oil MITSUBISHI LANCER EVOLUTION VIII 2004 User Guide

INTAKE, EXHAUST – AIR CLEANER153
Air Cleaner
Removal and Fitting
Note
The parts marked with a symbol are plastic components which contain recycled paper. Please note the following:
•When fixing or removing, or after fitting parts, be careful not to knock or apply force to these components.
• When assembling, fix the air cleaner body ASSY securely to the air cleaner cover using the clamp on the body.
Remarks
Parts marked with a
symbol use plastic that may contain recycled paper, so when scrapped are burnable.
Removal procedure
1.Battery
2. Air duct
3. Air flow sensor connector4.Air cleaner assembly
5.Air flow sensor
6. Gasket
7. Air cleaner cover8.Air cleaner element
9.Air cleaner body assembly
10. Vacuum hose• Air pipe E, air hose D, air bypass valve
assembly, air bypass hose.
• Oil level gauge assembly11.Air intake hose
12.Wastegate solenoid valve connector
13. Vacuum hose connection
14. Wastegate solenoid valve assembly15.Air cleaner bracket

MANUAL TRANSMISSION TROUBLESHOOTING2218
Code No.74 Proportional valve <ACD> systemAssumed cause of concern
In cases where the proportional valve <ACD> control circuit
is shorting, code No.74 is output.• Proportional valve <ACD> malfunction
• Harness, connector malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.11 Proportional valve current <ACD>
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Measurement at F25 proportional valve <ACD>
connector
• Undo connector, take measurement on proportional
valve side
• Resistance between 2 3
OK:4.7Ωor less
Measurement at F25 proportional valve <ACD>
connector
• Undo connector, take measurement on harness side
• Resistance between 2 – body earth
OK:2Ω or less
Connector check:F25, F22
NG > repair
Check harness between proportional valve <ACD>
body earth
•Check earth wire to see if broken or damaged
NG > repair Replace hydraulic unit
Connector check:F25, F22, C30, C133, C38
NG > repair
Check harness between 4WDECU and Proportional
valve <ACD>
•Check output wire to see if broken, shorting, or
damaged
NG > repair
MUTII/III Service data
• No.11 Proportional valve current <ACD>
OK:refer to P.2232 (Service Data List)*2
NG: replace 4WD ECU
OK > Intermittent malfunction
Code No.81 Electric pump relay systemAssumed cause of concern
Output when the circuit on the pump relay coil side is broken
or shorting.• Electric pump relay malfunction
• Harness, connector malfunction
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III actuator test
• No.04 Electric pump operation
OK:the electric pump operating sound is audible
OK > Intermittent malfunction
Check electric pump relay (refer P.2253)
*2
Measurement at B127 electric pump relay connector
• Undo connector, take measurement on harness side
• Resistance between 1 – body earth
OK:2Ωor less
Connector check:B127
NG > repair
Check harness between electric pump relay body earth
•Check earth wire to see if broken or damaged
NG > repair Replace electric pump relay
Connector check:B127, C38
NG > repair
Check harness between 4WDECU and electric pump relay
•Check power supply wire to see if broken, shorting,
or damaged
NG > repair
MUTII/III Actuator test
• No.04 Electric pump operation
OK:the electric pump operating sound is audible
NG:replace 4WD ECU
OK > NG
OK
OK
OK
OK
OK
NG
OK
OK
NG
NG
OK
OK
OK
NG
OK

FRONT SUSPENSION – STRUT ASSEMBLY33A2
STRUT ASSY
Vehicles fitted with Bilstein shock absorbers
Dismantling and Assembly
NOTE
When applying grease, ensure that
none of it is left on the insulator
rubber as this could lead to insulator
rubber damage.
Dismantling procedure
1.Dust cover
2.Selflocking nut
3. Strut insulator ASSY
4. Upper spring seat5.Bumper rubber6. Dust cover
7. Coil spring8.Lower spring pad
9. Strut ASSY
Important note on dismantling
Procedure remains unchanged, apart from the following point:
Removal of selflocking nut
1. Compress the coil spring using the following special tool
• Spring compressor body (MB991237)
• Arm set (MB991238)
A

