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Mitsubishi Evolution VIII Evo 8 2003-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Nickname: Evo 8 Product Name: Mitsubishi Evolution VIII Evo 8 2003-2005 Service Repair Manual PDF Generation Generation Code: CT9A Codes...
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Mitsubishi Evolution VIII Evo 8 2003-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII
Nickname:
Evo 8
Product Name:
Mitsubishi Evolution VIII Evo 8 2003-2005 Service Repair Manual PDF
Generation
Generation Code:
CT9A
Codes
Chassis Code:
CT9A
👋 Introduction
Market Position
Positioning:
Iconic rally-bred performance sedan, highly sought after by enthusiasts for its potent engine, sophisticated all-wheel-drive system, and tunable nature.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Subaru Impreza WRX
Key Features
Performance Focus:
Emphasis on high performance, handling, and all-weather capability.
Rally Heritage:
Direct lineage from Mitsubishi's World Rally Championship (WRC) success, influencing its design and engineering.
Drivetrain Technology:
Advanced ACD (Active Center Differential) and Super AYC (Active Yaw Control) systems for exceptional traction and agility.
📋 Manual Details
Coverage Areas
Years Covered:
2003, 2004, 2005
Regions Covered:
Global (based on common Evo VIII specifications, may vary by market)
Page Count
Estimated Page Count:
Over 1500 (typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
4G63T (2.0L DOHC MIVEC Turbocharged inline-4), Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System
Transmission:
6-Speed Manual Transmission (Type: Getrag MR977304 or similar), Clutch System, Drivetrain Components (Front/Rear Differentials, ACD - Active Center Differential)
Suspension And Steering:
Front McPherson Strut, Rear Multi-link, Power Steering System, Suspension Components (Springs, Dampers, Bushings, Control Arms)
Brakes:
Front Brembo 4-Piston Calipers, Rear Brembo 2-Piston Calipers, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake Hydraulics, Parking Brake
Electrical And Electronics:
Wiring Diagrams, Lighting System, Starting and Charging System, Instrumentation, Body Control Module (BCM), SRS (Supplemental Restraint System - Airbags), Immobilizer System
Body And Chassis:
Body Construction, Exterior Panels, Doors, Hood, Trunk Lid, Bumpers, Interior Trim, Seating, Glass, Seals
Hvac
HVAC System:
Heating, Ventilation, and Air Conditioning System Components, Refrigerant System
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement
Repair:
Engine Overhaul, Turbocharger Rebuild/Replacement, Transmission Rebuild, Clutch Replacement, Suspension Component Replacement, Brake System Overhaul, Electrical Component Diagnosis and Replacement
Troubleshooting:
Diagnostic Procedures for Engine Performance Issues, Electrical System Faults, Transmission Problems, Brakes, and HVAC
Diagnostics:
OBD-II (On-Board Diagnostics II) Procedures, Fault Code Interpretation, Live Data Analysis
Technical Depth
Depth:
Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) DOHC MIVEC Turbocharged Inline-4
Performance
Horsepower:
271 hp @ 6500 rpm (US Spec)
Torque:
273 lb-ft @ 3500 rpm (US Spec)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential multi-point injection
Fuel Type:
Unleaded Gasoline (Premium, 91 Octane or higher recommended)
Turbocharger
Turbo Details:
Mitsubishi TD05HRA-15G turbocharger with a larger intercooler (compared to Evo VII)
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission
Optional
Type:
N/A (6-speed manual was standard on all Evo VIII models)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Driver Selectable Modes (Tarmac, Gravel, Snow)
Rear Differential:
Super Active Yaw Control (Super AYC) for enhanced cornering stability (standard on GSR, optional/deleted on some MR models)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-80 (or equivalent, e.g., Mitsubishi DiaQueen LSD Gear Oil)
Fluid Capacities
Manual Transmission Capacity:
Approximately 2.2 Liters (Consult manual for exact specification)
📐 Dimensions
Exterior
Length:
4,400 mm (173.2 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1,450 kg (3,197 lbs) (Varies by trim and market)
Gross Vehicle Weight Rating:
Consult vehicle placard
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brakeforce Distribution
Traction Control:
AYC/ACD systems contribute to traction control and stability
Passive Features
Airbags:
Driver and Passenger Frontal Airbags, Side Airbags (Optional/Standard depending on market/trim)
Seatbelts:
3-point front and rear seatbelts with pretensioners and force limiters
Body Structure:
Reinforced body structure for crash energy management
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium sound system (e.g., Rockford Fosgate) and amplifier.
Display:
Basic LCD display for climate control and audio information.
Driver Assistance
Acd:
Active Center Differential for electronically controlled torque distribution.
Ayc:
Active Yaw Control (Super AYC on many models) for enhanced handling dynamics.
Connectivity
Bluetooth:
Typically not factory-equipped on early Evo VIII models; aftermarket solutions common.
Ecu Tuning
ECU Capabilities:
The factory ECU is highly tunable, leading to a massive aftermarket support for performance tuning.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles or 3 months (severe duty); 7,500 miles or 6 months (normal duty) - Always refer to manual for specific driving conditions.
Engine Oil Filter:
Replace with oil change
Air Filter:
Inspect every 7,500 miles, replace as needed (more frequently in dusty conditions).
Spark Plugs:
Replace every 60,000 miles (typically Iridium type)
Timing Belt:
Inspect at 60,000 miles, replace at 90,000 miles or 7 years (critical component - timing chain system is common on 4G63T, but this is a common service interval if belt-driven accessories are present or for older designs).
Fluid Specifications
Engine Oil:
5W-30 Synthetic (API SN or higher, ILSAC GF-5 or higher recommended). Consult manual for exact specification and viscosity for your climate.
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based, phosphate-free, pink/red coolant)
Brake Fluid:
DOT 3 or DOT 4 (High-temperature, low-moisture absorption)
Fluid Capacities
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Capacity:
Approximately 7.0 Liters (7.4 US Quarts)
Known Issues
Engine:
Rod bearing failure (especially with aggressive tuning/abuse), turbo oil starvation, valve seal issues, head gasket leaks.
Transmission:
Wear in 5th and 6th gear synchros, clutch wear, ACD pump failure.
Suspension:
Premature wear of control arm bushings, ball joints, and rear differential mounts.
Electronics:
Gauge cluster issues, SRS warning light illumination.
📚 Vehicle History
Brand Heritage
Rally Focus:
Mitsubishi's strong WRC history is integral to the Lancer Evolution's identity and development.
Model Evolution
Evolution Series:
The Evo VIII (CT9A) followed the Evo VII and introduced significant upgrades, including a stronger engine and improved chassis components.
Us Introduction:
The Evo VIII was the first Lancer Evolution model officially sold in the United States, marking a significant moment for performance car enthusiasts in North America.
Production
Production Years:
2003-2005
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently ranked highly in performance car benchmarks and enthusiast publications for its handling and raw capability.
Rally Influence Award:
Recognized as a homologation special for rally racing, bringing genuine motorsport DNA to the street.
Certifications
Safety Standards:
Meets all relevant safety certifications for its model years in the markets it was sold.
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