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Mitsubishi Evolution VIII Evo 8 2003-2005 Factory Manual

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The Mitsubishi Lancer Evolution VIII, also known as the Evo 8, is an iconic performance sedan produced from 2003 to 2005. Renowned for its rally-bred engineering and exceptional handling, the...
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Typ: Car
Anbieter:
Mitsubishi
Art.-Nr: 52581
Stichworte: 2003 2004 2005 Car Cars Evo 8 Evolution VIII Misc Mitsubishi
Mitsubishi Evolution VIII Evo 8 2003-2005 Factory ManualMitsubishi Evolution VIII Evo 8 2003-2005 Factory ManualMitsubishi Evolution VIII Evo 8 2003-2005 Factory ManualMitsubishi Evolution VIII Evo 8 2003-2005 Factory Manual
The Mitsubishi Lancer Evolution VIII, also known as the Evo 8, is an iconic performance sedan produced from 2003 to 2005. Renowned for its rally-bred engineering and exceptional handling, the Evo 8 features a potent 2.0-liter turbocharged 4G63 engine producing 271 horsepower and 273 lb-ft of torque, paired with a sophisticated Super All-Wheel Control (S-AWC) system. This advanced drivetrain, including the Active Center Differential (ACD) and Active Yaw Control (AYC), delivers unparalleled grip and agility, making it a favorite among enthusiast drivers and motorsport participants. Its aggressive styling and lightweight construction further underscore its performance-oriented design, solidifying its reputation as one of the most capable production cars of its era. This comprehensive Factory Service Repair Manual provides in-depth guidance for the Mitsubishi Lancer Evolution VIII (CT9A) model years 2003-2005. It covers all essential aspects of the vehicle, from routine maintenance procedures such as oil changes and fluid flushes to complex engine and transmission rebuilding. Detailed sections address the engine mechanicals, fuel and ignition systems, drivetrain, suspension, steering, brakes, and electrical systems, including the specialized S-AWC components. Furthermore, the manual offers extensive troubleshooting guidance, diagnostic procedures, and technical specifications, equipping owners, technicians, and mechanics with the necessary information to maintain, repair, and optimize the performance and reliability of this celebrated vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII (Evo 8)
Model Code:
CT9A
Production Years Covered:
2003, 2004, 2005
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Positioning:
Iconic performance sedan, widely regarded as one of the most capable rally-bred production cars of its era. Competes in the enthusiast-driven performance car segment.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Porsche 911, Lancia Delta Integrale (historical competitor).
Key Features
Performance Highlights:
All-wheel drive (S-AWC with ACD), turbocharged intercooled engine, aggressive aerodynamic styling, lightweight construction, advanced suspension.
Target Audience:
Enthusiast drivers, motorsport participants, tuners, and owners seeking in-depth knowledge for maintenance and modification.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Approximate Page Count:
Hundreds of Pages (Exact count not specified, but implied to be comprehensive)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, piston, crankshaft, camshaft, timing system, lubrication system, cooling system, intake and exhaust systems.
Engine Management:
Fuel injection system (MPI), ignition system, ECU (Engine Control Unit) operation and diagnosis, emissions control systems (catalytic converter, EGR).
Transmission Manual:
Manual transmission (AYC/ACD/S-AYC components), clutch operation, removal and installation, internal components, gear ratios, maintenance.
Transmission Acd:
Active Center Differential (ACD) system operation, diagnosis, fluid changes, and related components.
Drivetrain:
Front and rear differentials, drive shafts, CV joints, propeller shaft, hub assemblies.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, stabilizer bars, bushings, wheel alignment specifications.
Steering:
Power steering system operation, pump, rack and pinion, steering column, tie rods, diagnosis.
Brakes:
Front and rear brake systems (Brembo calipers), brake fluid, master cylinder, brake lines, ABS (Anti-lock Braking System) operation and diagnosis, parking brake.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting system, interior and exterior lights, horn, wipers, power windows, mirrors.
Body And Interior:
Body panels, doors, hood, trunk lid, bumpers, interior trim, seats, airbags, HVAC (Heating, Ventilation, and Air Conditioning) system.
Diagnostics And Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic procedures for all major systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid change, transmission fluid change, differential fluid change.
Component Removal Installation:
Detailed step-by-step instructions for removing and installing engine components, transmission, suspension parts, brake components, electrical modules, body panels.
Engine Rebuilding:
Complete engine disassembly, inspection, measurement, and reassembly procedures, including torque specifications and clearances.
Transmission Rebuilding:
Detailed procedures for manual transmission overhaul, including gear inspection, bearing replacement, seal replacement.
Suspension Alignment:
Wheel alignment specifications and procedures for camber, caster, and toe angles.
Brake System Service:
Brake pad and rotor replacement, caliper service, bleeding the brake system, ABS component testing.
Electrical Diagnostics:
Wiring diagrams, circuit testing procedures, component testing for sensors, actuators, and control modules.
Airbag System Service:
Safety precautions, SRS component removal and installation, diagnostic procedures.
