Mitsubishi Evolution VIII Evo 8 2003-2005 Repair Manual

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Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Nickname: Evo 8 Years Covered: 2003, 2004, 2005 Codes Chassis Code: CT9A Introduction Market Position Segment: Performance Sedan / Rally Homologation...

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Sku: 55032

Tags: 2003 2004 2005 Car Cars Evo 8 Evolution VIII Misc Mitsubishi

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Description

Basic Information
Identification
Make:	Mitsubishi
Model:	Lancer Evolution VIII
Nickname:	Evo 8
Years Covered:	2003, 2004, 2005
Codes
Chassis Code:	CT9A

Introduction
Market Position
Segment:	Performance Sedan / Rally Homologation Special
Target Audience:	Enthusiasts, Performance Drivers, DIY Mechanics
Competitive Analysis
Key Competitors:	Subaru WRX STI, Ford Focus RS, Honda Civic Type R
Key Features
Performance Focus:	Legendary handling, powerful engine, advanced AWD system
Rally Heritage:	Directly derived from WRC homologation requirements

Manual Details
Coverage Areas
Manual Type:	Workshop Repair Service Manual
Language:	English
Format:	PDF Download
Page Count
Estimated Page Count:	1500+
Manual Type
Manual Purpose:	Service, Maintenance, Troubleshooting, Repair

Manual Coverage
Systems Covered
Engine:	4G63T (2.0L Turbocharged Inline-4)
Engine Management:	ECU, Ignition System, Fuel System, Emissions Control
Transmission:	6-Speed Manual Transmission (Gearing, Clutch, Driveshafts)
Drivetrain:	All-Wheel Drive (AWD), Active Center Differential (ACD), Active Yaw Control (AYC), Super Active Yaw Control (S-AYC)
Suspension:	Front MacPherson Struts, Rear Multi-Link, Dampers, Springs, Bushings
Brakes:	Front Brembo 4-Piston Calipers, Rear Brembo 2-Piston Calipers, ABS, EBD
Steering:	Power Rack and Pinion
Electrical:	Wiring Diagrams, Charging System, Starting System, Lighting, ECUs
Body:	Exterior Panels, Interior Trim, Doors, Windows, Seats
Climate Control:	HVAC System, Air Conditioning
Procedures Included
Maintenance:	Scheduled Maintenance, Fluid Changes, Filter Replacements, Belt Inspections
Troubleshooting:	Diagnostic Charts, Symptom Analysis, Fault Code Interpretation
Repair:	Component Removal and Installation, Engine Rebuild, Transmission Overhaul, Suspension Work
Diagnostics:	OBD-II Scan Tool Procedures, Sensor Testing, Actuator Testing
Specifications:	Torque Specifications, Tolerances, Alignment Data
Technical Depth
Depth:	Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Manual Specifications
File Format
File Type:	PDF
Searchability:	Searchable Text Content
Print Quality
Printability:	Printable Pages
Binding Type
Binding:	N/A (Digital Download)
Paper Type
Paper Quality:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Code:	4G63T MIVEC
Displacement:	2.0 Liters (1997 cc)
Configuration:	Inline 4-Cylinder, DOHC, 16 Valves
Aspiration:	Turbocharged and Intercooled
Performance
Horsepower Hp:	271 hp @ 6500 rpm (USDM)
Torque Lb-Ft:	273 lb-ft @ 3500 rpm (USDM)
Fuel System
Fuel Delivery:	Electronic Fuel Injection (EFI)
Fuel Type:	Premium Unleaded Gasoline (91+ Octane Recommended)
Turbocharger
Turbocharger Model:	Mitsubishi TD05HRA-15G

Transmission
Standard
Type:	6-Speed Manual Transmission
Gear Ratios:	1st: 3.133, 2nd: 2.026, 3rd: 1.554, 4th: 1.194, 5th: 0.977, 6th: 0.865 (Typical)
Features
AWD System:	Driver Controlled Center Differential (DCCD) and Active Yaw Control (AYC)
Fluid Specs
Transmission Fluid:	API GL-4 or GL-5, SAE 75W-90 (Manual Transmission)

Dimensions
Exterior
Length:	176.9 inches (4495 mm)
Width:	69.9 inches (1775 mm)
Height:	55.7 inches (1415 mm)
Wheelbase:	103.3 inches (2625 mm)
Weights
Curb Weight:	3,274 lbs (1485 kg) (Approximate)
Gvw Rating:	Not Typically Specified

Safety Features
Ratings
NHTSA Front Crash:	4 Stars (Driver), 4 Stars (Passenger)
IIHS Side Impact:	Good
Active Features
ABS:	Standard (4-Channel, 4-Sensor)
Ebd:	Electronic Brake-force Distribution
Passive Features
Airbags:	Front Driver and Passenger Airbags
Seatbelts:	3-Point Front Seatbelts with Pretensioners and Load Limiters

Technology Features
Infotainment
Head Unit:	Factory AM/FM/CD Player (Typically Basic)
Audio System:	Factory Speaker System (Often 6 Speakers)
Driver Assistance
Traction Control:	Integrated with AYC and ACD systems, but often disabled by enthusiasts.
Connectivity
Connectivity Features:	Limited by modern standards; no Bluetooth or USB connectivity from factory.

Maintenance
Service Intervals
Oil Change Interval:	3,000 - 5,000 miles or 3-6 months (Recommended)
Air Filter Replacement:	15,000 - 30,000 miles or as needed
Spark Plug Replacement:	30,000 - 60,000 miles (Depending on type)
Timing Belt Replacement:	60,000 - 100,000 miles or 7-10 years (Critical Component)
Fluid Specifications
Engine Oil:	API SM/SN, ILSAC GF-4/GF-5, SAE 5W-30 or 10W-30 (Consult Manual for Specifics)
Coolant:	Mitsubishi Super Long Life Coolant (Blue) or equivalent HOAT antifreeze
Brake Fluid:	DOT 3 or DOT 4
Power Steering Fluid:	ATF Dexron III or equivalent
Known Issues
Engine Reliability:	Generally robust 4G63T, but can be sensitive to maintenance and abuse. Potential for connecting rod failure under extreme high-RPM use or poor tuning.
Turbocharger:	Potential for bearing wear or seal failure if oil is neglected or overheated.
Acd Pump:	ACD pump can fail over time, affecting AWD system operation.
Ayc Pump:	AYC pump and associated hydraulic system can develop leaks or failures.
Clutch:	Wear is dependent on driving style; performance clutches may have shorter lifespans.

Vehicle History
Brand Heritage
Brand Focus:	Performance, Rallying, Engineering Innovation
Model Evolution
Evo Lineage:	Fifth Generation Evolution (Following Lancer platform)
Key Differences From Evo Vii:	Larger turbocharger, helical front limited-slip differential, improved ACD, revised ECU mapping, updated styling
Production
Manufacturing Location:	Japan
Introduction Year Global:	2003

Awards & Recognition
Recognitions
Car And Driver 10Best:	Named to Car and Driver's 10Best list multiple times during its production run.
Ratings
Performance Reviews:	Universally praised by automotive journalists for its handling and performance capabilities.