Mitsubishi Lancer EVO 8 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII (Evo 8) Model Code: CT9A Production Years Covered: 2003-2005 Codes Chassis Code: CT9A Engine Code: 4G63T (MIVEC) 👋 Introduction Market...

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Sku: 484036

Tags: Car Cars Lancer EVO 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII (Evo 8)

Model Code:

Production Years Covered:

2003-2005

Codes

Chassis Code:

Engine Code:

4G63T (MIVEC)

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally-inspired Sports Car

Reputation:

Iconic performance vehicle known for its rally heritage and AWD capabilities.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Focus RS, Lancia Delta Integrale (historical context).

Key Features

Performance Highlights:

Powerful turbocharged engine, advanced AWD system (ACD/AYC), stiff chassis, performance-oriented suspension.

Rally Heritage:

Direct lineage from Mitsubishi's WRC success, offering a street-legal rally experience.

📋 Manual Details

Coverage Areas

Documentation Type:

Service Repair Workshop Manual

Content Scope:

Comprehensive, including diagnostics, maintenance, repair, and specifications.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Official Factory Service Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (4G63T MIVEC, turbocharger, fuel injection, ignition), Transmission (manual, automatic - if applicable), Drivetrain (AWD system, ACD, AYC), Clutch.

Chassis:

Suspension (front/rear McPherson strut, multi-link), Steering (power steering), Brakes (ABS, EBD, performance brakes).

Electrical:

Wiring diagrams, ECUs, sensors, lighting, instrumentation, audio system, power windows, central locking.

Body:

Exterior panels, interior trim, doors, windows, seats, HVAC system, body sealing.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug service, fluid checks and changes, belt inspections.

Diagnostics:

OBD-II troubleshooting, error code interpretation, component testing, sensor diagnosis.

Repair:

Engine overhaul, transmission rebuild, suspension component replacement, brake caliper service, electrical component repair, body panel replacement.

Installation:

Component replacement (e.g., turbocharger, injectors, clutch), accessory installation guidance.

Technical Depth

Level:

Advanced diagnostics, full component overhaul, torque specifications, wiring schematics, system testing procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable for quick information retrieval.

Print Quality

Quality:

High-resolution scans with clear, legible text and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4, DOHC, 16-valve, turbocharged with intercooler.

Engine Code:

4G63T (MIVEC version)

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower:

271 hp @ 6500 rpm (USDM GSR/MR)

Torque:

273 lb-ft @ 3500 rpm (USDM GSR/MR)

Fuel System

Induction:

Turbocharged, Intercooled

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Premium Unleaded (91+ octane recommended)

Technical Details

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valve Train:

DOHC with MIVEC (Mitsubishi Innovative Valve timing Electronic Control system)

Turbocharger Model:

Mitsubishi TD05H-16G (or similar variants)

🔧 Transmission

Standard

Type:

6-Speed Manual (Getrag Aisin)

Optional

Type:

5-Speed Automatic (less common, often found on non-performance variants or specific markets)

Features

AWD System:

Full-time Four-Wheel Drive with Active Center Differential (ACD) and Active Yaw Control (AYC - on MR models)

Gear Ratios:

Specific ratios detailed within the manual for each gear.

Fluid Specifications

Manual Transmission Fluid:

Mitsubishi DiaQueen GL-5 SAE 75W-90 (or equivalent)

Transfer Case Fluid:

Refer to manual for specific type (often GL-4 or GL-5).

Rear Differential Fluid:

Refer to manual for specific type (often GL-5).

📐 Dimensions

Exterior

Length:

Approx. 4490 mm (176.8 in)

Width:

Approx. 1770 mm (69.7 in)

Height:

Approx. 1415 mm (55.7 in)

Wheelbase:

Approx. 2625 mm (103.3 in)

Weights

Curb Weight:

Approx. 1400-1500 kg (3086-3307 lbs) depending on trim and options.

Gross Vehicle Weight Rating:

Refer to vehicle placard.

Cargo

Trunk Volume:

Approx. 10.8 cu ft (subject to regional variations).

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

Not consistently rated for all trims/years in all markets. Consult specific regional data.

IIHS Crash Test Performance:

Varies by test and year. Generally good for its era, but not always top-tier compared to modern vehicles.

Active Features

Standard Anti-lock Braking System

Standard Electronic Brakeforce Distribution

AWD Acd:

Active Center Differential for optimal torque distribution.

Active Yaw Control (standard on MR, available on others) for enhanced cornering stability.

Passive Features

Airbags:

Front airbags (driver and passenger), side airbags (optional/market dependent).

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts.

Chassis Construction:

Reinforced chassis structure designed for performance and safety.

💡 Technology Features

Infotainment

Audio System:

Stock Mitsubishi audio system with CD player, AM/FM radio. Higher trims may have premium sound systems (e.g., Rockford Fosgate).

Navigation:

Optional factory navigation system on some higher trims.

Driver Assistance

Traction Control:

Integrated into the AWD and AYC systems.

Cruise Control:

Standard on most models.

Connectivity

Bluetooth:

Not standard; typically an aftermarket addition.

Usb Ports:

Not standard; typically an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions recommended for performance cars).

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed based on inspection.

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (refer to manual for specific recommendations).

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 5 years (critical interval due to interference engine).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 Liters (4.8 US Quarts) with filter change (refer to manual for exact capacity).

Engine Oil Type:

5W-30 or 10W-30 Synthetic (API SN or higher, ACEA A3/B4 recommended).

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with OAT/HOAT technology).

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific recommendation).

Known Issues

Engine Reliability:

Generally robust 4G63T, but susceptible to issues from improper maintenance, overheating, or extreme abuse (e.g., turbo failure, ringland failure).

Transmission Wear:

Manual transmissions can experience clutch wear and synchro issues with hard use. ACD and AYC systems can require specialized maintenance.

Suspension Components:

Bushings and ball joints can wear over time, especially with aggressive driving.

Electrical Gremlins:

Can occur with age, but typically manageable with proper diagnostic procedures.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi has a strong history in World Rally Championship (WRC) with Lancer Evolution models, winning multiple championships.

Model Evolution

Generations:

The Evo 8 is the eighth generation of the Lancer Evolution, building upon the success of its predecessors.

Key Variants Evo8:

GSR, RS, MR (GSR and MR were more common in North America).

Production

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Years:

2003-2005

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Frequently cited as a benchmark for performance and handling in its class.

Sport Compact Car Of The Year:

Received numerous accolades from automotive publications for its performance capabilities.

Certifications

Emissions Standards:

Complies with relevant emissions standards for its production year (e.g., EPA, Euro IV).