2003 Mitsubishi Evolution 8 Factory Workshop Service Repair Manual

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

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标签: 2003 Car Cars Evolution 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Year:

Codes

Chassis Code:

Engine Code Primary:

4G63T

👋 Introduction

Market Position

Segment:

Performance Compact Sedan / Rally Homologation Special

Description:

The Mitsubishi Lancer Evolution VIII (CT9A) is a legendary performance car celebrated for its rally-bred engineering, advanced all-wheel-drive system, and powerful turbocharged engine.

Competitive Analysis

Competitors 2003:

Subaru Impreza WRX STI, Subaru Impreza WRX, Mitsubishi Lancer Ralliart

Key Features

Performance Focus:

Engineered for high-performance driving, track days, and rallying.

AWD Technology:

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

Turbocharged Engine:

Iconic 4G63T turbocharged inline-4 engine known for its robust construction and tuning potential.

Braking System:

High-performance Brembo braking system for exceptional stopping power.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair information for the 2003 Mitsubishi Lancer Evolution VIII

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, overhaul, timing belt, seals, gaskets, pistons, rings, connecting rods, crankshaft, cylinder head, valves, camshafts

Engine Electrical:

Ignition system, starting system, charging system, ECU, sensors (MAP, MAF, TPS, O2, knock), wiring diagrams, diagnostic trouble codes (DTCs)

Fuel System:

Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel lines, fuel filter, EVAP system

Cooling System:

Radiator, thermostat, water pump, cooling fan, coolant hoses, pressure cap

Exhaust System:

Exhaust manifold, catalytic converter, muffler, O2 sensors

Transmission Manual:

Removal, installation, disassembly, assembly, clutch, flywheel, gears, bearings, seals, maintenance

Transmission Awc:

Active Yaw Control (AYC) system, AYC pump, differential, sensors, actuators, hydraulic system, maintenance, troubleshooting

Drivetrain AWD:

All-Wheel Drive (AWD) system, transfer case, front differential, rear differential, driveshafts, CV joints, maintenance, troubleshooting

Suspension Front:

MacPherson strut, control arms, ball joints, bushings, springs, shock absorbers, steering knuckle, alignment specifications

Suspension Rear:

Multi-link suspension, trailing arms, control arms, bushings, springs, shock absorbers, subframe, alignment specifications

Steering:

Power steering system, steering rack, steering column, tie rod ends, power steering fluid specifications

Brakes Front:

Brake calipers (Brembo), brake pads, brake discs, brake fluid specifications, bleeding procedures

Brakes Rear:

Brake calipers, brake pads, brake discs, brake fluid specifications, bleeding procedures

ABS System:

Anti-lock Braking System (ABS) components, wheel speed sensors, ABS modulator, ABS control module, wiring, troubleshooting

Wheels Tires:

Wheel specifications, tire pressure recommendations, lug nut torque specifications

Body Exterior:

Body panels, bumpers, doors, hood, trunk lid, spoilers, trim, paint codes, collision repair guidelines

Body Interior:

Seating systems, dashboard, trim panels, interior lighting, HVAC controls, airbags

Electrical Lighting:

Headlights, taillights, interior lights, fog lights, wiring diagrams

Electrical Audio:

Factory audio system, speaker wiring, antenna

Electrical HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, evaporator, condenser, blower motor, refrigerant specifications

Safety Airbags:

Airbag system components, sensors, control module, deployment procedures, safety precautions

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, OBD-II scanning and interpretation

Repair Procedures:

Step-by-step repair instructions for all major components and systems

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and differential rebuilds

Installation Procedures:

Guidance for installing new or replacement parts

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical resistance values

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle systems

Technical Depth

Depth:

In-depth mechanical and electrical repair, diagnostic procedures, and troubleshooting for professional technicians and experienced DIYers

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Turbocharger:

Mitsubishi TD05HR-16G turbocharger with intercooler

Performance

Horsepower Hp:

271 hp @ 6500 rpm (JDM/European), 276 hp @ 6500 rpm (USDM)

Torque Lb-Ft:

