🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution VIII (Evo VIII)

Production Year:

2004

Model Code:

CT9A (chassis), 4G63T (engine)

Engine Code:

4G63T (DOHC turbocharged inline-4)

Chassis Code:

CT9A

👋 Introduction

Positioning:

High-performance, rally-bred sports sedan, a homologation special for WRC

Competitors:

Subaru Impreza WRX STI, Mitsubishi Lancer (standard models), Ford Focus RS, Honda Civic Type R (earlier generations)

Performance Focus:

Aggressive aerodynamics, potent turbocharged engine, advanced all-wheel-drive system (ACD/S-AYC)

Driver Engagement:

Raw driving experience, excellent handling, direct steering feedback

Rally Heritage:

Directly derived from Mitsubishi's successful World Rally Championship (WRC) cars

📋 Manual Details

Coverage:

Complete official service and repair

Models Covered:

All models and trim levels of the 2004 Lancer Evolution VIII

Engines Covered:

All engine variants for the 2004 Lancer Evolution VIII

Estimated Pages:

Likely over 1000 pages (typical for a complete factory service manual)

Type:

Official Factory Service Manual (FSM)

Format:

PDF

Language:

English

📖 Manual Coverage

Engine:

Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions, turbocharger system

Drivetrain:

Clutch, manual transmission (Getrag 5-speed or optional 6-speed), transfer case, propeller shaft, drive shafts, differentials (front, center, rear - ACD)

Suspension:

Front strut suspension, rear multi-link suspension, dampers, springs, bushings, control arms, anti-roll bars

Steering:

Power steering system, steering column, steering rack

Brakes:

Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS, EBD, brake fluid, hydraulic lines, rotors, pads

Electrical:

Battery, charging system, starting system, lighting, instrumentation, body electrical, engine control module (ECM), powertrain control module (PCM), wiring diagrams

Body:

Body panels, interior trim, exterior trim, doors, windows, sunroof, seats, safety systems (SRS)

HVAC:

Heating, ventilation, and air conditioning system

Chassis Control:

Active Center Differential (ACD), Super Active Yaw Control (S-AYC) (if equipped)

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement

Troubleshooting:

Diagnostic trouble codes (DTCs), common fault finding procedures for all systems

Repair:

Engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and replacement

Disassembly Assembly:

Step-by-step instructions for removing and installing major components and sub-assemblies

Diagnostics:

On-board diagnostics (OBD-II) procedures, sensor testing, actuator testing

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and troubleshooting trees

📊 Manual Specifications

Format:

PDF

Searchable:

Likely searchable text (common for official PDFs)

Printable:

Likely printable pages

Quality:

Digital; quality depends on original source scan/creation

Type:

Not applicable (digital PDF)

Type:

Not applicable (digital PDF)

⚙️ Engine Specifications

Engine Type:

4G63T (MIVEC - Mitsubishi Innovative Valve timing Electronic Control, introduced later models)

Configuration:

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

Displacement:

2.0 Liters (1997 cc)

Horsepower:

Approximately 271 hp @ 6500 rpm (USDM spec, varies slightly by market)

Torque:

Approximately 273 lb-ft @ 3500 rpm (USDM spec, varies slightly by market)

Redline:

Approximately 7000 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI) with Denso 550cc fuel injectors

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Turbo Model:

Mitsubishi TD05HR-16G 8cm^2 (often referred to as 'Big Turbo')

🔧 Transmission

Transmission Type:

Getrag 5-speed manual transaxle

Transmission Type:

Some markets may have offered a 6-speed manual (often referred to as Evo IX transmission but sometimes found on late Evo VIII models)

Drivetrain:

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

Acd Modes:

Tarmac, Gravel, Snow

Manual Transmission Fluid:

API GL-4 or GL-5, viscosity 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil).

Transfer Case Fluid:

API GL-4, viscosity 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil).

Rear Differential Fluid:

API GL-5, viscosity 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil, specifically for ACD/LSD units).

📐 Dimensions

Length:

Approximately 4,490 mm (176.8 in)

Width:

Approximately 1,770 mm (69.7 in)

Height:

Approximately 1,415 mm (55.7 in)

Wheelbase:

Approximately 2,625 mm (103.3 in)

Curb Weight:

Approximately 1,450 kg (3,197 lbs)

Gross Vehicle Weight:

Varies by market, typically around 1,800 kg

🛡️ Safety Features

NHTSA Rating:

Specific NHTSA ratings for the 2004 Evo VIII may not be readily available or comparable to modern standards. Generally considered a robust vehicle.

