Mitsubishi Lancer EVO 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Codes Chassis Code: CT9A 👋 Introduction Market Position Positioning: Iconic rally-bred performance sedan, positioned as a...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo 8

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Iconic rally-bred performance sedan, positioned as a highly capable enthusiast vehicle

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (depending on specific market and generation)

Key Features

Performance Focus:

All-wheel drive, turbocharged engine, advanced differentials, and performance-oriented chassis

Rally Heritage:

Direct lineage to Mitsubishi's World Rally Championship (WRC) success

📋 Manual Details

Coverage Areas

General Coverage:

All repairs covered A-Z, All models covered

Trim Level Coverage:

All trim levels of the Lancer Evolution VIII

Page Count

Estimated Page Count:

3000+

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, and tuning of the 4G63T engine

Transmission:

Manual and Automatic transmission repair, clutch system, drivetrain components (front/rear differentials, ACD)

Suspension:

Front and rear suspension systems, steering system, wheel alignment specifications

Brakes:

Brake system diagnostics, repair, ABS, brake fluid specifications

Electrical:

Wiring diagrams, electrical component testing, ECU diagnostics, lighting systems, audio systems

Body:

Body panel repair, interior trim, exterior components, glass replacement

Cooling System:

Radiator, coolant, cooling fan, thermostat repair and replacement

Fuel System:

Fuel pump, injectors, fuel filter, fuel tank, emissions control system

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics and repair

Procedures Included

Maintenance:

Routine maintenance tasks, fluid changes, filter replacements, tune-ups

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault code interpretation

Repair:

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

Rebuilds:

Engine and transmission overhaul procedures, turbocharger rebuilds

Calibration:

ECU calibration, ACD system calibration, throttle body synchronization

Installation:

Component replacement and installation procedures

Technical Depth

Depth:

Comprehensive; covers basic maintenance to full engine and transmission rebuilds, advanced diagnostics

Professional Level:

Yes, equivalent to factory-authorized workshop manuals

📊 Manual Specifications

File Format

Type:

Digital PDF

Searchable:

Yes, text-searchable for quick information retrieval

Printable:

Yes, allows for printing of individual pages or sections

Print Quality

Quality:

High-resolution, clear diagrams and text

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

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

Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Usdm:

271 hp @ 6500 rpm

Torque Usdm:

273 lb-ft @ 3500 rpm

Horsepower Jdm Eedm:

280 PS (276 hp) @ 6500 rpm

Torque Jdm Eedm:

30.0 kgf⋅m (294 Nm / 217 lb-ft) @ 3500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded premium gasoline (91 octane or higher recommended)

Turbocharger

Type:

Mitsubishi TD05HR-16G 8cm² twin-scroll turbocharger

🔧 Transmission

Standard

Type:

6-speed manual (Getrag 6-speed)

Optional

Type:

N/A for Evo VIII

Features

Drivetrain:

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

Clutch:

Hydraulically actuated single dry plate clutch

📐 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)

Weights

Curb Weight Usdm:

Approx. 1420 kg (3130 lbs)

Gross Weight Rating:

Not specified in product info, typically higher than curb weight

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated or widely published for the specific Evo VIII generation in the US

IIHS Side Impact:

Not explicitly rated or widely published for the specific Evo VIII generation in the US

Active Features

Active Center Differential (ACD) system for torque distribution

S Ayc:

Super Active Yaw Control (S-AYC) on GSR models for rear differential torque vectoring

Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point front and rear seat belts with pre-tensioners and force limiters

Body Structure:

Reinforced chassis and body structure for enhanced safety and rigidity

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM CD player with optional premium audio system (e.g., Rockford Fosgate)

Dashboard Displays:

Analog gauges for speed, tachometer, fuel, temperature; digital odometer; ACD status indicator

Driver Assistance

Traction Control:

Partially integrated with AWD and ACD systems, though not a dedicated "traction control" button in the modern sense.

Cruise Control:

Standard on most models

Connectivity

Auxiliary Input:

Not standard; aftermarket modifications common for modern connectivity

Bluetooth:

Not standard; aftermarket modifications common

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (severe vs. normal)

Timing Belt:

Replace every 60,000-70,000 miles or 5-7 years (critical component for 4G63T)

Spark Plugs:

Inspect every 30,000 miles, replace as needed (recommend high-performance plugs for spirited driving)

Transmission Fluid:

Change every 30,000-50,000 miles (manual transmission)

Differential Fluid:

Change every 30,000-50,000 miles (front and rear differentials)

Coolant:

Flush and replace every 30,000-50,000 miles or 2-3 years

Fluid Specifications

Engine Oil:

API SG, SH, SJ, or SL, SAE 5W-30 or 10W-30 (check manual for specific recommendations; high-performance synthetic recommended)

Transmission Fluid Manual:

API GL-4 or GL-5 SAE 75W-90 (specific fluid type for Getrag gearbox is crucial)

Differential Fluid:

API GL-5 SAE 75W-90 (front and rear, limited-slip differentials may require specific additive)

Coolant:

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

Brake Fluid:

DOT 3 or DOT 4 brake fluid (high-temperature performance brake fluid recommended for spirited driving)

Known Issues

Engine Reliability:

Generally robust 4G63T, but prone to issues like cracked cylinder heads or rod bearing failure if not maintained or if subjected to excessive abuse/improper tuning.

Turbocharger:

Potential for turbo seal wear and oil consumption over time, especially with higher mileage or aggressive use.

Acd Pump:

ACD pump failure can occur, leading to differential performance issues.

Suspension Bushings:

Wear on suspension bushings can lead to poor handling and noise.

Clutch Wear:

Clutch wear is accelerated with aggressive driving.

📚 Vehicle History

Brand Heritage

Motorsport Roots:

Mitsubishi's extensive rally heritage, including multiple WRC manufacturer and driver championships

Model Evolution

Evolution Lineage:

Part of the Lancer Evolution series, which debuted in 1992 as a homologation special for WRC

Evo Viii Introduction:

Introduced in 2003, continuing the performance lineage with significant chassis and powertrain updates

Production

Production Years:

2003-2005

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Consistently praised by automotive journalists and enthusiasts for its exceptional handling, braking, and all-wheel-drive performance.

Tuning Potential:

Renowned for its tuning potential, making it a popular platform for performance modifications.