Mitsubishi Lancer Evolution 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Generation: VIII Model Code: CT9A (JDM), VIII (Global) Codes Chassis Code: CT9A Engine Code: 4G63 (MIVEC) 👋 Introduction Market Position...

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Mots clés: Car Cars Lancer Evolution 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Generation:

Model Code:

CT9A (JDM), VIII (Global)

Codes

Chassis Code:

Engine Code:

4G63 (MIVEC)

👋 Introduction

Market Position

Market Position:

Performance rally-bred homologation special, enthusiast-focused sports sedan

Competitive Analysis

Competitors:

Subaru WRX STI, Lancia Delta Integrale, Ford Focus RS, Audi S3

Key Features

Key Features:

Symmetrical All-Wheel Drive (SAWD), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), potent turbocharged engine, robust chassis

Target Audience

Target Audience:

Enthusiasts, DIY mechanics, performance tuners, owners seeking in-depth technical understanding

Unique Selling Proposition

Unrivaled all-wheel-drive system and rally heritage translated to a road-going performance icon.

📋 Manual Details

Coverage Areas

Coverage:

Complete Service and Repair

Page Count

Page Count:

Likely 1000+ pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Official Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63 MIVEC Turbocharged, lubrication, cooling, fuel, ignition, emissions control, starting, charging

Transmission:

6-speed manual (Getrag), drivetrain components, propeller shaft, rear differential, driveshafts

Brakes:

ABS, EBD, front Brembo 4-piston calipers, rear Brembo 2-piston calipers, brake fluid, bleeding procedures

Suspension:

Front MacPherson struts, rear multi-link, springs, shock absorbers, sway bars, alignment procedures

Steering:

Power assisted rack and pinion, steering column, tie rods

Electrical:

Battery, alternator, starter, lighting, ignition system, CAN bus, ECU, sensors, wiring diagrams, fuses, relays

Bodywork:

Exterior panels, interior trim, doors, windows, locks, glass, bumpers, aerodynamics

HVAC:

Heating, Ventilation, and Air Conditioning system components, refrigerant, troubleshooting

Safety Systems:

SRS airbags, seatbelts, seatbelt pretensioners

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and replacements

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, fault diagnosis for all major systems

Repair:

Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component repair

Disassembly Assembly:

Step-by-step instructions for removing, installing, and reassembling all major components

Diagnostics:

OBD-II diagnostics, ECU data interpretation, sensor testing, actuator testing

Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, pressure specifications

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics)

📊 Manual Specifications

File Format

File Format:

Searchable:

Yes (if OCR processed)

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4G63 MIVEC Inline-4 DOHC Turbocharged

Displacement:

2.0 Liters (1997 cc)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Power Output Hp:

275 hp (205 kW) @ 6500 rpm (JDM Spec), 276 hp (206 kW) @ 6500 rpm (US Spec)

Torque Output Lb Ft:

273 lb-ft (370 Nm) @ 3500 rpm (JDM Spec), 286 lb-ft (388 Nm) @ 3500 rpm (US Spec)

Performance

Redline:

7000 rpm

Fuel System

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

Fuel Delivery:

Electronic Fuel Injection (EFI) with Turbocharger

Turbocharger:

Mitsubishi TD05H-16G (Single Scroll)

Engine Management

Multi-point Fuel Injection, Electronic Ignition Control

🔧 Transmission

Standard

Transmission Type:

6-speed Manual (Getrag Type D)

Optional

Optional Transmission:

None (Manual was standard)

Features

Drivetrain:

All-Wheel Drive (SAWD) with Active Center Differential (ACD)

Differential Control:

ACD with tarmac, gravel, and snow modes; Super AYC (Active Yaw Control) for rear differential torque vectoring

Fluid Specs

Transmission Fluid Type:

API GL-4 or GL-5 (check specific manual for exact spec, often synthetic)

📐 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)

Ground Clearance:

135 mm (5.3 in)

Weights

Curb Weight:

Approx. 1450 kg (3197 lbs)

Gross Vehicle Weight Rating:

Approx. 1800 kg (3968 lbs)

Wheels Tires

Wheel Size:

17 x 8.0 inches (standard GSR/MR)

Tire Size:

235/45R17 (standard)

Bolt Pattern:

5x114.3 mm (5x4.5 inch)

Offset:

ET38 (standard)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated by NHTSA for this specific model year, but generally good for its class.

