2003 Mitsubishi Lancer Evolution VIII (Evo 8) Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Year: 2003 Codes Chassis Code: CT9A 👋 Introduction Market Position Positioning: High-performance compact sports sedan, celebrated for its rally-bred pedigree and advanced all-wheel-drive system. Competitive Analysis Competitors: Subaru Impreza WRX STI, Honda Civic Type R (later generations), Ford Focus RS. Key Features Performance Focus: Iconic 4G63 engine, sophisticated AWD with ACD and AYC, potent braking, and stiff chassis. Target Audience: Enthusiasts, performance drivers, motorsport participants, and DIY mechanics seeking in-depth knowledge. Manual Value Purpose: Essential resource for maintaining, diagnosing, and repairing the 2003 Mitsubishi Lancer Evolution VIII. 📋 Manual Details Coverage Areas Engines Covered: 4G63 (2.0L Turbocharged Inline-4) Trim Levels Covered: All US Market Trim Levels (e.g., GSR, MR) Transmissions Covered: 6-speed Manual Transmission Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Fuel System, Ignition System, Exhaust System, Turbocharger System Drivetrain: Manual Transmission, Transfer Case, Front Differential, Rear Differential, ACD (Active Center Differential), Super AYC (Active Yaw Control) Chassis: Suspension System (Front & Rear), Steering System, Brake System (ABS, EBD) Electrical: Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, Wiring Diagrams Body: Exterior Panels, Interior Trim, Climate Control System, Safety Restraints (Airbags) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Common Issues and Solutions Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Service, Electrical Component Diagnosis and Replacement Specifications: Torque Specifications, Clearances, Timing Specifications, Component Dimensions Special Tools: Required Special Tools for Specific Repairs and Adjustments Technical Depth Depth: Comprehensive (from basic fluid changes to full engine/transmission rebuilds) 📊 Manual Specifications File Format Searchable Text: Yes Printable: Yes Print Quality Resolution: High-resolution scans for clear text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Displacement: 2.0 Liters (1997cc) Configuration: Inline 4-cylinder, DOHC, 16-valve, turbocharged Performance Horsepower Usdm: 271 hp @ 6500 rpm Torque Usdm: 273 lb-ft @ 3500 rpm Fuel System Induction: Multi-point Fuel Injection (MPI) with Mitsubishi TD05HR-16G turbocharger and intercooler Fuel Type: Premium Unleaded (91 octane or higher recommended) Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent Ignition System Ignition Type: Electronic Ignition (Distributorless Twin-Ignition Coil System) 🔧 Transmission Standard Type: 6-speed Manual Transmission (F5M51) Optional Type: N/A (Evo VIII USDM was exclusively manual) Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Center Differential (ACD) Rear Differential: Helical Limited-Slip Differential (LSD) or Active Yaw Control (AYC) depending on trim/spec Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (Check manual for specific Mitsubishi recommendation) Acd Fluid: Mitsubishi Genuine ACD Fluid (or equivalent spec DEXRON III/VI) Ayc Fluid: Mitsubishi Genuine AYC Fluid (or equivalent spec DEXRON III/VI) 📐 Dimensions Exterior Length: 170.5 in (4330 mm) Width: 69.1 in (1755 mm) Height: 57.0 in (1450 mm) Wheelbase: 103.3 in (2625 mm) Weights Curb Weight: 3,296 lbs (1,495 kg) - approximate Gross Vehicle Weight Rating: Approx. 4,000 lbs (1815 kg) Wheel And Tire Wheel Size: 17 x 8.0 inches Bolt Pattern: 5x114.3 mm Tire Size: 235/45R17 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5 Stars (for models equipped with side airbags) NHTSA Frontal Passenger: 4 Stars IIHS Front Offset: Good (for models equipped with side airbags) Active Features ABS: Yes, with Electronic Brakeforce Distribution (EBD) Traction Control: Yes (AYC/ACD system contributes) Passive Features Airbags: Driver and Front Passenger Airbags, Optional Side Curtain Airbags Seatbelts: 3-point front and rear seatbelts with pretensioners Chassis Safety Structural Enhancements: Reinforced chassis for rigidity and impact resistance. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional Rockford Fosgate premium audio system. Display: Digital odometer, trip computer, external temperature display. Driver Assistance Acd: Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow). Ayc: Active Yaw Control (AYC) for enhanced cornering stability (standard on some trims, optional on others). ABS: Anti-lock Braking System with Electronic Brakeforce Distribution (EBD). Connectivity Original Features: Limited by 2003 standards; no factory Bluetooth or USB connectivity. 🔧 Maintenance Service Intervals Oil Change: Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions, recommended) Engine Air Filter: Inspect every 7,500 miles (12,000 km), replace as needed Cabin Air Filter: Replace every 7,500 miles (12,000 km) or 12 months Spark Plugs: Replace every 30,000 miles (48,000 km) (Iridium type recommended) Timing Belt: Replace every 60,000 miles (96,000 km) or 5 years (Crucial component, failure is catastrophic) Fluid Specifications Engine Oil: 5W-30 Synthetic (API SN or higher, ILSAC GF-5 or higher), Capacity: 4.5 US quarts (4.3 L) with filter Coolant: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent (50/50 mix), Capacity: Approx. 7.8 US quarts...