Mitsubishi Lancer Evolution 8 2003-2005 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Production Years Covered: 2003-2005 Codes Chassis Code Range: CT9A 👋 Introduction Market Position Segment: Performance Sedan...

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Sku: 497373

Tags: 2003 2004 2005 Car Cars Lancer Evolution 8 Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo 8

Production Years Covered:

2003-2005

Codes

Chassis Code Range:

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally Homologation Special

Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer (non-Evo variants), Ford Focus RS, Volkswagen Golf R

Competitive Analysis

Key Selling Points:

Legendary 4G63T engine, advanced AWD system (ACD/S-AYC), superior handling, rally heritage, accessible performance

Key Features

Iconic Engine:

4G63T: A highly tunable and robust 2.0L inline-4 turbocharged engine

Advanced AWD:

ACD and S-AYC systems provide exceptional traction and cornering agility

Performance Brakes:

Brembo braking system offering superior stopping power

Rally Proven:

Direct lineage to WRC-winning vehicles, embodying motorsport DNA

📋 Manual Details

Coverage Areas

Primary Regions:

Global (North American and JDM variations are often covered in factory manuals)

Specific Models Covered:

Mitsubishi Lancer Evolution VIII (all trims and variants within the specified years)

Page Count

Estimated Pages:

1500-2000 (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63T (2.0L DOHC MIVEC Turbocharged Inline-4)

Transmission:

6-speed Manual Transmission (Getrag/Mitsubishi)

Drivetrain:

All-Wheel Drive (S-AYC - Super Active Yaw Control, ACD - Active Center Differential, Sports ABS)

Suspension:

Front: MacPherson Strut; Rear: Multi-link

Brakes:

Front: Brembo 4-piston calipers with 320mm vented discs; Rear: Brembo 2-piston calipers with 300mm vented discs

Electrical System:

Comprehensive wiring diagrams, component locations, diagnostic procedures for all electrical systems

Body And Chassis:

Body panel repair, structural integrity, interior trim, glass, bumpers

Fuel System:

Fuel injection, fuel pump, fuel tank, fuel lines

Cooling System:

Radiator, fan, water pump, thermostat, coolant flow

Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors

HVAC:

Air conditioning, heating, ventilation system components and service

Safety Systems:

Airbags, seatbelts, ABS, S-AYC, ACD control modules

Procedures Included

Scheduled Maintenance:

Detailed oil change intervals, filter replacements, fluid checks, spark plug replacement, timing belt inspection/replacement

Diagnostics Troubleshooting:

Symptom-based troubleshooting guides, fault code interpretation (OBD-II), diagnostic connector locations

Engine Repair:

Engine disassembly, assembly, component testing, cylinder head overhaul, piston and connecting rod installation

Transmission Repair:

Transmission disassembly, clutch replacement, gear inspection, rebuild procedures

Brake System Repair:

Brake pad replacement, rotor replacement, caliper service, bleeding procedures, ABS system diagnostics

Suspension And Steering Repair:

Strut replacement, shock absorber service, ball joint inspection, power steering system service, alignment specifications

Electrical Component Replacement:

Alternator, starter motor, battery service, ignition system components, sensor replacement

Bodywork And Trim:

Door panel removal, bumper replacement, headlight/taillight service, interior trim panel removal

Special Tool Identification:

Lists and descriptions of specialized tools required for specific procedures

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds

Diagnostic Capability:

Advanced diagnostic procedures, component testing, calibration of electronically controlled systems

Performance Tuning Data:

Torque specifications for critical components, engine timing data, basic performance parameters

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (OCR processed)

Print Quality

Printability:

Printable pages

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline-4, DOHC, 16-valve, Turbocharged with Intercooler

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valve Actuation:

DOHC with MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Performance

Horsepower Hp:

270-280 hp (approximate, depending on market and specific tune)

Torque Lb Ft:

270-275 lb-ft (approximate, depending on market and specific tune)

Redline:

7000 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Premium (91+ Octane Recommended)

Fuel Injectors:

High-flow injectors (e.g., 560cc for later models/JDM)

Turbocharger

Turbocharger Type:

Mitsubishi TD04-15G (or similar variation)

Wastegate Type:

Internal

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Transmission Manufacturer:

Getrag / Mitsubishi

Optional

Optional Transmission:

N/A (Manual transmission was standard for Evo 8 in most markets)

Features

Gear Ratios:

Refer to manual for specific gear ratios (variations exist)

Clutch Type:

Hydraulically Actuated, Single Dry Plate

Fluid Specifications

Transmission Fluid Type:

API GL-4 or GL-5, SAE 75W-90 (Check manual for exact specifications and capacity)

📐 Dimensions

Exterior

Length:

4490 mm (approx.)