A
A
B

FRONT SUSPENSION – STRUT ASSEMBLY33A3
CAUTION
(1) To compress the coil spring securely, ensure that the
special tool is extended as far as the spring will allow,
then fitted evenly to the coil spring.
(2)There is a danger of special tool damage, so do not use
an impact wrench.
2. Using the following special tools, release the selflocking nut.
• Special spanner (MB991367)
• Pin (MB991385)
CAUTION
There is a danger of the lock nut inside the strut piston rodworking loose, so when loosening the selflocking nut, do
not use an impact wrench.
Important note on assembly
Fitting selflocking nut
1. With the coil spring compressed with the special tool,
temporarily tighten the selflocking nut.
2. Match up strut assembly hole in lower spring seat, and hole in
upper spring seat.
Remarks
Using a lever to align the holes can make this job easier.
3. Match both tips of coil spring precisely with the slots on the
spring seats, and release the special tool.
4. Using the special tool, tighten the selflocking nut to the
specified torque.
Tightening tor
que: 60 ± 10N·m
CAUTION
There is a danger of the lock nut inside the strut piston rod
working loose, so when loosening the selflocking nut, do
not use an impact wrench.
A

341REAR SUSPENSION GENERAL – SHOCK ABSORBER ASSY
SECTION 34
REAR SUSPENSION
CONTENTS
General........................................................1 Shock Absorber Assy................................1
General
Important servicing information has been specified along with.the adoption of Bilstein shock absorbers.
Shock Absorber Assy
Vehicles fitted with Bilstein shock absorbers
Dismantling and Assembly
Dismantling procedure
1. Selflocking nut
2.Washer
3. Bush B
4. Bracket ASSY5.Spring upper pad6. Collar
7.Bush A
8. Cup ASSY
9. Dust cover10.Coil spring
11. Bumper rubber
12. Shock absorber
Remarks
Carry out dismantling and assembly following existing servicing instructions
A
D

C

B
A

EXTERIOR – FRONT BUMPER513
Dismantling procedure
1.Three diamonds badge
2. Licence plate garnish
3. Licence plate bracket
4. Licence plate bracket ASSY5.Front bumper plate
6. Cover7.Front air dam panel
8. Front bumper lower plate ASSY
9. Front bumper lower reinforcement
ASSY
10. Front bumper upper plate ASSY11. Bumper net
12. Front bumper side cover
13. Bumper side net (LH)
14.Oil cooler duct
15. Bumper side net (RH)
• Water spray hose and nozzle (ref.
Section 15)
16.Front bumper side plate ASSY
17. Front bumper upper reinforcement
ASSY
18. Front bumper facing
AA
Important notes on dismantling
Front bumper side plate removal
Same as for existing front bumper rivet removal.
Important notes on assembly
Fitting front bumper side plate
Same as for existing front bumper rivet fitting.A
A

GENERAL INFORMATION - DETAILS OF CHANGES0-3
Main circuit Name of circuit Page Details of change
J/C - p.3-2• Partial changes to circuit and
destination system names in J/C(1) —
(6)
-• With the introduction of manual air
conditioning, the circuit used by the
fusible link No.2 has been changed.
• Wastegate solenoid valve 2 added to
load of special fuse No.3.
• Rating of special fuse No.10 changed
from 15A to 20A.
Power supply - p.3-10• Partial changes to destination system
names.
• Earth No.13 added.
• Rating of special fuse No.10 changed
from 15A to 20A.
• Partial changes to circuit details, due
to removal of sunroof.
Engine control - p.3-16• Rating of special fuse No.10 changed
from 15A to 20A.
• Earth No.13 added.
• Some changes to circuit, due to
addition of wastegate solenoid valve
2 (B-32).
• Partial changes, due to removal of
DVD-MMCS
Lighting Interior lights, boot interior
light, ignition key cylinder
illumination light, door not
closed indicator light-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Reversing lights -• Change to terminal number in J/C(2)
(C-119) on line linking reversing light
and rear combination light (LH).
(No.18 " No.19)Signal
Stop lights p.3-24• Spare connector (F-28) added, and
circuit partially changed.
Meters / Gauges -Meters
Remaining fuel warning
light, oil pressure warning
light, brake warning light,
seatbelt warning light-• Change to terminal number in J/C(1)
(C-07) on line inking J/B (general fuse
No.18) and combination meter. (No.4
" No.8)
• Change to terminal number in J/C(4)
(C-110) on line linking combination
meter and fuel gauge unit (sub).
(No.20 " No.21)
Door opening
controlElectric windows -• Change to terminal number in J/C(2)
(C-119) on line linking power window
main switch and diagnosis connector.
(No.12 " No.14)
Fully automatic air
conditioning-• Change to terminal number in J/C(1)
(C-07) on line linking J/B (general
fuse No. 18) and A/C-ECU. (No.6 "
No.4)
• Change to terminal number in J/C(5)
(C-06) on line linking A/C-ECU and
diagnosis connector. (No.8 " No.9)Air
conditioning
Manual air conditioning p.3-26• With the adoption of manual air
conditioning, a new circuit has been
installed.
Windscreen wipers and
washers-Safety and
visibility
Electric retractable remote
control door mirrors-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Circuit diagrams
M3000004500157

