Mitsubishi Lancer Evolution 8 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo VIII Year: 2003 Codes Chassis Code: CT9A Engine Code: 4G63 👋 Introduction Market Position Positioning: High-performance rally-bred...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo VIII

Year:

Codes

Chassis Code:

Engine Code:

👋 Introduction

Market Position

Positioning:

High-performance rally-bred sports sedan, positioned as a homologation special for motorsport competition.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (though generally a class above), Mitsubishi Lancer Evolution VII predecessor.

Key Features

Performance Focus:

Exceptional handling, acceleration, and braking for its class, advanced AWD system.

Rally Heritage:

Direct lineage from Mitsubishi's WRC (World Rally Championship) program.

Value Proposition

Manual Value:

Essential resource for owners and enthusiasts seeking to maintain, repair, and optimize the performance of their Evo VIII.

📋 Manual Details

Coverage Areas

Primary Coverage:

Factory Service Repair Manual

Additional Coverage:

Maintenance, Troubleshooting, Repair, Diagnostics, Specifications

Page Count

Estimated Page Count:

Approx. 1000+ pages (typical for comprehensive factory manuals)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

4G63 MIVEC Turbocharged inline-4; Engine Mechanical, Lubrication, Cooling, Fuel System, Ignition System, Emission Control, Engine Control System (ECU), Turbocharger System, MIVEC System

Transmission:

6-speed Manual Transmission (Type TY856WB1CA); Gearbox, Clutch, Drive Shafts, Differential (Front, Center, Rear ACD)

Drivetrain:

All-Wheel Drive (AWD) with Active Center Differential (ACD), Super Active Yaw Control (S-AYC)

Suspension:

Front MacPherson Struts, Rear Multi-link; Shock Absorbers, Springs, Bushings, Control Arms, Anti-roll Bars

Brakes:

Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers; Brake System Diagnosis, Hydraulic System, Parking Brake

Steering:

Power Rack and Pinion Steering System

Electrical:

Wiring Diagrams, Fuses, Relays, Battery, Charging System, Starting System, Lighting System, Instruments and Gauges, HVAC Controls, Power Windows, Door Locks, Audio System

Body And Chassis:

Body Structure, Exterior Panels, Interior Trim, Doors, Hood, Trunk, Glass, Seats, Safety Belts, Airbag System

Climate Control:

HVAC System, Air Conditioning (A/C), Heater, Defroster, Ventilation

Diagnostics:

OBD-II (On-Board Diagnostics II), Trouble Code Diagnosis, Diagnostic Tool Procedures, Sensor Testing

Procedures Included

Maintenance:

Oil Change, Filter Replacement, Spark Plug Replacement, Fluid Checks and Replacements (Coolant, Brake Fluid, Power Steering Fluid, Transmission Fluid), Belt Inspection and Replacement

Repair:

Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service, Electrical Component Repair, Body Panel Repair

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues, fault finding trees

Specifications:

Torque Specifications for all fasteners, Fluid Capacities, Electrical Specifications, Diagnostic Parameters

Disassembly And Assembly:

Detailed instructions for component removal and reinstallation with illustrations

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds

Detail Level:

Factory level detail with clear diagrams and step-by-step instructions

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (text-based PDF)

Printable:

Print Quality

Quality:

High-resolution scans of original factory documents

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

Completeness

Completeness:

Full Factory Service Manual covering all systems and procedures

⚙️ Engine Specifications

Primary Engine

Engine Type:

4G63 MIVEC Turbocharged Inline-4

Displacement:

2.0 Liters (1997cc)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Valvetrain:

DOHC (Dual Overhead Camshafts), 16 Valves, MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft

Performance

Horsepower Bhp:

270 bhp @ 6500 rpm (JDM/UK Spec), 265 bhp @ 6500 rpm (US Spec)

Torque Lb-Ft:

273 lb-ft @ 3500 rpm (JDM/UK Spec), 272 lb-ft @ 3500 rpm (US Spec)

Fuel System

Fuel Type:

Premium Unleaded Gasoline (91+ Octane Recommended)

Injection System:

Multi-point Fuel Injection (MPI)

Turbocharger:

Mitsubishi TD05HR-16G6-10.5T (or similar variant depending on market)

Fluid Specifications

Engine Oil:

API SG/SH/SJ, ACEA A2/A3, SAE 10W-30 or 5W-40 (refer to manual for specific climate conditions)