Width:

1770 mm (approx.)

Height:

1415 mm (approx.)

Wheelbase:

2625 mm (approx.)

Front Track:

1500 mm (approx.)

Rear Track:

1495 mm (approx.)

Weights

Curb Weight:

1450 kg (approx.)

Gross Vehicle Weight Rating:

Refer to manual

Towing Capacity:

N/A (Not Designed for Towing)

Wheel Bolt Pattern:

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

Wheel Size:

17x8.0JJ or 17x8.5JJ (OE)

Tire Size:

235/45R17 (OE)

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

4 Stars (Driver), 4 Stars (Passenger) for 2003 Model (US Spec)

IIHS Ratings:

Good (Frontal Offset) for 2003 Model (US Spec)

Active Features

Active Center Differential:

ACD: Electronically controlled torque distribution

Super Active Yaw Control:

S-AYC: Rear differential torque vectoring for enhanced cornering

Sports ABS:

ABS with EBD (Electronic Brakeforce Distribution) and enhanced performance calibration

Traction Control:

AYC/ACD system functions as a form of traction control

Passive Features

Airbags:

Front dual-stage airbags

Seatbelts:

3-point front seatbelts with pretensioners and load limiters, rear seatbelts

Body Structure:

Reinforced passenger safety cell, energy-absorbing front and rear crumple zones

💡 Technology Features

Infotainment

Head Unit:

Factory AM/FM/CD stereo system (variations by market, e.g., Rockford Fosgate audio option)

Display:

Basic LCD display for climate and radio information

Driver Assistance

Anti-lock Braking System (ABS) with EBD

Traction Control:

Integrated with ACD and S-AYC systems

Connectivity

Connectivity Features:

Basic (e.g., power windows, power locks, optional cruise control)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months (severe duty) / 7,500 miles or 12 months (normal duty) - Consult manual for specifics.

Engine Air Filter Replacement:

Every 15,000 miles or 12 months, or as needed based on driving conditions.

Spark Plug Replacement:

Approximately every 60,000 miles (iridium type).

Timing Belt Replacement:

Check condition at 60,000 miles, replace typically around 100,000 miles or 7 years. Critical component – inspect regularly.

Coolant Replacement:

Initial change at 30,000 miles or 2 years, then every 30,000 miles or 2 years thereafter.

Transmission Fluid Change:

Every 30,000 miles or 24 months (or as per manual recommendations, especially for performance driving).

Fluid Specifications

Engine Oil Type:

API SN or SP, SAE 5W-30 or 5W-40 Synthetic Recommended (especially for spirited driving).

Engine Oil Capacity:

4.5 Liters (with filter change)

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based, pink/red coolant)

Brake Fluid Type:

DOT 3 or DOT 4 (Check manual for specific type and DOT rating, performance use may warrant higher rating)

Power Steering Fluid Type:

ATF Dexron III or equivalent (Consult manual)

Known Issues

Engine:

Cracked cylinder heads (especially with aggressive tuning/overheating), piston ring land failure, turbo seal issues, oil slinger failure.

Transmission:

Synchro wear, occasional gearbox input shaft failure under extreme abuse.

AWD Systems:

ACD pump failure, differential wear with aggressive use, failure of S-AYC solenoids.

Suspect Areas:

Rear differential bushings, clutch wear, exhaust manifold cracks, suspension bushings.

📚 Vehicle History

Brand Heritage

Rally Dominance:

Mitsubishi's long and successful history in the World Rally Championship (WRC)

Model Evolution

Evolution Lineage:

The Evo VIII is the eighth generation in the Lancer Evolution series, a direct homologation special for rally racing.

Evo Vii To Viii Changes:

Key improvements included a new 6-speed manual transmission, larger turbocharger, revised suspension geometry, and a more robust ACD and S-AYC system.

Production

Production Period:

2003-2005

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

Notable Variants:

GSR, MR (Limited Edition - UK/Japan), RS (Rally Sport)

🏆 Awards & Recognition

Recognitions

Car And Driver నించે:

Frequently featured on Car and Driver's '10Best' lists during its production run, lauded for its driving dynamics.

Motortrend నించે:

Often recognized by automotive journalists for its exceptional performance and handling characteristics.

Ratings

Performance Metrics:

Praised for acceleration (0-60 mph in low 5-second range) and track capability.

Certifications

Homologation Status:

Designed as a homologation special for Group A/WRC rally regulations.