🏷️ Basic Information

Make:

Mitsubishi

Model:

Lancer Evolution VIII

Year:

2004

Trim Level:

Evo VIII (Lancer Evolution VIII)

Vin Partial Prefix:

JA3AH86D

Engine Model Code:

4G63

Engine Code Common Name:

4G63T (Turbocharged)

👋 Introduction

Market Segment:

High-performance compact sedan / Rally homologation special

Reputation:

Iconic, enthusiast-focused vehicle renowned for its motorsport heritage and AWD performance.

Key Competitors Era:

Subaru Impreza WRX STI, Mitsubishi Lancer Evolution (previous generations), Subaru Impreza WRX, Ford Focus RS, Honda Civic Type R (later generations)

Performance Focus:

All-wheel-drive, turbocharged engine, advanced differential systems (ACD/AYC), stiff chassis, rally-bred engineering.

Driver Engagement:

Mechanical feedback, direct steering, communicative chassis, driver-centric interior.

Target Audience:

Mitsubishi Evo VIII owners, performance tuners, mechanics specializing in Japanese performance vehicles, enthusiasts performing DIY maintenance and repairs.

📋 Manual Details

Primary Coverage:

Complete Service and Repair for 2004 Mitsubishi Lancer Evolution VIII

Included Regions:

Global (with potential regional variations noted in specific sections)

Estimated Pages:

1500+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, diagnosis, lubrication, cooling, fuel injection, emission control, turbocharger system, timing belt/chain, seals, gaskets

Engine Electrical:

Ignition system, starting and charging system, ECU, sensors, actuators, wiring diagrams, diagnostic trouble codes (DTCs)

Transmission:

Manual transmission (Gated 6-speed Getrag), clutch system, transfer case, driveshafts, differentials (front and rear ACD/AYC)

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, wheel alignment specifications

Steering:

Power steering system, steering column, tie rods, rack and pinion assembly

Brakes:

Brake system components (Brembo calipers on Evo VIII GSR/MR), hydraulic system, ABS, EBD, parking brake, pad and rotor replacement

Body And Chassis:

Body panels, doors, windows, interior trim, chassis structure, rust prevention, underbody coatings, structural repairs

Electrical Body:

Lighting system, wipers, horn, power windows, central locking, mirrors, seats, HVAC controls, audio system wiring

Heating Ventilation Air Conditioning HVAC:

Refrigerant system, compressor, condenser, evaporator, blower motor, climate control unit

Safety Systems:

Airbag system, seat belt pre-tensioners, SRS module

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-ups, tire rotation

Diagnostics:

Troubleshooting guides for common and uncommon issues, diagnostic trouble code (DTC) interpretation, live data analysis (with appropriate scan tool)

Repair Procedures:

Step-by-step instructions for component removal, installation, overhaul, and adjustment for all major vehicle systems

Rebuilds:

Detailed instructions for engine, transmission, and differential rebuilds, including torque specifications, clearances, and component tolerances

Electrical Repair:

Wiring diagrams, connector pinouts, component testing, repair of electrical faults

Bodywork:

Panel replacement, dent repair, rust remediation, glass replacement

Software Updates:

Information on ECU flashing and potential software updates (where applicable and accessible)

Depth:

Comprehensive - Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and component-level repair.

Diagnostic Tools:

References to necessary diagnostic tools (e.g., MUT-III or compatible OBD-II scanners)

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text content

Resolution:

High-resolution (suitable for printing)

Printability:

Printable pages

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

4G63T

Engine Type:

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

Displacement:

2.0 Liters (1997 cc)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.8:1

Horsepower:

271 hp @ 6500 rpm (U.S. Spec)

Torque:

273 lb-ft @ 3500 rpm (U.S. Spec)

Redline:

7000 rpm (approx.)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Turbocharger:

Mitsubishi TD04-15G Turbocharger (or similar variant)

Oil Capacity:

4.5 US Quarts (4.2 Liters) with filter change

Recommended Oil Viscosity:

5W-30 (API SG or higher)

Coolant Capacity:

7.5 US Quarts (7.1 Liters)

Coolant Type:

Mitsubishi Genuine Long Life Coolant (or equivalent ethylene glycol-based coolant)

🔧 Transmission

Type:

6-speed Manual Transmission (Getrag Type)

Gear Ratios:

Refer to manual for specific gear ratios (1st-6th, Reverse)

Type:

N/A (Evolution VIII was exclusively manual)

All Wheel Drive System:

Super Active Center Differential (S-AYC) and Active Center Differential (ACD)

Rear Differential:

Active Yaw Control (AYC) rear differential (on GSR and MR models)

Transmission Fluid:

Refer to manual for specific GL-4 or GL-5 gear oil specifications

Transmission Fluid Capacity:

Approx. 2.0-2.2 Liters (Refer to manual for exact capacity)

📐 Dimensions

Length:

4490 mm (176.8 in)

Width:

1770 mm (69.7 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2630 mm (103.5 in)

Front Track:

1515 mm (59.6 in)

Rear Track:

1510 mm (59.4 in)

Curb Weight:

1450-1480 kg (3197-3263 lbs) (approx.)

