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Mitsubishi Lancer Evolution 8 EVO VIII 2003 2004 2005 Car Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII (EVO VIII) Product Name: Mitsubishi Lancer Evolution 8 EVO VIII 2003 2004 2005 Car Workshop Repair Service Manual Download Codes...
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Mitsubishi Lancer Evolution 8 EVO VIII 2003 2004 2005 Car Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII (EVO VIII)
Product Name:
Mitsubishi Lancer Evolution 8 EVO VIII 2003 2004 2005 Car Workshop Repair Service Manual Download
Codes
Platform Code:
CT9A
Engine Code Primary:
4G63
Engine Code Variant Primary:
4G63T (MIVEC)
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, tuners, owners seeking in-depth repair knowledge
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (older generations)
Key Features
Legendary Status:
Iconic rally-bred performance car
Drivetrain Technology:
Symmetrical All-Wheel Drive, Active Center Differential (ACD), Super Active Yaw Control (optional)
Engine Reputation:
Robust and highly tunable 4G63T engine
📋 Manual Details
Coverage Areas
Covered Years:
2003, 2004, 2005
Market Coverage:
Global (primarily JDM, USDM, EUDM)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (complete overhaul, timing, lubrication, cooling)
Engine Management:
Yes (ECU, sensors, ignition, fuel injection, emissions control, MIVEC)
Transmission:
Yes (manual and SST, including differential, transfer case)
Drivetrain:
Yes (front/rear differentials, driveshafts, ACD - Active Center Differential)
Suspension:
Yes (front MacPherson strut, rear multi-link, coilover adjustments, bushings)
Brakes:
Yes (front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS, EBD)
Steering:
Yes (power steering system, steering column, alignment specifications)
Electrical System:
Yes (wiring diagrams, battery, charging system, starting system, lighting, accessories)
Body And Chassis:
Yes (body panels, doors, glass, frame, rust prevention, undercoating)
HVAC:
Yes (heating, ventilation, air conditioning system)
Interior Trim:
Yes (seats, dashboard, door panels, carpeting)
Procedures Included
Maintenance:
Yes (scheduled maintenance, fluid changes, filter replacements, tune-ups)
Repair:
Yes (component removal, installation, overhaul, replacement)
Troubleshooting:
Yes (diagnostic charts, symptom-based solutions, error code interpretation)
Diagnostics:
Yes (OBD-II, sensor testing, circuit testing)
Specifications:
Yes (torque values, clearances, alignment settings, fluid capacities)
Technical Depth
Depth:
Comprehensive (from basic adjustments to full engine/transmission rebuilds)
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchable Text:
Yes (if original digital file)
Printable:
Yes
Print Quality
Illustration Quality:
High-resolution, clear diagrams and illustrations
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder, DOHC, 16-Valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Ps Jdm:
280 PS @ 6500 rpm (often underestimated, JDM 'gentleman's agreement')
Horsepower Ps Usdm:
271 hp @ 6500 rpm (USDM specification)
Torque Nm Jdm:
343 Nm @ 3000 rpm (JDM specification)
Torque Lb-Ft Usdm:
273 lb-ft @ 3500 rpm (USDM specification)
Turbocharger:
Mitsubishi TD05HR-16G (twin-scroll)
Engine Technology:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (premium, 91 octane or higher recommended)
Fuel Injectors:
Bosch 550cc (stock, often upgraded for tuning)
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (Getrag 'Dogleg' option not available on VIII, standard H-pattern)
Optional
Type:
None (only manual offered for EVO VIII in most markets)
Features
Drivetrain Control:
Symmetrical AWD with Active Center Differential (ACD) and front helical LSD
Acd Modes:
Tarmac, Gravel, Snow
Rear Differential:
Helical Limited Slip Differential (LSD)
📐 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)
Track Front:
1510 mm (59.4 in)
Track Rear:
1505 mm (59.3 in)
Ground Clearance:
140 mm (5.5 in)
Weights
Curb Weight:
Approx. 1400-1450 kg (3086-3197 lbs)
Gross Vehicle Weight Rating:
Not specified in standard manual, typically around 1800 kg
Towing Capacity:
Not rated
🛡️ Safety Features
Ratings
NHTSA Crash Test Front Impact:
4-star (driver), 4-star (passenger) - 2004 Model Year (USDM)
IIHS Crash Test Side Impact:
Acceptable (2004 Model Year, varies by specific test)
Active Features
ABS:
Yes (Anti-lock Braking System) with EBD (Electronic Brakeforce Distribution)
Traction Control:
Yes (Active Traction Control - ATC)
Stability Control:
No (Not equipped with Electronic Stability Control - ESC/VSC)
Passive Features
Airbags Front:
Yes (Driver and Passenger SRS Airbags)
Airbags Side:
Optional/Market Dependent (Side SRS Airbags not standard)
Seatbelts:
3-point ELR seatbelts with pretensioners and force limiters
Rollover Protection:
Reinforced chassis structure
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD player (aftermarket options common)
Speaker System:
Basic factory speaker system (often upgraded by owners)
Driver Assistance
Cruise Control:
Yes
Parking Sensors:
No
Connectivity
Bluetooth:
No (factory installed)
Usb Port:
No (factory installed)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (severe use interval may be shorter)
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km) (Iridium plugs)
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 4 years (CRITICAL component, includes tensioner and idlers)
Fluid Specifications
Engine Oil:
SAE 5W-30 (API SG or higher, ILSAC GF-2 or higher). Consider synthetic for performance driving.
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change
Coolant:
Mitsubishi Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant, 50/50 mix with distilled water.
Transmission Fluid:
Dia Queen LSD Gear Oil GL-5 75W-90 (for front and rear LSDs). Check ACD fluid spec separately.
Transfer Case Fluid:
Dia Queen Gear Oil GL-4 75W-85
Brake Fluid:
DOT 3 or DOT 4 (high-performance synthetic recommended for spirited driving)
Known Issues
Engine Bearing Failure:
Rod bearing failure can occur, especially with aggressive tuning and lack of proper oil maintenance.
Turbocharger Wear:
The TD05HR-16G is robust but can suffer from oil starvation if not maintained. Cracked turbine housings also a possibility.
Acd Pump Failure:
The hydraulic pump for the ACD can fail over time, leading to AWD system issues.
Clutch Wear:
Aggressive driving and frequent launches can accelerate clutch wear.
Suspension Bushings:
Rubber bushings in suspension can degrade over time, affecting handling.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Deep roots in World Rally Championship (WRC) success
Model Evolution
Evolution Series:
VIII is the eighth generation of the Lancer Evolution, representing a significant leap from the VII.
Key Updates From Evo Vii:
Revised ACD, stronger gearbox, updated suspension geometry, larger turbo, MIVEC on intake.
Trim Levels:
GSR (standard), RS (homologation special, lighter), MR (Momo steering wheel, Bilstein suspension, titanium-alloy turbocharger - specific to Japan)
Production
Production Period:
2003-2005
Manufacturing Location:
Japan
Production Volume:
Limited global production, high demand
🏆 Awards & Recognition
Recognitions
Rally Homologation:
Developed to homologate for WRC Group A regulations
Performance Reviews:
Consistently praised by automotive journalists for its handling, grip, and raw performance.
Ratings
Car And Driver Best 10:
Often featured on 'Ten Best' lists for its class and performance capabilities.
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