273 lb-ft @ 3500 rpm (JDM/European), 287 lb-ft @ 3500 rpm (USDM)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (91+ octane recommended)

Cooling System

Cooling Type:

Liquid-cooled

Oil System

Oil Capacity Quarts:

4.4 US quarts (4.2 Liters) with filter

Oil Type Recommendation:

API SG or SH, SAE 10W-30 (or 5W-30 in colder climates)

🔧 Transmission

Standard

Type Standard:

6-speed Manual Transmission (Getrag 6-speed)

Optional

Type Optional:

None offered for the Evolution VIII

Features

AWD System:

Full-time Symmetrical All-Wheel Drive (SAWD) with Active Yaw Control (AYC)

Ayc Description:

Hydraulically controlled active center differential and rear differential to distribute torque and enhance cornering.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (Mitsubishi Genuine Gear Oil or equivalent)

Ayc Pump Fluid:

Mitsubishi DiaQueen ATF SP III (or equivalent)

Fluid Capacities

Manual Transmission Capacity Liters:

2.3 Liters

📐 Dimensions

Exterior

Length Mm:

4490 mm

Width Mm:

1770 mm

Height Mm:

1415 mm

Wheelbase Mm:

2625 mm

Front Track Mm:

1520 mm

Rear Track Mm:

1515 mm

Weights

Curb Weight Kg:

1450 kg

Gross Weight Kg:

1800 kg

Fuel Tank Capacity Liters:

50 Liters

Cargo

Cargo Volume Liters:

Approx. 420 Liters (trunk)

Wheels Tires

Wheel Size:

17 x 8.0 inches

Tire Size Standard:

235/45R17

Bolt Pattern:

5x114.3mm

Lug Nut Torque Nm:

108 Nm (79.7 lb-ft)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

Not specifically rated for 2003 model year in standard tests, but generally robust construction.

IIHS Ratings:

Not specifically rated for 2003 model year in standard tests.

Active Features

Standard 4-wheel Anti-lock Braking System (ABS)

Standard Active Yaw Control (AYC)

Standard Symmetrical All-Wheel Drive (SAWD)

Passive Features

Airbags Driver:

Standard driver's airbag

Airbags Passenger:

Standard passenger airbag

Seatbelts:

3-point seatbelts with pre-tensioners

Body Structure:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with 6 speakers.

Driver Assistance

Ayc Control Modes:

While not digitally adjustable like later Evos, the AYC system actively manages torque distribution.

Connectivity

Auxiliary Input:

No factory auxiliary input or Bluetooth connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles:

Every 3,750 miles or 6 months (severe use/performance driving), 7,500 miles or 12 months (normal use)

Air Filter Replacement:

Every 15,000 miles or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 30,000 miles (iridium type recommended)

Timing Belt Replacement:

Every 60,000 miles or 5 years

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Coolant Type:

Mitsubishi Super Long Life Coolant (Green) or equivalent

Known Issues

Engine Sludge:

Risk of engine sludge formation if oil changes are neglected, especially under hard use. Importance of using correct oil and frequent changes.

Clutch Wear:

Performance clutch can wear faster with aggressive driving.

Ayc Pump Failure:

AYC pump can be prone to failure over time due to heat and wear. Leaks in the system can also occur.

Turbo Charger Wear:

Early models can experience turbo wear if oil changes are neglected or if the engine is shut off immediately after hard driving without a cool-down period.

📚 Vehicle History

Brand Heritage

Mitsubishi Motorsport:

Mitsubishi has a rich history in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution achieved significant success.

Model Evolution

Evo Lineage:

The Evolution line originated from the Lancer sedan and was developed to homologate Mitsubishi's rally cars. The Evolution VIII marked the eighth generation of this celebrated performance model.

Production

Production Years:

2003-2005

Assembly Location:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Performance Car Awards:

Consistently praised by automotive journalists for its handling, performance, and rally heritage. Often cited as a benchmark for AWD performance cars of its era.

Ratings

Handling Performance:

Exceptional grip, agility, and driver feedback due to advanced AWD and suspension tuning.

Certifications

Oem Standards:

Adheres to Mitsubishi's Original Equipment Manufacturer specifications and quality standards.