Coolant:

Mitsubishi Genuine Super Long Life Coolant (or equivalent ethylene glycol based, silicate-free)

Oil Capacity Quarts:

4.5 quarts (4.3 liters) with filter change

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual Transmission

Transmission Model:

TY856WB1CA

Optional

Optional Transmission:

None (Manual transmission was standard for Evo VIII)

Features

Drivetrain Features:

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

Transmission Fluid:

Mitsubishi Genuine DiaQueen LSD Gear Oil (GL-5, 75W-90) for rear differential (LSD), GL-5, 75W-90 for front and center differentials and transmission

Fluid Capacity

Transmission Oil Capacity Liters:

Approximately 3.0 liters (refer to manual for exact)

📐 Dimensions

Exterior

Length Mm:

4490 mm

Width Mm:

1770 mm

Height Mm:

1415 mm

Wheelbase Mm:

2625 mm

Front Track Mm:

1515 mm

Rear Track Mm:

1510 mm

Weights

Curb Weight Kg:

1450 kg (approx.)

Gross Weight Kg:

1910 kg (approx.)

Wheel And Tire

Standard Wheel Size:

17x8.0JJ

Standard Tire Size:

235/45R17

Bolt Pattern:

5x114.3 mm

Offset:

+38 mm (typical)

🛡️ Safety Features

Ratings

NHTSA Ratings:

No specific NHTSA ratings available for this era/model in many markets due to low volume/specialty status. Often based on general Lancer safety structure.

Active Features

Yes (Anti-lock Braking System)

Traction Control:

Yes (Active Stability Control - ASC, often linked with ACD/AYC)

AWD System:

ACD (Active Center Differential) and S-AYC (Super Active Yaw Control) significantly enhance dynamic stability and traction.

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seatbelts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts

Body Structure:

Reinforced chassis and body structure designed for rally competition resilience.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional Rockford Fosgate audio upgrade.

Display:

Basic digital climate control display, instrument cluster with multiple gauges.

Driver Assistance

Stability Control:

ASC (Active Stability Control) integrated with AWD system.

Traction Control:

ACD and AYC systems provide advanced traction and handling assistance.

Connectivity

Connectivity Features:

Limited by modern standards; typically includes power windows, power mirrors, central locking. No Bluetooth or advanced connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles Km:

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

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Inspect every 7,500 miles (12,000 km), replace as needed.

Spark Plug Replacement:

Approximately 30,000-60,000 miles (48,000-96,000 km) depending on plug type (iridium recommended).

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 2 years for normal use, more frequent for spirited driving/track use.

Brake Fluid Flush:

Every 24 months (2 years) or 15,000 miles (24,000 km).

Fluid Specifications

Power Steering Fluid:

Dexron III/VI ATF or equivalent power steering fluid.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Issues Performance:

Head gasket failures (especially on modified engines), turbocharger wear, clutch wear due to aggressive driving, differential (ACD/AYC) system issues if not properly maintained.

Common Issues General:

Rust/corrosion in certain climates, minor electrical gremlins (e.g., power window switches), exhaust system corrosion.

Maintenance Part Numbers

Oil Filter Oem:

MD345655 or equivalent (e.g., Wix 57060, K&N HP-1008)

Air Filter Oem:

MR552207 or equivalent

Spark Plugs Oem:

NGK BKR7E-11 (standard) or NGK BKR7EIX-11 (Iridium, recommended for performance)

📚 Vehicle History

Brand Heritage

Brand Focus:

Mitsubishi Motors Corporation, known for its engineering prowess, particularly in turbocharged engines and four-wheel-drive systems.

Model Evolution

Evolution Series Origin:

Born from homologation requirements for the World Rally Championship (WRC).

Evolution Viii Introduction:

Launched in 2003 for the 2003 model year, representing the eighth generation of the Lancer Evolution.

Evolution Viii Distinction:

Key advancements included the MIVEC engine and the introduction of the Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) systems, significantly enhancing its dynamic capabilities.

Production

Production Years:

2003-2005 (for Evo VIII)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Performance Awards:

Consistently praised by automotive media for its exhilarating performance, handling, and rally-inspired driving dynamics. Often featured in 'best sports car' or 'performance car' lists for its era.

Motorsport Success:

The Lancer Evolution platform has a storied history of success in the World Rally Championship (WRC), contributing to its performance reputation.