🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution

Generation:

VIII

Production Years Covered:

2003-2005

Chassis Code:

CT9A

👋 Introduction

Segment:

Performance Compact Sedan / Rally-inspired Sport Compact

Positioning:

The Lancer Evolution VIII represented the pinnacle of Mitsubishi's performance engineering, a homologation special built for rallying success with street-legal performance.

Key Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer Ralliart, Ford Focus RS, Volkswagen Golf GTI (performance variants).

Drivetrain:

Advanced All-Wheel Drive (AWD) system with Active Yaw Control (AYC) for superior handling and traction.

Engine Type:

Iconic 4G63T turbocharged inline-4 engine.

Chassis:

Reinforced chassis for rally-bred stiffness and durability.

Brakes:

High-performance Brembo braking system.

📋 Manual Details

Language:

English

Manual Type:

Factory Workshop Service Repair Manual

Format:

Digital Download (likely PDF)

Estimated Page Count:

1000+ pages (typical for factory service manuals of this era)

📖 Manual Coverage

Engine:

Complete coverage of the 4G63T engine, including tuning, diagnostics, and rebuild procedures.

Powertrain:

Detailed sections on the 5-speed manual transmission (W5M33), transfer case, and Active Yaw Control (AYC) system.

Suspension:

Front and rear suspension systems, including MacPherson struts, multi-link rear, shock absorbers, springs, and bushings.

Brakes:

Brake system components (Brembo front and rear), hydraulic system, ABS, and rotor/pad replacement.

Electrical:

Comprehensive electrical diagrams, ECU pinouts, starter, alternator, battery, lighting, and accessory circuits.

Fuel System:

Fuel pump, injectors, fuel lines, fuel pressure regulator, and EVAP system.

Cooling System:

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

Exhaust System:

Exhaust manifold, catalytic converter, muffler, and emissions control components.

Steering:

Power steering system, steering column, and rack and pinion assembly.

HVAC:

Heating, ventilation, and air conditioning system components and troubleshooting.

Body And Interior:

Body panel removal/installation, interior trim, seats, and airbags.

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, and basic inspections.

Troubleshooting:

Diagnostic procedures for common and complex issues, fault code interpretation, and wiring harness checks.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components.

Overhaul:

Complete engine and transmission overhaul procedures, including component specifications and assembly sequences.

Diagnostics:

Advanced diagnostic techniques using factory scan tools (like MUT-III) and manual methods.

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment.

Timing Belt Replacement:

Critical procedures for timing belt replacement, including cam and crank timing.

Depth:

Comprehensive, from basic fluid changes to full engine and transmission rebuilds, including specialized systems like AYC.

📊 Manual Specifications

File Type:

PDF (standard for digital service manuals)

Searchability:

Likely text-searchable for quick information retrieval.

Illustrations:

High Resolution, detailed diagrams, photos, and illustrations.

Diagrams:

Component diagrams, exploded views, and system schematics.

Binding:

Not applicable for digital download, but original factory manuals were typically professionally bound.

Paper Quality:

Not applicable for digital download, but original factory manuals used durable, high-quality paper.

⚙️ Engine Specifications

Engine Code:

4G63T

Configuration:

Inline-4, DOHC, 16-valve, Turbocharged

Displacement:

2.0 Liters (1997 cc)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Turbocharger:

Mitsubishi TD05HR-16G (or similar variant depending on market/spec)

Horsepower Usa Spec:

271 hp @ 6500 rpm

Torque Usa Spec:

273 lb-ft @ 3500 rpm

Redline:

7,200 RPM

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Injection

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Oil Type:

API SG, SH, SJ or higher, SAE 10W-30 or 10W-40 (consult manual for specific viscosity recommendations based on temperature)

Engine Oil Capacity:

4.5 Liters (4.8 US quarts) with filter change

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant, 50/50 mix with distilled water)

Coolant Capacity:

7.0 Liters (7.4 US quarts)

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Transmission Model:

W5M33

Drivetrain Type:

All-Wheel Drive (AWD) with Active Yaw Control (AYC)

Ayc System:

Active Yaw Control electronically controls torque distribution between the rear wheels for enhanced cornering stability.

