Mitsubishi Lancer Evolution 8 2003-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Code: CT9A Production Years Covered: 2003, 2004, 2005 Generation Generation Name: Eighth Generation (CT9A) Codes Chassis Code: CT9A 👋...

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类型: Car

斯库: 466207

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

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Code:

Production Years Covered:

2003, 2004, 2005

Generation

Generation Name:

Eighth Generation (CT9A)

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Performance Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, performance drivers, tuners, and DIY mechanics.

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (performance variants).

Key Features

Rally Heritage:

Directly derived from Mitsubishi's World Rally Championship (WRC) dominance.

Performance Focus:

All-wheel-drive, turbocharged engine, advanced differentials (AYC), and robust chassis.

Manual Value Proposition:

Empowers owners and technicians with detailed knowledge for optimal maintenance and repair.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive Workshop Service and Repair

Page Count

Estimated Pages:

Approximately 1500+

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Detailed diagnostics, repair, overhaul for 4G63T engine, including turbocharger, intercooler, and lubrication systems.

Drivetrain System:

Covers front/rear differentials, transfer case, viscous coupling (VC), active yaw control (AYC), and associated components.

Transmission System:

Manual transmission (G5M) repair, overhaul, clutch replacement, torque specifications, and fluid requirements.

Suspension System:

Front MacPherson strut, multi-link rear suspension, alignment procedures, component replacement, and torque specifications.

Braking System:

Brembo braking system details, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), rotor/pad replacement, bleeding procedures.

Electrical System:

Wiring diagrams, ECU diagnostics, starter, alternator, battery, lighting, ignition system, and sensor troubleshooting.

Fuel System:

Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel tank and lines, emissions control.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation, and maintenance.

HVAC System:

Air conditioning system, heater core, blower motor, climate control operation, and refrigerant handling.

Body And Chassis:

Body panel removal/installation, door mechanisms, interior trim, glass replacement, chassis identification.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic flowcharts, common fault codes (DTCs), symptom-based troubleshooting for all major systems.

Component Repair And Overhaul:

Detailed step-by-step instructions for engine, transmission, differential, turbocharger, and AYC unit rebuilds.

Diagnosis And Testing:

Procedures for testing sensors, actuators, electrical components, and mechanical systems using specialized tools.

Recalibration And Adjustment:

Procedures for AYC calibration, idle speed adjustment, and other critical system adjustments.

Technical Depth

Depth Of Coverage:

Full factory-level detail, from basic fluid changes to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Includes guidance on using diagnostic tools (e.g., MUT-III, OBD-II scanners) for fault finding.

Special Tools Requirements:

Lists required special tools and their usage for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Image Quality:

High-resolution diagrams and illustrations

Print Quality

Printable:

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Completeness

Manual Completeness:

Full workshop service and repair manual content.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Usdm:

271 hp @ 6500 rpm (approx.)

Torque Usdm:

273 lb-ft @ 3500 rpm (approx.)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Turbocharger Model:

Mitsubishi TD05HR-16G6-10.5T

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended)

Engine Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter

Coolant Type:

Ethylene Glycol based, Mitsubishi Super Long Life Coolant (or equivalent)

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Transmission Model:

G5M (G5M-391)

Optional

Optional Transmission:

None available for Evolution VIII

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC)

Transfer Case Fluid:

Genuine Mitsubishi Diaqueen SS III or equivalent (API GL-4/GL-5 75W-85)

Rear Differential Fluid:

Genuine Mitsubishi Diaqueen LSD Gear Oil 80W-90 or equivalent

Transmission Fluid:

Genuine Mitsubishi Diaqueen API GL-4 SAE 75W-85 or GL-5 (check specific requirements)

📐 Dimensions

Exterior

Length:

4490 mm (176.8 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2625 mm (103.3 in)

Track Front:

1515 mm (59.6 in)

Track Rear:

1510 mm (59.4 in)

Weights

Curb Weight:

1430 kg (3153 lbs)

Gross Weight:

1800 kg (3968 lbs)

Front Axle Load:

850 kg (1874 lbs)

Rear Axle Load:

950 kg (2094 lbs)

Fuel Tank Capacity:

50 Liters (13.2 US Gallons)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not rated or unavailable for this specific model year/trim

IIHS Front Impact:

Not rated or unavailable for this specific model year/trim

Active Features

Standard Anti-lock Braking System

Standard Electronic Brakeforce Distribution

Traction Control:

Standard (integrated with AYC/ACD)

Passive Features

Airbags Driver:

Standard front driver airbag

Airbags Passenger:

Standard front passenger airbag

Seatbelts:

3-point front and rear seatbelts, pre-tensioners, load limiters

Chassis Structure:

Reinforced unibody construction for crash safety

💡 Technology Features

Infotainment

Head Unit:

Factory Mitsubishi CD/Radio system (various revisions existed).

Speaker System:

Standard 6-speaker system (some models had optional Rockford Fosgate upgrades).

Driver Assistance

Ayc System:

Active Yaw Control (AYC) manages torque distribution between rear wheels for enhanced cornering stability.

Acd System:

Active Center Differential (ACD) electronically controls the locking action of the center differential, adjusting front/rear torque split.

Connectivity

OBD Ii:

Standard OBD-II diagnostic port for engine management and emissions data.

ECU Tuning Potential:

Highly tunable ECU (Electronic Control Unit) for performance modifications.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first.

Air Filter Replacement Interval:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement Interval:

Every 30,000 miles (48,000 km) (specific plug type dependent).

Timing Belt Replacement Interval:

Every 60,000 miles (96,000 km) or 4 years (critical component).

Transmission Fluid Change Interval:

Every 30,000 miles (48,000 km) or 24 months.

Coolant Flush Interval:

Every 30,000 miles (48,000 km) or 24 months.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific grade)

Power Steering Fluid:

Mitsubishi Diaqueen PSF or equivalent ATF Dexron II/III

Known Issues

Engine Issues:

Head gasket failures (especially under high stress/modification), turbocharger wear, piston ring land cracking (severe abuse).

Ayc Issues:

Failure of the AYC pump or hydraulic system, loss of yaw control functionality.

Transmission Issues:

Grinding gears, worn synchros, clutch wear (typical for high-performance manual transmissions).

Suspension Issues:

Worn bushings, strut mounts, and ball joints, especially on high-mileage or track-used vehicles.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Motorsport:

Long and successful history in motorsports, particularly WRC, forming the basis for the Evo lineage.

Model Evolution

Evolution Lineage:

The Lancer Evolution series began in 1992 as a homologation special for Group A rallying. Each generation refined the AWD, turbocharged performance formula.

Evolution Viii Introduction:

Introduced to the US market in 2003, marking a significant milestone for performance car enthusiasts in North America. Based on the Lancer Cedia platform.

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Total Units Est:

Approximately 30,000 units globally (all trims for 2003-2005).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Frequently lauded by automotive publications for its performance and handling, though not always specific '10 Best' awards for Evo VIII.

Ratings

Overall Performance Rating:

Exceptional, widely recognized as a benchmark for AWD performance sedans of its era.

Certifications

Emissions Compliance:

Meets US Federal emissions standards for model years 2003-2005.