2004 Mitsubishi LANCER EVO 8 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Designation: Evolution VIII (Evo 8) Model Code: CT9A Model Generation: Seventh Generation Year: 2004 Codes Chassis Code: CT9A Engine...

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标签: 2004 Car Cars LANCER EVO 8 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Designation:

Evolution VIII (Evo 8)

Model Code:

Model Generation:

Seventh Generation

Year:

Codes

Chassis Code:

Engine Code Primary:

4G63T (2.0L DOHC MIVEC Turbocharged Inline-4)

👋 Introduction

Market Position

Segment:

Performance Compact Sedan, Rally Homologation Special

Positioning:

High-performance, driver-focused vehicle known for its rally heritage and advanced drivetrain technology.

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Honda Civic Type R (in relevant markets), Ford Focus RS.

Key Features

Drivetrain:

Advanced Super All-Wheel Control (S-AWC) with Active Center Differential (ACD) and Active Yaw Control (AYC).

Engine:

Powerful 4G63T 2.0L MIVEC turbocharged inline-four engine.

Braking:

High-performance Brembo braking system.

Aerodynamics:

Aggressive body kit, large rear wing, functional hood vents for cooling.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete repair and service for the 2004 Mitsubishi Lancer Evolution VIII.

Region Applicability:

Primarily North American specifications, with potential for international variations noted where significant.

Page Count

Estimated Pages:

Over 2000

Manual Type

Type:

Factory Authorized Service Repair Manual

Distinction:

Distinct from Owner's Manual; designed for professional technicians and advanced DIYers.

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (4G63T MIVEC Turbo), Fuel System, Exhaust System, Cooling System, Lubrication System.

Drivetrain:

Manual Transmission (Getrag 5-speed or optional 6-speed depending on market/trim), All-Wheel Drive (AYC/ACD) System, Differentials, Driveshafts, Axles.

Chassis:

Suspension (Front MacPherson Strut, Rear Multi-link), Steering System, Braking System (Front Brembo 4-piston, Rear Brembo 2-piston).

Electrical:

ECU, Engine Control, Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio Systems, Body Electrical, Power Accessories.

Body:

Body Panels, Interior Trim, Exterior Trim, Glass, Doors, Hood, Trunk, Sealing Systems.

HVAC:

Heating, Ventilation, and Air Conditioning System.

Safety Systems:

Airbag System, ABS (Anti-lock Braking System).

Procedures Included

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), circuit diagrams, component testing procedures.

Maintenance:

Scheduled maintenance intervals, fluid changes, filter replacements, inspections.

Repair:

Detailed step-by-step repair instructions for all major components and systems, including engine rebuild, transmission overhaul, suspension component replacement.

Adjustment:

Component adjustments (e.g., clutch, brakes), alignment specifications.

Installation:

Procedures for installing and removing components, including specialized parts.

Specifications:

Torque specifications for all fasteners, clearances, measurements.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds.

Diagnostic Capability:

Advanced diagnostic procedures, including use of scan tools and interpretation of sensor data.

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick access to information.

Print Quality

Quality:

High-resolution digital scans for clear text and sharp illustrations.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Configuration:

2.0L (1997 cc) DOHC Turbocharged Inline-4 with MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Performance

Horsepower Std:

271 hp @ 6500 RPM (US Market)

Torque Std:

273 lb-ft @ 3500 RPM (US Market)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Redline:

7000 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Port Injection

Fuel Type:

Premium Unleaded (91 octane or higher recommended)

Turbocharger:

Mitsubishi TD05H-16G (or similar variant)

Intercooler:

Air-to-Air Front-Mounted Intercooler

🔧 Transmission

Standard

Type:

5-speed Manual (MGN-101)

Optional

Type:

6-speed Manual (MGN-201) available on certain higher trims/markets

Features

AWD System:

Super All-Wheel Control (S-AWC) including Active Center Differential (ACD) and Active Yaw Control (AYC).

Clutch Type:

Hydraulically Actuated, Single Dry Plate

Gear Ratios:

Specific ratios detailed in manual (vary by 5-speed/6-speed and market).

