2003 Mitsubishi Lancer Evolution VIII (Evo 8) Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII Model Nickname: Evo 8 Year: 2003 Codes Chassis Code: CT9A 👋 Introduction Market Position Positioning: High-performance compact sports sedan, celebrated...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Model Nickname:

Evo 8

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

High-performance compact sports sedan, celebrated for its rally-bred pedigree and advanced all-wheel-drive system.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Honda Civic Type R (later generations), Ford Focus RS.

Key Features

Performance Focus:

Iconic 4G63 engine, sophisticated AWD with ACD and AYC, potent braking, and stiff chassis.

Target Audience:

Enthusiasts, performance drivers, motorsport participants, and DIY mechanics seeking in-depth knowledge.

Manual Value

Purpose:

Essential resource for maintaining, diagnosing, and repairing the 2003 Mitsubishi Lancer Evolution VIII.

📋 Manual Details

Coverage Areas

Engines Covered:

4G63 (2.0L Turbocharged Inline-4)

Trim Levels Covered:

All US Market Trim Levels (e.g., GSR, MR)

Transmissions Covered:

6-speed Manual Transmission

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Fuel System, Ignition System, Exhaust System, Turbocharger System

Drivetrain:

Manual Transmission, Transfer Case, Front Differential, Rear Differential, ACD (Active Center Differential), Super AYC (Active Yaw Control)

Chassis:

Suspension System (Front & Rear), Steering System, Brake System (ABS, EBD)

Electrical:

Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, Wiring Diagrams

Body:

Exterior Panels, Interior Trim, Climate Control System, Safety Restraints (Airbags)

Procedures Included

Maintenance:

Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements

Diagnostics:

Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Common Issues and Solutions

Repair:

Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Service, Electrical Component Diagnosis and Replacement

Specifications:

Torque Specifications, Clearances, Timing Specifications, Component Dimensions

Special Tools:

Required Special Tools for Specific Repairs and Adjustments

Technical Depth

Depth:

Comprehensive (from basic fluid changes to full engine/transmission rebuilds)

📊 Manual Specifications

File Format

Searchable Text:

Printable:

Print Quality

Resolution:

High-resolution scans for clear text and diagrams

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Displacement:

2.0 Liters (1997cc)

Configuration:

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

Performance

Horsepower Usdm:

271 hp @ 6500 rpm

Torque Usdm:

273 lb-ft @ 3500 rpm

Fuel System

Induction:

Multi-point Fuel Injection (MPI) with Mitsubishi TD05HR-16G turbocharger and intercooler

Fuel Type:

Premium Unleaded (91 octane or higher recommended)

Cooling System

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent

Ignition System

Ignition Type:

Electronic Ignition (Distributorless Twin-Ignition Coil System)

🔧 Transmission

Standard

Type:

6-speed Manual Transmission (F5M51)

Optional

Type:

N/A (Evo VIII USDM was exclusively manual)

Features

Drivetrain Layout:

All-Wheel Drive (AWD) with Active Center Differential (ACD)

Rear Differential:

Helical Limited-Slip Differential (LSD) or Active Yaw Control (AYC) depending on trim/spec

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (Check manual for specific Mitsubishi recommendation)

Acd Fluid:

Mitsubishi Genuine ACD Fluid (or equivalent spec DEXRON III/VI)

Ayc Fluid:

Mitsubishi Genuine AYC Fluid (or equivalent spec DEXRON III/VI)

📐 Dimensions

Exterior

Length:

170.5 in (4330 mm)

Width:

69.1 in (1755 mm)

Height:

57.0 in (1450 mm)

Wheelbase:

103.3 in (2625 mm)

Weights

Curb Weight:

3,296 lbs (1,495 kg) - approximate

Gross Vehicle Weight Rating:

Approx. 4,000 lbs (1815 kg)

Wheel And Tire

Wheel Size:

17 x 8.0 inches

Bolt Pattern:

5x114.3 mm

Tire Size:

235/45R17

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

5 Stars (for models equipped with side airbags)

NHTSA Frontal Passenger:

4 Stars

IIHS Front Offset:

Good (for models equipped with side airbags)

Active Features

Yes, with Electronic Brakeforce Distribution (EBD)

Traction Control:

Yes (AYC/ACD system contributes)

Passive Features

Airbags:

Driver and Front Passenger Airbags, Optional Side Curtain Airbags

Seatbelts:

3-point front and rear seatbelts with pretensioners

Chassis Safety

Structural Enhancements:

Reinforced chassis for rigidity and impact resistance.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Rockford Fosgate premium audio system.

Display:

Digital odometer, trip computer, external temperature display.

Driver Assistance

Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow).

Active Yaw Control (AYC) for enhanced cornering stability (standard on some trims, optional on others).

Anti-lock Braking System with Electronic Brakeforce Distribution (EBD).

Connectivity

Original Features:

Limited by 2003 standards; no factory Bluetooth or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions, recommended)

Engine Air Filter:

Inspect every 7,500 miles (12,000 km), replace as needed

Cabin Air Filter:

Replace every 7,500 miles (12,000 km) or 12 months

Spark Plugs:

Replace every 30,000 miles (48,000 km) (Iridium type recommended)

Timing Belt:

Replace every 60,000 miles (96,000 km) or 5 years (Crucial component, failure is catastrophic)

Fluid Specifications

Engine Oil:

5W-30 Synthetic (API SN or higher, ILSAC GF-5 or higher), Capacity: 4.5 US quarts (4.3 L) with filter

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent (50/50 mix), Capacity: Approx. 7.8 US quarts (7.4 L)

Brake Fluid:

DOT 3 or DOT 4

Known Issues

Engine:

Head gasket failures (especially with aggressive tuning), turbocharger wear, valve stem seals.

Drivetrain:

ACD pump failure, clutch wear, rear differential bearing noise.

Chassis:

Subframe rust, wheel bearing premature wear, bushing degradation.

Electrical:

Mass Air Flow (MAF) sensor issues, idle air control (IAC) valve problems.

📚 Vehicle History

Brand Heritage

Motorsport Link:

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

Model Evolution

Eighth Generation:

Represents the first generation of the Lancer Evolution officially sold in the United States.

Key Upgrades From Evo Vii:

Revised front bumper, HID headlights, optional Recaro seats, larger intercooler, revised AYC system for some models.

Production

Production Years Globally:

2001-2003

Us Market Introduction:

Production Location

Factory:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver's 10Best list in 2003.

Motorsport Legacy:

Consistently lauded for its motorsport heritage and track-day capabilities.

Certifications

Emissions:

Meets US EPA and California ARB emissions standards for its model year.