IIHS Rating:

Specific IIHS ratings for the 2004 Evo VIII may not be readily available or comparable to modern standards.

ABS:

Standard Anti-lock Braking System (ABS)

Ebd:

Standard Electronic Brakeforce Distribution (EBD)

Acd:

Standard Active Center Differential (ACD) for torque distribution management

Sayc:

Optional Super Active Yaw Control (S-AYC) for rear differential torque vectoring

Airbags:

Driver and front passenger airbags (SRS)

Seatbelts:

3-point front and rear seatbelts with pre-tensioners and load limiters

Body Structure:

Reinforced chassis and safety cell designed for high-performance driving and impact absorption

💡 Technology Features

Audio System:

Factory AM/FM/CD stereo with optional Rockford Fosgate premium audio system.

Instrumentation:

Includes boost gauge, oil pressure gauge, and ACD mode indicator.

Advanced Features:

Active Center Differential (ACD) system allows driver to select traction modes (Tarmac, Gravel, Snow). Optional Super Active Yaw Control (S-AYC) for enhanced cornering stability.

Connectivity Options:

Limited by 2004 standards; typically analog connections for audio accessories, no Bluetooth or integrated smartphone connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles or 3-6 months, especially for performance driving. Refer to manual for specific conditions.

Engine Air Filter:

Inspect every 7,500 miles, replace as needed or every 15,000-30,000 miles depending on conditions.

Spark Plugs:

Replace approximately every 30,000-60,000 miles depending on plug type (iridium recommended for longevity).

Timing Belt:

Inspect timing belt tensioner and idlers at 60,000 miles. Replace timing belt, tensioner, idlers, and water pump at 90,000-105,000 miles or 7-8 years.

Coolant Flush:

Replace engine coolant every 30,000-60,000 miles or 2-4 years. Use Mitsubishi Super Long Life Coolant (or equivalent blue long-life coolant).

Engine Oil:

0W-40 or 5W-30 synthetic oil meeting API SM or higher, ILSAC GF-4 or higher. Capacity: 4.7 liters (4.9 US quarts) with filter.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (e.g., Mitsubishi Super Brake Fluid).

Power Steering Fluid:

Mitsubishi Power Steering Fluid or Dexron III/Mercon ATF.

Windshield Washer Fluid:

Water and/or windshield washer fluid concentrate.

Engine Reliability:

The 4G63T engine is generally robust, but prone to head gasket failures under high boost or poor tuning. Connecting rod failures (stock rods) can occur at significantly increased power levels.

Clutch:

Stock clutch can wear quickly with aggressive driving or abuse. Upgraded clutches are common.

Acd/Ayc Pump:

The ACD pump and AYC hydraulic system can be prone to leaks or pump failure over time, requiring specialized diagnosis and repair.

Fuel Injectors:

Stock 550cc injectors can become clogged or fail, especially with fuel quality issues. Regular cleaning or replacement may be needed.

Turbocharger:

The TD05HR-16G turbocharger is reliable but requires proper lubrication and cooling. Failure can result from oil starvation or prolonged high heat.

📚 Vehicle History

Heritage:

Mitsubishi has a strong motorsport heritage, particularly in rallying with the Lancer Evolution series

Evo Lineage:

The Evolution VIII, introduced in 2003, represented a significant evolution from the Evo VII, featuring improved aerodynamics, updated suspension, and enhanced electronics. It was the first Evo to be officially sold in North America.

Key Updates Evo Viii:

Introduction of ACD and optional S-AYC, improved intercooler, revised turbocharger, stiffer body structure, and introduction to the US market

Production Years:

Lancer Evolution VIII produced from 2003 to 2005 (model years 2003-2005)

Manufacturing Location:

Japan (Mizushima Plant)

🏆 Awards & Recognition

Performance Awards:

Consistently lauded by automotive journalists and enthusiasts for its performance, handling, and rally-bred capabilities. Named 'Sports Car of the Year' by Car and Driver in 2004.

Enthusiast Ratings:

Highly regarded by the tuning and performance community for its potential for modification and its motorsport pedigree.

Homologation:

Built as a homologation special for FIA Group A rally regulations.