Differential Type:

Front Helical LSD, Rear Helical LSD (integrated with AYC).

📐 Dimensions

Exterior

Length:

4490 mm (176.8 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2630 mm (103.5 in)

Track Width Front:

1515 mm (59.6 in)

Track Width Rear:

1510 mm (59.4 in)

Weights

Curb Weight Std:

Approximately 1420 kg (3130 lbs) for GSR, 1385 kg (3053 lbs) for RS (US Spec)

Gross Vehicle Weight Rating:

1800 kg (3968 lbs) (Approximate)

Towing Capacity:

Not Recommended/Specified

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for 2004 model year, standard Lancer)

IIHS Side Impact:

Good (for 2004 model year, standard Lancer)

Active Features

Standard Anti-lock Braking System with Electronic Brake-force Distribution (EBD).

Traction Control:

Active Stability Control (ASC) available on some trims.

Driving Dynamics:

AYC (Active Yaw Control) and ACD (Active Center Differential) contribute to stability and cornering grip.

Passive Features

Airbags:

Driver and Front Passenger Airbags.

Seatbelts:

3-point Front and Rear Seatbelts with pretensioners and force limiters.

Body Structure:

Reinforced Body Structure for crash energy absorption.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional Rockford Fosgate premium audio system on some trims.

Display:

Digital Odometer, Trip Computer, Exterior Temperature Gauge, ACD/AYC Mode Display.

Driver Assistance

Standard ABS.

Optional Active Stability Control (ASC).

Connectivity

Oem Features:

Limited by era; focus on performance systems. No factory Bluetooth or USB typically.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first, especially under spirited driving conditions.

Air Filter Replacement:

Every 15,000-20,000 miles or as needed.

Spark Plug Replacement:

Every 30,000-45,000 miles (depending on plug type).

Timing Belt Replacement:

Every 60,000-90,000 miles or 5-7 years (critical item for 4G63T).

Coolant Flush:

Every 2 years or 30,000 miles.

Fluid Specifications

Engine Oil:

5W-30 Synthetic (API SG/SH/SJ or higher, ACEA A3/B3 or higher) - Capacity: 4.5 L (4.8 US qt)

Transmission Fluid Mt:

API GL-4 Hypoid Gear Oil (75W-90) - Capacity: 2.5 L (2.6 US qt)

Transfer Case Fluid:

API GL-5 Hypoid Gear Oil (75W-90) - Capacity: 0.8 L (0.8 US qt)

Rear Differential Fluid:

API GL-5 Hypoid Gear Oil (75W-90) - Capacity: 1.3 L (1.4 US qt)

Brake Fluid:

DOT 3 or DOT 4

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent silicate-free, ethylene glycol based antifreeze. (50/50 mix) - Capacity: 7.0 L (7.4 US qt)

Known Issues

Engine Internal:

Connecting rod failure (especially with aggressive tuning or poor maintenance), turbocharger failure, oil consumption.

Drivetrain:

AYC/ACD pump failure, clutch wear, differential issues if abused.

Suspension:

Worn bushings, strut failure over time.

Electrical:

Corrosion on wiring harnesses, ECU issues.

Body:

Rusting in common areas (fender arches, rocker panels), especially in regions with salt exposure.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation

Motorsport Roots:

Directly derived from Mitsubishi's successful World Rally Championship (WRC) Lancer Evolution models.

Model Evolution

Predecessor:

Mitsubishi Lancer Evolution VII (Evo 7)

Successor:

Mitsubishi Lancer Evolution IX (Evo 9)

Key Changes From Evo 7:

Improved engine response, revised ACD control, lighter chassis components, updated styling.

Production

Production Years:

2003-2005

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Motor Trend Import Car Of The Year:

Nominee (for Lancer line)

Sport Compact Car Magazine:

Frequent winner of 'Best Handling' and 'Best Bang for Your Buck' awards in its segment.

Wrc Success:

Multiple World Rally Championship titles contributed to its performance reputation.