Mitsubishi Lancer Evolution 8 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Year: 2004 Codes Chassis Code: CT9A Engine Code Primary: 4G63 👋 Introduction Market Position Positioning: High-performance...

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Mots clés: 2004 Car Cars Lancer Evolution 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo 8

Year:

Codes

Chassis Code:

Engine Code Primary:

👋 Introduction

Market Position

Positioning:

High-performance rally homologation special, enthusiast-focused.

Competitive Analysis

Competitors 2004:

Subaru Impreza WRX STI, Ford Focus RS, Audi S3, VW Golf R32.

Key Features Vehicle

Performance Orientation:

All-wheel-drive, turbocharged engine, advanced active center differential.

Key Features Manual

Target Audience:

Professional Technicians, DIY Enthusiasts, Performance Tuners.

Value Proposition

Value:

Provides factory-level diagnostic and repair information essential for maintaining the Evo 8's complex systems.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Factory Service Repair

Geographic Market:

Global (with potential for regional variations noted)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63 DOHC Turbocharged (including MIVEC where applicable), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System

Transmission:

6-Speed Manual (Getrag 03C), Drivetrain, Transfer Case, Rear Differential (ACD/AYC systems)

Suspension:

Front McPherson Strut, Rear Multi-link, Dampers, Springs, Bushings, Alignment Specifications

Brakes:

Front Brembo 4-Piston Calipers, Rear Brembo 2-Piston Calipers, ABS, EBD, Brake System Hydraulic Components

Electrical:

ECU, Wiring Diagrams, Lighting, Instruments, Power Accessories, Audio System, Security System

Body Chassis:

Body Structure, Exterior Panels, Interior Trim, Doors, Windows, Seats, Chassis Components

Climate Control:

HVAC System, Refrigerant, Blower Motor, Controls

Troubleshooting

Diagnostic Procedures:

Fault Diagnosis Charts, Symptom-Based Troubleshooting, DTC Code Explanations

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections

Repair Overhaul:

Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Service, Electrical Component Repair

Disassembly Assembly:

Step-by-step instructions for removing and installing major components

Specifications Data:

Torque Specifications, Clearances, Gaps, Pressures, Electrical Resistances

Engine Management:

ECU diagnostics, sensor testing, fuel injector flow testing, emissions system diagnosis.

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment.

Technical Depth

Depth:

Comprehensive: Covers from basic maintenance to complete engine and transmission rebuilds, including complex electronic systems.

Diagrams Illustrations:

Includes detailed exploded view diagrams, electrical schematics, and repair illustrations.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (OCR optimized for most versions)

Print Quality

Image Resolution:

High resolution for clear diagrams and schematics

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, turbocharged, intercooled, DOHC

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valvetrain:

DOHC 16-valve with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft

Performance

Horsepower Ps:

280 PS @ 6500 rpm (Manufacturer's Estimate, often higher in reality)

Torque Nm:

332 Nm @ 3500 rpm (Manufacturer's Estimate, often higher in reality)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Turbocharger:

Mitsubishi TD05H-16G (or similar variant), Ball Bearing

Intercooler:

Air-to-air front-mounted

Recommended Fuel:

Premium Unleaded Gasoline (91 Octane RON or higher)

🔧 Transmission

Standard

Type:

6-speed Manual (Getrag Type 03C)

Optional

Optional Type:

N/A (Exclusively Manual for Evolution VIII)

Features

Drivetrain:

All-Wheel Drive (AWD)

Transfer Case:

Active Center Differential (ACD) with electronic control

Rear Differential:

Active Yaw Control (AYC) or Super AYC (on specific variants)

📐 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)

Front Track:

1515 mm (59.6 in)

Rear Track:

1505 mm (59.3 in)

Weights

Curb Weight Kg:

1450-1500 kg (approx.)

Gross Weight Rating Kg:

1900 kg (approx.)