Technical Depth
Depth Of Information:
Comprehensive from basic maintenance to advanced diagnostics and complete component overhauls. Covers factory specifications, procedures, and tolerances.
📊 Manual Specifications
File Format
File Format Type:
PDF
Searchable Text:
Likely searchable, as is standard for factory service manuals in PDF format.
Print Quality
Printability:
Designed for printing, allowing users to print specific sections or the entire manual.
Binding Type
Binding Type For Printout:
N/A (Digital download, user prints and binds as desired - e.g., 3-ring binder)
Paper Type
Recommended Paper Type For Printout:
Standard copier paper or heavier stock for durability.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63
Engine Type:
Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Usdm:
271 hp @ 6500 rpm
Torque Usdm:
273 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Turbocharging
Turbocharger Type:
Mitsubishi TD05HRA-15G 8cm² twin-scroll turbocharger
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission
Optional
Optional Transmission:
N/A (Only manual offered for Evo VIII in most markets)
Features
Drivetrain Features:
Super All-Wheel Control (S-AWC) system including Active Center Differential (ACD), Active Yaw Control (AYC) on rear differential.
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil (Specific Mitsubishi part numbers available in manual).
Acd Fluid Type:
API GL-5, SAE 80W-90 hypoid gear oil (Specific Mitsubishi part numbers available in manual).
📐 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)
Weights
Curb Weight:
1450-1500 kg (3197-3307 lbs) depending on trim and options
Gross Vehicle Weight Rating:
Not explicitly stated, but typically around 1900-2000 kg.
Cargo
Trunk Volume:
Approximately 10.4 cu ft (0.29 m³)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-Star (for 2004 model year)
IIHS Front Impact Rating:
Good
Active Features
Traction Control:
Yes (Integral part of S-AWC system)
Electronic Stability Control:
Yes (Active Stability Control - ASC, often integrated with S-AWC)
ABS:
Yes (Bosch 5.3 ABS system)
Passive Features
Airbags:
Driver and front passenger airbags, optional side curtain airbags on some trims.
Seatbelts:
3-point inertia reel seatbelts with pre-tensioners and load limiters.
Rollover Protection:
Reinforced body structure designed for rally homologation.
💡 Technology Features
Infotainment
Audio System:
Factory fitted Clarion or Mitsubishi CD/MP3 audio system with AM/FM tuner. Some models may have Rockford Fosgate premium audio upgrade.
Display:
Basic LCD display for audio information and climate control. No integrated navigation or color screens.
Driver Assistance
Traction Control Systems:
S-AWC (Super All-Wheel Control) with ACD and AYC, offering advanced torque vectoring and differential management.
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth:
Not standard; aftermarket solutions are common.
Usb Ports:
Not standard; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions), 7,500 miles (12,000 km) or 12 months (under normal conditions).
Engine Oil Filter Replacement:
With every oil change.
Spark Plug Replacement Interval:
Approximately 30,000 - 60,000 miles (refer to manual for specific plug type and interval).
Coolant Flush Interval:
Every 30,000 miles or 24 months.
Timing Belt Replacement Interval:
70,000 - 105,000 miles (112,000 - 168,000 km) or 7 years (critical inspection/replacement recommended).
Fluid Specifications
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter, using SAE 5W-30 or 5W-40 synthetic oil.
Coolant Capacity:
Approximately 7.5 Liters (7.9 US Quarts) of long-life coolant.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Reliability:
Generally robust 4G63 engine, but prone to issues from aggressive tuning (e.g., rod knock, turbo failures), excessive heat can lead to piston ring land damage, potential head gasket issues if overheated.
Acd Issues:
ACD pump failure, sensor issues, or incorrect fluid leading to system malfunction. Regular fluid changes are crucial.
Clutch Wear:
Performance-oriented clutch can wear faster under aggressive driving. OEM clutch life is generally good with moderate use.
Suspension Wear:
Bushings and control arms can wear over time, especially with spirited driving. Check for play during inspections.
Rust And Corrosion:
Vulnerable in areas with harsh winters, particularly to underbody components, wheel arches, and sills. Rust prevention and inspection are important.
📚 Vehicle History
Brand Heritage
Rally Legacy:
The Mitsubishi Lancer Evolution lineage is directly descended from Mitsubishi's extensive success in the World Rally Championship (WRC).
Model Evolution
Evo Viii Introduction:
The Evo VIII was the first Lancer Evolution officially sold in the United States, marking a significant moment for the model's global presence.
Key Advancements Evo Viii:
Introduction of the 6-speed manual gearbox and the sophisticated Super All-Wheel Control (S-AWC) system with Active Center Differential (ACD).
Production
Production Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Global Availability:
Initially released in Japan in 2003, followed by North America, Europe, and other markets.
🏆 Awards & Recognition
Recognitions
Sport Compact Car Of The Year:
Often received accolades from automotive publications for performance and handling, frequently appearing on 'best of' lists for affordable sports cars.
Motortrend Car Of The Year Contender:
While not winning the overall award, the Evo lineup was consistently recognized for its performance capabilities.
Certifications
Homologation Status:
Built to WRC Group A homologation standards, which dictated many of its performance features.
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