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle placard

Towing Capacity:

Not Recommended

Trunk Volume:

Approx. 10.2 cu ft (subject to regional specifications)

🛡️ Safety Features

NHTSA Crash Test Front:

Refer to NHTSA documentation (may vary by model year and region)

NHTSA Crash Test Side:

Refer to NHTSA documentation (may vary by model year and region)

IIHS Crash Test Front:

Refer to IIHS documentation (may vary by model year and region)

IIHS Crash Test Side:

Refer to IIHS documentation (may vary by model year and region)

Active Center Differential:

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

Active Yaw Control:

AYC (Active Yaw Control) rear differential (on GSR/MR)

Anti Lock Braking System:

ABS (4-wheel, 4-channel)

Electronic Brakeforce Distribution:

EBD

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point front seatbelts with pre-tensioners, 3-point rear seatbelts

Body Structure:

Reinforced safety cell, energy-absorbing front and rear crush zones

💡 Technology Features

Audio System:

Factory AM/FM/CD player, often with Rockford Fosgate premium audio option.

Display:

Basic digital clock and radio display, often integrated with climate controls.

Traction Control:

Integral to the AWD system (ACD), but no separate 'Traction Control' button as commonly found on modern cars. Driver-selectable ACD modes manage traction.

Cruise Control:

Standard cruise control system.

Auxiliary Input:

Typically no standard auxiliary audio input; aftermarket solutions are common.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Oil And Filter Change:

Every 3,750 miles or 6 months, whichever comes first (for severe driving conditions typical of performance vehicles).

Engine Air Filter:

Inspect every 15,000 miles, replace as needed.

Cabin Air Filter:

Replace every 15,000 miles or annually.

Spark Plugs:

Replace every 30,000 - 45,000 miles (depending on type, e.g., platinum or iridium recommended for performance).

Transmission Fluid:

Replace every 30,000 miles or 2 years.

Transfer Case And Rear Differential Fluid:

Replace every 30,000 miles or 2 years.

Coolant Flush:

Replace every 30,000 miles or 2 years.

Timing Belt:

Inspect every 60,000 miles, replace as per manual recommendations (typically around 70,000-90,000 miles or 7 years).

Engine Oil Specification:

API SG/SH/SJ/SL/SM or ILSAC GF-I/GF-II/GF-III certified, SAE 5W-30 viscosity grade.

Transmission Fluid Specification:

Refer to manual for specific API GL-4 or GL-5 gear oil. Common recommendations include Red Line MTL or equivalent.

Transfer Case Fluid Specification:

Refer to manual for specific gear oil, often same as transmission or specific ACD fluid.

Rear Differential Fluid Specification:

Refer to manual for specific API GL-5 gear oil. If equipped with AYC, specific AYC fluid may be required.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid (high-performance synthetic recommended).

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid (or Dexron II/III ATF)

Engine:

Head gasket failures (especially in modified engines), connecting rod failures (high boost applications), turbocharger wear, valve seat recession on older/abused engines.

Transmission:

Clutch wear (due to performance driving), synchro wear in 1st/2nd gear (on high-mileage units), ACD/AYC pump failures.

Suspension:

Worn bushings, strut/shock absorber fatigue, wheel bearing failures.

Electrical:

Alternator issues, starter motor failures, SRS warning light illumination (related to airbag sensors/modules).

Cooling System:

Radiator leaks, thermostat failure, water pump leaks.

📚 Vehicle History

Motorsport Roots:

Mitsubishi has a deep and successful history in motorsport, particularly in the World Rally Championship (WRC) with the Lancer platform.

Evolution Lineage:

The Evolution VIII is the eighth generation of the Lancer Evolution, a performance variant born from homologation requirements for rallying. It represented a significant technological leap from the Evo VII.

Key Evolutions From Evii:

Introduction of the 6-speed manual transmission, upgraded ACD/AYC systems, improved chassis rigidity, and revised engine tuning.

Production Years For Eviii:

2003-2005

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Notable Variants:

GSR (standard), MR (Mamet/Ralliart, often with Bilstein suspension, revised AYC, carbon fiber roof, Recaro seats)

🏆 Awards & Recognition

Motorsport Titles:

While the Evo VIII itself wasn't a direct WRC car for that specific year, its platform and lineage are intrinsically linked to numerous WRC manufacturer and driver championships.

Automotive Press Accolades:

Consistently lauded by automotive media for its handling, performance, and rally-bred capabilities. Often featured in 'best performance cars' lists.

Performance Handling Score:

Exceptional (subjective rating based on contemporary reviews and enthusiast consensus).

Manufacturing Standards:

Produced under Mitsubishi's global manufacturing quality standards.