Cargo

Trunk Volume Liters:

295 Liters (approx.)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

4-Star (for 2004 Model Year, typical for the era)

NHTSA Frontal Passenger:

4-Star (for 2004 Model Year, typical for the era)

IIHS Small Overlap Front:

Not Tested (Vehicle pre-dates extensive IIHS testing protocols for this category)

Active Features

Standard, with EBD (Electronic Brakeforce Distribution)

Traction Control:

Standard (ASCD - Active Stability Control)

Stability Control:

Standard (ASCD - Active Stability Control)

AWD System:

ACD (Active Center Differential) with driver-selectable modes (Tarmac, Gravel, Snow)

Passive Features

Airbags Front:

Driver and Passenger SRS Airbags

Airbags Side:

Optional or Standard depending on market/trim (Front Side Airbags)

Seatbelts:

3-point ELR front seatbelts with pre-tensioners and load limiters, 3-point ELR rear seatbelts

Body Structure:

Reinforced chassis and safety cell design.

💡 Technology Features

Infotainment

Head Unit:

Factory AM/FM/CD player (often with Rockford Fosgate audio system in higher trims).

Speaker System:

Optional premium sound system (e.g., Rockford Fosgate).

Driver Assistance

Standard Anti-lock Braking System.

Traction Control:

Standard Active Stability Control (ASCD).

Performance Electronics:

ACD (Active Center Differential) and AYC (Active Yaw Control) represent advanced drivetrain technology for the era.

Connectivity

Connectivity Features:

Limited by 2004 standards. Primarily focused on audio input (CD).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe driving may require more frequent changes.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 60,000 miles (96,000 km) (platinum or iridium type recommended).

Coolant Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 5 years. Crucial due to interference engine design.

Fluid Specifications

Engine Oil:

API SG or SH, ILSAC GF-II or GF-III, SAE 5W-30 or 10W-30 (check specific market recommendations and climate).

Engine Oil Capacity Liters:

4.5 Liters (with filter change)

Transmission Fluid:

API GL-4 or GL-5 SAE 75W-90 Synthetic Gear Oil (for Getrag 03C).

Transfer Case Fluid:

API GL-5 SAE 75W-90 Synthetic Gear Oil.

Rear Differential Fluid:

API GL-5 SAE 75W-90 Synthetic Gear Oil (check for LSD/AYC specific requirements).

Coolant:

Mitsubishi Genuine Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors) mixed 50/50 with distilled water.

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron III/Mercon ATF (Automatic Transmission Fluid).

Known Issues

Engine:

Turbocharger failure (oil starvation, lack of maintenance), Head gasket failure (especially in heavily modified cars), connecting rod issues (in extreme cases of abuse/high power).

Drivetrain:

ACD pump failure, AYC pump failure, clutch wear, differential wear.

Suspension:

Worn bushings, premature strut wear, wheel bearing failure.

Electrical:

Alternator failure, ECU issues, sensor failures (e.g., MAP, crank position).

Body Chassis:

Rust and corrosion (especially in certain climates), interior trim rattles.

📚 Vehicle History

Brand Heritage

Heritage:

Mitsubishi's long history in motorsports, particularly in the World Rally Championship (WRC), forms the foundation of the Lancer Evolution lineage.

Model Evolution

Evolution Series:

The Evo VIII (CT9A) is the eighth generation of the Lancer Evolution, building upon the success of its predecessors.

Key Developments Gen 8:

Introduction of the ACD, improved turbocharger, stronger engine internals, revised suspension geometry, and the iconic Brembo braking system.

Production

Production Years Gen 8:

2003-2005

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Market Introduction Usdm:

Introduced to the North American market for the 2003 model year, marking a significant expansion for the model.

🏆 Awards & Recognition

Recognitions

Motorsport Legacy:

The entire Lancer Evolution lineage is renowned for its motorsport success, particularly in WRC.

Car And Driver Best:

Consistently lauded in automotive media for its performance and handling, often appearing on 'Best Handling Cars' lists.

Performance Benchmark:

Considered a benchmark for AWD performance sedans and a driver's car across automotive publications.