2003 Mitsubishi LANCER EVO 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Code: CT9A Year: 2003 Codes Chassis Code: CT9A Engine Code: 4G63T 👋 Introduction Market Position Segment: Performance Sedan /...

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Tags: 2003 Car Cars LANCER EVO 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Code:

Year:

Codes

Chassis Code:

Engine Code:

4G63T

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, performance drivers, rally participants, dedicated DIY mechanics

Competitive Analysis

Key Competitors:

Subaru WRX STI, Ford Focus RS, Honda Civic Type R (in spirit, though different classes)

Key Features

Rally Heritage:

Direct descendant of the World Rally Championship Lancer Evolution series

Performance Focus:

Designed for high-performance driving and track capability

AWD System:

Advanced Mitsubishi All-Wheel Control (AWC) system with Active Center Differential (ACD) and Active Yaw Control (AYC)

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily focused on markets where the Evo VIII was officially sold, with potential for regional variations)

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive service manuals)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system

Engine Electrical:

Ignition system, fuel injection system, starting system, charging system, sensor diagnostics, ECU (Engine Control Unit) operation

Transmission:

Manual transmission (6-speed), clutch system, driveline, transfer case, rear differential, driveline components

Suspension:

Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, alignment specifications

Brakes:

Front and rear brake systems (Brembo on many models), hydraulic system, ABS (Anti-lock Braking System), parking brake, rotor and pad replacement

Steering:

Power steering system, steering column, tie rods, steering rack, alignment

Electrical System:

Wiring diagrams, lighting, power windows, power locks, mirrors, audio system, HVAC controls, body control module (BCM)

Body And Chassis:

Body construction, doors, hood, trunk lid, bumpers, interior trim, chassis components, corrosion protection

HVAC:

Heating, Ventilation, and Air Conditioning system diagnostics and repair

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, EVAP system

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement intervals, belt inspections

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical diagnostics

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Rebuilding:

Detailed procedures for engine and transmission rebuilds

Specifications And Tolerances:

Torque specifications, clearances, fluid capacities, alignment settings

Special Tools:

Identification and usage of specialized tools required for specific repairs

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including diagnostics and component-level repair.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable for quick information retrieval

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Type:

N/A (Digital PDF format)

Paper Type

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2.0L DOHC 16-valve turbocharged inline-4

Engine Code:

4G63T

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Performance

Horsepower Usdm:

276 hp @ 6500 rpm

Torque Usdm:

286 lb-ft @ 3500 rpm

Redline:

7500 rpm

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI) with electronic control

Fuel Type:

Unleaded premium gasoline (91 octane or higher recommended)

Turbocharger:

Mitsu TD05H-16G turbocharger with intercooler

Fluid Capacity

Engine Oil Capacity:

4.5 liters (4.8 US quarts) with filter change

Fluid Specifications

Engine Oil Type:

API SG or SH, ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations)

🔧 Transmission

Standard

Transmission Type:

6-speed manual transmission

Optional

Transmission Type:

None (only manual offered)

Features

Awc System:

Active Center Differential (ACD), Active Yaw Control (AYC) on rear differential

Fluid Capacity

Manual Transmission Fluid Capacity:

Approx. 2.2 liters (2.3 US quarts) GL-4 or GL-5 SAE 75W-90

Fluid Specifications

Manual Transmission Fluid Type:

GL-4 or GL-5 SAE 75W-90 (refer to manual for specific recommendations)

📐 Dimensions

Exterior

Length:

4400 mm (173.2 in)

Width:

1770 mm (69.7 in)

Height:

1450 mm (57.1 in)

Wheelbase:

2625 mm (103.3 in)

Weights

Curb Weight:

Approximately 1450 kg (3197 lbs)

Gross Vehicle Weight Rating:

N/A (Specific GVWR not commonly cited for performance models)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not officially rated in all markets, but generally considered robust.

IIHS Side Impact:

Not officially rated in all markets.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Active Traction Control (TCL)

Electronic Stability:

Standard Active Stability Control (ASC) (often integrated with AWC)

Passive Features

Airbags:

Driver and front passenger airbags, side airbags (optional or standard depending on market)

Seatbelts:

3-point ELR seatbelts with pretensioners and load limiters

Structure:

Reinforced chassis and safety cell construction

💡 Technology Features

Infotainment

Head Unit:

Factory-provided AM/FM/CD audio system (upgrades common)

Display:

Basic multi-information display in instrument cluster

Driver Assistance

Awc System:

Mitsubishi All-Wheel Control (AWC) system with driver-selectable ACD modes (Tarmac, Gravel, Snow)

Connectivity

Bluetooth:

Not typically equipped from factory (aftermarket solutions common)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (severe use may require more frequent changes)

Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 60,000 miles (iridium type)

Timing Belt Replacement:

Every 105,000 miles or 7 years (critical component, consult manual for specific procedure)

Fluid Specifications

Coolant Type:

Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant

Brake Fluid Type:

DOT 3 or DOT 4 compatible (refer to manual)

Known Issues

Engine Reliability:

Generally robust 4G63T, but susceptible to issues from aggressive modification, poor maintenance, or oil starvation. Check for rod knock.

Turbocharger:

Turbocharger can develop issues if oil is not changed regularly or if oil feed/return lines become clogged.

Clutch Wear:

Clutch can wear prematurely with aggressive driving or track use.

Suspension Bushings:

Rubber suspension bushings can degrade over time, leading to less precise handling.

Rust Corrosion:

Subframes, sills, and wheel wells are common areas for rust, especially in areas with road salt.

📚 Vehicle History

Brand Heritage

Heritage:

Mitsubishi Motors has a long history in motorsport, particularly in rallying with the Lancer Evolution lineage.

Model Evolution

Evolution Series:

The Lancer Evolution VIII is the eighth generation of Mitsubishi's iconic performance car, building upon decades of rally-bred technology and development.

Key Changes From Evo Vii:

Updated ACD, revised AYC, new 6-speed transmission, improved suspension geometry, and engine tuning.

Production

Production Years:

2003-2005

Manufacturing Location:

Japan (Mizushima Plant)

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Consistently praised by automotive journalists and enthusiasts for its exceptional handling, acceleration, and rally-bred performance. Often cited as a benchmark for affordable performance cars.

Ratings

Car And Driver Ranking:

Often featured on '10Best' lists or praised in comparison tests against competitors.