Transmission Fluid Type:

API GL-4, SAE 75W-90 Gear Oil (for manual transmission and transfer case)

Transmission Fluid Capacity:

2.0 Liters (2.1 US quarts) for manual transmission; 0.7 Liters (0.7 US quarts) for transfer case

📐 Dimensions

Length:

177.0 inches (4495 mm)

Width:

69.7 inches (1770 mm)

Height:

57.5 inches (1460 mm)

Wheelbase:

103.0 inches (2615 mm)

Curb Weight:

3200 - 3300 lbs (approximate, depending on trim and options)

Gross Vehicle Weight Rating:

Approx. 4200 lbs (consult manual for exact spec)

Towing Capacity:

Not Recommended/Specified

Trunk Volume:

Approx. 10.4 cubic feet

🛡️ Safety Features

NHTSA Front Impact Driver:

5-Star (for models equipped with airbags)

NHTSA Front Impact Passenger:

5-Star (for models equipped with airbags)

IIHS Moderate Overlap Front:

Good (for models tested)

ABS:

Standard Anti-lock Braking System

Traction Control:

Standard Traction Control System (TCL)

Electronic Brakeforce Distribution:

Standard Electronic Brakeforce Distribution (EBD)

Airbags:

Driver and front passenger airbags, optional side-impact airbags.

Seatbelts:

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

Rollover Protection:

Reinforced body structure for enhanced rollover protection.

💡 Technology Features

Audio System:

Factory AM/FM/CD player with premium speaker options (e.g., Rockford Fosgate in some trims).

Display:

Basic digital clock and display for climate control/audio. No advanced touchscreen infotainment systems.

ABS:

Standard Anti-lock Braking System (ABS)

Ayc:

Active Yaw Control (AYC) as a key performance and stability enhancement.

Usb Aux:

Not standard on 2003-2005 models. Aftermarket solutions likely required for modern connectivity.

Acd:

Optional Active Center Differential (ACD) on some JDM models, which is not standard on all USDM Evo VIII models but is a related advanced drivetrain technology.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (highly recommended for performance engines, especially if driven hard). Consult manual for exact factory recommendation.

Tire Rotation:

Every 5,000-7,500 miles.

Spark Plug Replacement:

Typically around 30,000-60,000 miles, depending on spark plug type (platinum/iridium are longer lasting). Consult manual.

Timing Belt Replacement:

Crucial: 60,000 miles or 5 years, whichever comes first. Failure can cause catastrophic engine damage.

Brake Fluid Change:

Every 2-3 years or 30,000 miles.

Engine Wear:

Ringland failure on early 4G63T engines under extreme stress (often due to aggressive tuning or detonation). Manual will detail proper maintenance to mitigate.

Ayc Pump:

AYC pump and accumulator can fail over time, leading to AYC system warnings. Manual will include troubleshooting.

Clutch Wear:

Performance-oriented clutch can wear faster with aggressive driving.

Turbo Maintenance:

Proper warm-up and cool-down procedures are critical for turbocharger longevity. Manual emphasizes this.

📚 Vehicle History

Brand Focus:

Mitsubishi has a strong motorsport heritage, particularly in rallying, which directly influenced the development of the Lancer Evolution.

Evolution Lineage:

The Evolution VIII is the eighth generation in a series of high-performance variants of the Mitsubishi Lancer, developed to homologate vehicles for the World Rally Championship.

Key Changes From Vii:

Introduction of the 6-speed manual transmission in some markets (though the manual specified here is 5-speed), updated AYC system, and revised body styling. The US market received the Evo VIII primarily with a 5-speed gearbox and a slightly detuned engine compared to JDM models.

Manufacturing Location:

Japan

Notable Variants Usdm:

GSR, MR (though MR designation typically referred to a specific trim or engine for later generations, the VIII MR was often a lightweight version).

🏆 Awards & Recognition

Car And Driver 10Best:

The Mitsubishi Lancer Evolution VIII (and subsequent models) were frequently recognized by automotive publications like Car and Driver on their '10Best' lists for their performance and handling.

Motorsport Legacy:

Directly derived from Mitsubishi's extensive experience and success in the World Rally Championship, making it a homologation special.