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-5
Main circuit Name of Circuit Circuit Diagram
J/B -!
J/C -#
Central junction -#
Power supply -#
Start up -!
Ignition -!
Charging -!
Engine control -#
Coolant -!
Headlights (excluding discharge type)!
Headlight (discharge type)!
Tail lights, side lights, licence plate lights, lighting monitor
warning buzzer!
Cabin lights, boot interior light, ignition key cylinder
illumination light, door not closed indicator light *2!
Fog lights!
Lighting
Headlight levelling system
!
Indicator lights, hazard warning lights!
Reversing lights *2!
Stop lights#
Signalling
Horn
!
Meters / Gauges *2!Meters
Remaining fuel warning light, oil pressure warning light,
brake warning light, seatbelt warning light *2
!
Electric windows *2!
Central door locking (vehicle not fitted with keyless entry)!
Door opening control
Central door locking (vehicle fitted with keyless entry)
!
Heater!
Fully automatic air conditioning!
Air conditioning
Manual air conditioning
#
List of Circuit Diagrams
M3000006000169
Notes:
1. This list of circuit diagrams indicates whether each circuit has been modified or added.
2. The “●” symbol indicates a circuit that has been modified or added. Diagrams for these circuits are included in
this supplement.
3. The “


” symbol indicates a circuit that is unchanged. Details of these circuits can be found in the existing
Electrical Wiring Diagram manual (’03-1 No.1036K77).
4. The “X” symbol indicates a circuit that is unrelated to the vehicle referred to in this manual.
5. The “*1” symbol marks circuits whose names have been changed the previous names.
6. The “*2” symbol marks circuits whose J/C terminal numbers have changed. For more information, please refer
to the “Details of Changes” table above.

WIRING DIAGRAMS - ENGINE TRANSMISSION1-2
ENGINE TRANSMISSION
M3010000400494
B-01 (1-black) Engine oil pressure switch
B-02 (1) Alternator
B-03 (4-grey) Alternator
B-04 (1) Starter
B-05 (1-black) Starter
B-06 (4-black) Throttle position sensorB-07 (2-black) Purge control solenoid valve
B-08 (7-black) Airflow sensor
B-12 (5-grey) Windscreen wiper motor
B-13X (1) Engine speed detection connector
B-14X (5) Starter relay
B-17X (4) Ignition coil relay
Connector
symbol -
B
-01
∫
-32
AC311230AB
Control harness
Battery harness

CIRCUIT DIAGRAMS - CENTRAL JUNCTION3-9
Fusible link (Relay box inside engine space)
Power supply circuitFuse No.Rated
current (A)ID
colourApplied loads
Battery / Alternator (fusible
link No. 6)320YellowO2sensor, secondary are
control solenoid valve, idle
speed control servo, ignition
coil 1, ignition coil 2, waste
gate solenoid valve 1, waste
gate solenoid valve 2, air
flow sensor, engine ECU,
engine control relay, cam
position sensor, crank angle
sensor, purge control
solenoid valve, fuel pressure
solenoid valve, radiator fan
control relay, register (for
injector)
1020YellowFuel pump relay 3, fuel pump
register, fuel pump & fuel
gauge unit (main)
Forward
direction of
vehicle