IIHS Side Impact:

Not explicitly rated by IIHS for this specific model year, but generally good for its class.

Active Features

Standard (Bosch 5.3 ABS)

Standard (Electronic Brake-force Distribution)

Standard (Active Center Differential)

Sayc:

Standard on MR trim, optional/integrated with ACD on GSR

Passive Features

Airbags:

Driver and Passenger Airbags (SRS)

Seatbelts:

3-point front and rear seatbelts with pretensioners

Roll Cage:

Reinforced chassis structure, often referred to as a 'safety cage' for rally homologation

💡 Technology Features

Infotainment

Infotainment System:

Basic factory CD player with AM/FM radio. Later models might have options for upgraded head units.

Speakers:

Typically 6-speaker system.

Driver Assistance

Driver Assistance Features:

ABS, EBD, ACD, S-AYC (on MR trim).

Connectivity

Connectivity Options:

Limited. Primarily basic audio inputs. Aftermarket solutions for Bluetooth/USB.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 - 5,000 miles or 6 months, whichever comes first (depending on driving conditions; severe use requires more frequent changes).

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Every 30,000 - 60,000 miles (depending on plug type and manufacturer recommendation).

Timing Belt Replacement:

Crucial: Every 60,000 - 90,000 miles or 5-7 years. Failure is catastrophic.

Coolant Flush:

Every 30,000 - 60,000 miles or 2-4 years.

Transmission Fluid Change:

Every 30,000 - 60,000 miles, especially for spirited driving.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 - 5.0 Liters (with filter)

Engine Oil Recommendation:

0W-30, 5W-30, or 5W-40 Synthetic (API SN or higher, ACEA A3/B4 recommended for performance).

Coolant Type:

Mitsubishi Super Long Life Coolant (DIA-QUEEN SUPER LONG LIFE COOLANT) or equivalent OAT/HOAT coolant, typically red or pink.

Brake Fluid Type:

DOT 3 or DOT 4 (preferably DOT 4 for higher performance).

Known Issues

Engine:

Head gasket failures (especially on modified engines), turbocharger wear, piston ring wear, connecting rod bearing failures (high mileage/abuse).

Drivetrain:

ACD/AYC pump failures, manual transmission synchro wear, rear differential issues.

Electrical:

Faulty ACD/AYC pump relays, ABS sensor failures, ECU failures.

Suspension Steering:

Worn suspension bushings, strut mounts, power steering pump leaks.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mitsubishi has a long and storied history in the World Rally Championship (WRC), with the Lancer Evolution series being its flagship rally homologation model.

Model Evolution

Evolution Lineage:

The Evo VIII (CT9A) followed the Evo VII and was part of a continuous development cycle driven by rally success. It introduced significant chassis and drivetrain improvements.

Production

Production Years:

2003-2005

Assembly Location:

Japan

Variants

Notable Variants:

GSR (standard, often more creature comforts), RS (lighter, stripped-down, rally-focused), MR (premium trim, Bilstein suspension, Recaro seats, usually a more aggressive ACD/AYC setup)

🏆 Awards & Recognition

Recognitions

Performance Awards:

Consistently recognized by automotive media for its handling, performance, and rally-inspired driving dynamics. Often praised as one of the best affordable performance cars of its era.

Ratings

Enthusiast Ratings:

Highly rated by enthusiasts for its tuning potential and engaging driving experience.

Certifications

Homologation Status:

Rally homologation special, built to meet FIA regulations for Group A rallying.