Level Checks and Replenishments, Belt Inspections and Replacements

Repair And Rebuild:

Engine Overhaul, Turbocharger Replacement, Transmission Rebuild, Clutch Replacement, Suspension Component Replacement, Brake Caliper Overhaul, Electrical Component Diagnosis and Replacement

Diagnostics:

Troubleshooting Charts, Symptom-based Diagnostics, DTC (Diagnostic Trouble Code) Interpretation and Resolution, Wiring Diagrams

Specifications:

Torque Specifications, Clearances, Measurements, Component Dimensions

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, crucial for troubleshooting electrical issues.

Troubleshooting Guide:

Extensive troubleshooting guides for common vehicle problems, broken down by system and symptom.

Technical Depth

Depth:

Comprehensive; Covers from basic maintenance to full engine and transmission rebuilds, including detailed electrical system diagnostics.

Diagnostic Tools And Software:

Information on diagnostic connectors (OBD-II), trouble codes (DTCs), and potentially proprietary Mitsubishi diagnostic procedures.

Emissions Control:

Details on emissions control systems, components, and diagnostic procedures related to emissions.

📊 Manual Specifications

File Format

PDF Quality:

High Resolution (scanned or native digital, typically searchable text)

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

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

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Usdm:

271 HP @ 6500 RPM

Torque Usdm:

273 lb-ft @ 3500 RPM

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Multi-Port Injection

Fuel Type:

Premium Unleaded Gasoline (91+ Octane Recommended)

Cooling System

Coolant Capacity:

Approximately 7.0 Liters (7.4 US Quarts)

Turbocharger

Turbocharger Model:

Mitsubishi TD05H-16G (or similar Twin-Scroll)

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual Transmission (Getrag)

Optional

Optional Transmission:

N/A for Evolution VIII USDM

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Center Differential (ACD) and Helical Limited-Slip Front Differential (LSD), Viscous Coupling Limited-Slip Rear Differential (VLSD)

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (Refer to Manual for specific Mitsubishi recommendations, e.g., DiaQueen LSD Gear Oil)

Fluid Capacity

Manual Transmission Fluid Capacity:

Approximately 2.0 Liters (2.1 US Quarts)

📐 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)

Front Track:

1500 mm (59.1 in)

Rear Track:

1500 mm (59.1 in)

Weights

Curb Weight Usdm:

Approximately 1450 kg (3200 lbs)

Gross Vehicle Weight Rating:

Refer to vehicle placard

Towing Capacity:

Not Recommended / Not Specified

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-Star Driver, 5-Star Passenger (for 2004 Lancer, specific Evo VIII ratings may vary)

IIHS Front Impact:

Good (for 2004 Lancer, specific Evo VIII ratings may vary)

Active Features

Active Safety Systems:

Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Active Center Differential (ACD)

Passive Features

Passive Safety Systems:

Driver and Front Passenger Airbags, Side-Impact Airbags (optional), Reinforced Body Structure, Front and Rear Crumple Zones

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with 6 speakers. Premium audio system (e.g., Rockford Fosgate) was optional on some trims.

Navigation:

Optional factory navigation system available on some models.

Driver Assistance

Driver Assistance Features:

ABS, EBD, ACD (electronic center differential control). No electronic stability control (ESC) or traction control (except that provided by the AWD system) in the USDM Evolution VIII.

Connectivity

Connectivity Features:

Limited by 2004 standards. May include basic antenna for radio. Aftermarket solutions common for Bluetooth/USB.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 3,750 miles (6,000 km) or 6 months (whichever comes first) for severe driving conditions, 7,500 miles (12,000 km) or 12 months for normal conditions. (Consult Manual for specifics)

Spark Plugs:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (e.g., Iridium recommended). (Consult Manual)

Timing Belt:

Crucial component. Check for replacement recommendation, typically around 60,000 - 100,000 miles (96,000 - 160,000 km). If not replaced, consider it a priority. (Consult Manual)

Transmission Fluid:

Every 30,000 - 45,000 miles (48,000 - 72,000 km). ACD and rear diff fluids may have similar or shorter intervals. (Consult Manual)

Fluid Specifications

Engine Oil:

API SG, SH, SJ, SL or ILSAC GF-2, GF-3, 5W-30 or 10W-30 (Check manual for specific viscosity based on temperature range. High-quality synthetic recommended for performance driving.)

Coolant:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors), typically a pink or red color.

Brake Fluid:

DOT 3 or DOT 4 (High-performance racing fluid recommended for spirited driving).

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid or Dexron III (or equivalent ATF, verify with manual).

Transfer Case Fluid:

API GL-5, SAE 75W-90 (Refer to manual for specific Mitsubishi recommendations)

Known Issues

Engine Mechanical:

Head gasket failures (especially if modified or poorly maintained), piston ring wear, turbocharger oil starvation (critical maintenance required), connecting rod bearing failures at high mileage or with aggressive tuning.

Drivetrain:

ACD pump failure, clutch wear (especially with aggressive driving), differential seal leaks, manual transmission synchro wear in higher mileage units.

Electrical:

Idle Air Control Valve (IACV) issues causing rough idle, alternator and starter motor reliability can vary.

Suspension And Brakes:

Worn control arm bushings, premature brake rotor warping (if subjected to extreme heat cycling), wheel bearing wear.

Clutch Release Bearing:

Can wear out, leading to noise when clutch pedal is depressed. Clutch assembly replacement is the solution.

Fluid Capacities

Transfer Case Fluid Capacity:

Approximately 1.0 Liter (1.1 US Quarts)

Engine Specs

Ignition Timing:

Electronically controlled by ECM. Specifications and adjustment procedures detailed in the manual.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Mitsubishi has a strong heritage in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution achieved legendary status.

Model Evolution

Eighth Generation Introduction:

The Evolution VIII, introduced for the 2003 model year in Japan, marked a significant evolution with chassis improvements and a more potent 4G63 engine. This is the first generation officially sold in North America.

2004 Updates:

Minor updates for the 2004 model year, including potential wheel design changes and slight interior trim enhancements depending on the market.

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Motorsport Dominance:

The Lancer Evolution platform is synonymous with motorsport success, particularly in WRC, influencing its desirability and performance reputation.

Performance Reviews:

Consistently praised by automotive journalists for its exceptional handling, AWD system, and exhilarating performance, often outperforming more expensive sports cars.