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Mitsubishi Lancer Evolution Evo 8 Complete Workshop Service Repair Manual 2003 2004

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII (Evo 8) Platform: CT9A Codes Chassis Code: CT9A Engine Code Primary: 4G63 👋 Introduction Market Position Positioning: High-performance rally-bred sedan,...
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Mitsubishi Lancer Evolution Evo 8 Complete Workshop Service Repair Manual 2003 2004
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VIII (Evo 8)
Platform:
CT9A
Codes
Chassis Code:
CT9A
Engine Code Primary:
4G63
👋 Introduction
Market Position
Positioning:
High-performance rally-bred sedan, renowned for its sophisticated all-wheel-drive system, turbocharged engine, and exceptional handling dynamics.
Competitive Analysis
Competitors:
Subaru WRX STI, Ford Focus RS, Audi S3, BMW M3 (E46)
Key Features
Performance Features:
Symmetrical All-Wheel Drive, Active Center Differential (ACD), Active Yaw Control (AYC), turbocharged intercooled engine, advanced aerodynamics.
Manual Value Proposition:
Provides essential, in-depth technical knowledge for owners and technicians to maintain, diagnose, and repair the Mitsubishi Lancer Evolution VIII effectively and efficiently.
📋 Manual Details
Coverage Areas
Market Focus:
Global (specifically covering models relevant to 2003-2004 production years)
Page Count
Estimated Pages:
Over 1500
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, connecting rods, valvetrain, timing system, lubrication, cooling system
Engine Electrical:
Ignition system, fuel injection system (ECU, sensors, actuators), starting system, charging system, engine control modules (ECM)
Transmission:
Manual transmission (Gearing, clutch, synchronizers, shift mechanisms, transfer case), ACD (Active Center Differential), AYC (Active Yaw Control) system
Drivetrain:
Front differential, rear differential, driveshafts, CV joints
Suspension:
Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (Multi-link, coil springs, dampers, anti-roll bar)
Brakes:
Brake system components (master cylinder, brake lines, calipers, rotors, pads), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Steering:
Power steering system (pump, rack, linkages), steering column, wheel alignment specifications
Electrical Body:
Lighting system, wipers, horn, power windows, power mirrors, central locking, interior controls
Electrical Chassis:
Wiring diagrams for all systems, fuse box locations and functions, relays, diagnostic connectors
Bodywork Chassis:
Chassis construction, body panels, doors, hood, trunk, interior trim, noise insulation
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, components, diagnosis
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, tire rotation, brake pad/rotor inspection and replacement
Troubleshooting:
Diagnostic charts, common problems and solutions, error code explanations
Repair:
Complete disassembly and reassembly procedures for all major components and systems
Diagnostics:
OBD-II diagnostic procedures, sensor testing, actuator testing, wiring harness testing
Calibration Adjustment:
Wheel alignment, idle speed adjustment, clutch adjustment (if applicable), ACD/AYC system calibration
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and complex electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, searchable text and clear diagrams
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Hp:
271 hp @ 6500 rpm (JDM/USDM specifications may vary slightly)
Torque Lb Ft:
273 lb-ft @ 3500 rpm (JDM/USDM specifications may vary slightly)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Multi-Port Injection
Fuel Type:
Unleaded gasoline, premium octane (91+ RON/91+ AKI recommended)
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission
Optional
Transmission Type:
None (Only manual transmission offered for Evo VIII)
Features
Drivetrain System:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and front helical LSD, rear mechanical LSD
Acd Modes:
Tarmac, Gravel, Snow
Ayc System:
Active Yaw Control (AYC) on rear differential for enhanced cornering stability
Clutch:
Hydraulically operated, single dry plate clutch
📐 Dimensions
Exterior
Length:
Approx. 4490 mm (176.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Weights
Curb Weight:
Approx. 1450-1500 kg (3197-3307 lbs) depending on trim and options
Cargo
Trunk Volume Cu Ft:
Approx. 11.0 cu ft (subject to regional variations)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not specifically rated by NHTSA as a whole, but individual crash test data exists from various agencies.
Active Features
Driver Assistance:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), ACD (Active Center Differential), AYC (Active Yaw Control)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags (depending on market)
Seatbelts:
3-point front and rear seatbelts with pre-tensioners and force limiters
Body Structure:
Reinforced chassis and safety cage construction
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD player with optional premium sound system (e.g., Rockford Fosgate).
Instrument Cluster:
Performance-oriented gauges including boost gauge, oil pressure, and oil temperature (depending on trim).
Driver Assistance
AWD Management:
Sophisticated electronic control of the AWD system (ACD and AYC) to optimize traction and handling in various conditions.
Connectivity
Diagnostics:
OBD-II compliant diagnostic port for engine and system data retrieval.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions may require more frequent changes).
Air Filter Replacement:
Every 15,000 miles (24,000 km)
Spark Plug Replacement:
Every 30,000-45,000 miles (48,000-72,000 km), depending on type (platinum or iridium).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years (critical component for 4G63 engine).
Fluid Specifications
Engine Oil Type:
API SG or higher, ACEA A2/A3, SAE 5W-30 or 10W-30 (check owner's manual for exact recommendations based on climate).
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with appropriate anti-corrosion additives).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 (specific Mitsubishi part numbers are detailed in the manual).
Differential Fluid:
API GL-5, SAE 80W-90 for rear differential; API GL-4 for front differential (specific Mitsubishi part numbers are detailed in the manual).
Brake Fluid:
DOT 3 or DOT 4 high-performance brake fluid.
Known Issues
Engine:
Head gasket failures (especially in modified engines), turbocharger wear, connecting rod bearing issues (under high load/poor maintenance).
Drivetrain:
ACD pump failures, AYC pump failures, differential wear (if abused or improperly maintained).
Suspension:
Strut mounts, ball joints, and bushings can wear over time due to the car's performance nature.
Electrical:
Intermittent issues with power windows, door lock actuators, and sometimes fuel pump relay failures.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's deep roots in the World Rally Championship (WRC) heavily influenced the development and engineering of the Lancer Evolution series.
Model Evolution
Evo Viii Introduction:
Introduced in 2003, the Evo VIII marked significant advancements over its predecessor, including a stronger engine, a new 6-speed transmission, and refined AWD electronics.
Production
Production Years Evo Viii:
2003-2005
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently recognized by automotive publications for its exceptional handling, performance, and value in the affordable sports car segment.
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