MITSUBISHI LANCER EVOLUTION VIII 2004 Owner's Guide

LANCER
EVOLUTION VIII
MR
FOREWORD
This manual contains details of the main changes to
the 2004 model Lancer Evolution VIII MR. Only
differences to the current Lancer Evolution VIII are
included, so please use this manual in conjunction with
the related information specified on the next page.
This information relates to the current vehicle (February
2004). Since specifications will change, some of the
information contained here will inevitably be
superseded.
Note that SI units are used in this manual. Old units are
not shown alongside them.
(However, old units are used for some figures we have
taken from existing documents).
Any opinions, requests, or questions concerning this
manual, should be written on the ‘Servicing
Comments Form’ at the end, and sent to us by fax.
February 2004
MITSUBISHI MOTOR CORPORATION
This manual is printed on recycled paper.
CONTENTS
General ..........................................
Body construction .......................
Standard measurements .............Changing welded panels.............
Rust treatment ..............................
Plastics parts................................
Body colour ..................................
Wiring layout and diagrams ........
Reference materials .....................
There are no changes to the shaded chapters,
so they are not included at all in this manual.
0
1
2
3
4
5
6
7
8

TitleNo.Issue dateTitleNo.Issue date
New model manualsBody Service Manuals
•Mirage, Lancer1036F3010/1995•Mirage, Lancer
(supplement)1036F528/1996
•Mirage, Lancer1036F311/1996•Lancer Sedia1036K505/2000
•Mirage, Lancer1036F328/1996•Lancer Sedia
(supplement)1036K517/2000
•Mirage, Lancer1036F337/1997•Lancer Evolution VII
(supplement)1036K525/2001
•Lancer1036F341/1998•Lancer Sedia
(supplement)1036K5310/2001
•Mirage, Lancer1036F3510/1998
•Lancer1036F361/1999
•Lancer1036F3712/1999
•Lancer Sedia1036K305/2000
•Lancer Sedia1036K317/2000
•Lancer Evolution VII1036K321/2001Wiring layout diagram
Service Manuals
•Lancer Sedia1036K335/2001•Lancer Evolution VIII1036K771/2003
•Lancer Sedia1036K345/2001•Lancer Evolution VII
MR (Supplement)1036K802/2004
•Lancer Evolution VII1036K351/2001
•Lancer Sedia1036K365/2002
•Lancer Evolution VIII1036K371/2003
•Lancer1036K382/2003
•Lancer1036K3912/2003
•Lancer Evolution VIII MR1036K402/2004
Service ManualsEngine Service Manuals
•Lancer Sedia1036K005/2000•4G6 Engine1039G461/2001
•Lancer Sedia1036K017/2000•4G6 Engine1039G631/2003
•Lancer Evolution VII
(supplement)1036K021/2001
•Lancer Sedia (supplement)1036K035/2001
•Lancer Sedia (supplement)1036K0410/2001Transmission Service
Manuals
•Lancer Evolution VII
(supplement)1036K051/2002•W5M51 Manual
Transmission1039M171/2001
•Lancer Sedia (supplement)1036K065/2002•W5M51Manual
transmission(Supplement)1039M221/2003
•Lancer Evolution VII
(supplement)1036K071/2003•W6MAA Manual
transmission1039M231/2003
•Lancer (supplement)1036K082/2003
•Lancer (supplement)1036K0912/2003
•Lancer Evolution VIII MR1036K102/2004
Related information
Precautions to be taken when servicing vehicles with seatbelts fitted with SRS Airbag and Pretensioners
Precautions
1. Incorrect inspection or servicing of SRS airbag and pretensioner fitted seatbelt parts, as well as any related
components, could lead to major damage or nonoperation as a result of sudden, unintentional operation of SRS
airbag and pretensioner fitted seatbelts (incorrect deployment).
2.In cases where heating from painting processes occurs, the SRSECU, driver side airbag module, passenger side
airbag module, pretensioner fitted seatbelts, and cross springs, should be removed.
• 93°C and above: SRSECU, driver side airbag module, passenger side airbag module, cross springs
• 90°C and above: pretensioner fitted seatbelts3.Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must,
without fail, be done by a Mitsubishi Motors authorized dealer.
4. Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must be
done paying scrupulous attention to the relevant service manual (particularly in the case of Group 52B – SRS
airbags).

01
GENERAL MODEL LINEUP , APPLIED VEHICLES
SECTION 0
GENERAL
CONTENTS
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
Model lineup...........................................01
Applied vehicle numbers .......................01Main specifications.................................02
ModelVersion’04 ModelGradeEngine ModelTransmissionFuel System
GHCT9ASNDFZ
SJDFZ
SJGFZ

RS
RS
GSR4G63
(2 000 DOHC 16 valve
intercooler turbo)W5M51 (4WD, 5M/T)
W6MAA (4WD, 6 M/T)MPI

02GENERAL MAIN SPECIFICATIONS
ITEMGHCT9A
SNDFZSJDFZSJGFZ
ClassOrdinary
UsePassenger
vehicle
Body
shapeSaloon
4490
1770
1450
Vehicle length mm
Vehicle width mmVehicle height mm
Distance between axles mm
2625
Front1515*1,
1500*21515*1Distance between
wheels mm
Rear1515*1,
1500*21515*1
Minimum ground clearance mm140
Length1880
Width1425
Interior dimensions
mm
Height1185
Front825
Dimensions
Body overhang mm
Rear875
Toein mm0±2
Camber *31º 00´ ±30´ or 2º 00´ ±30´
Castor3º 55´ ±30´
Front
wheels
King pin angle13º 45´
Toein mm3 ±2Rear
wheels
Camber1º 00´ ±30´
Driving
devices
Tyre size205/65R15 94H
235/45ZR17235/45ZR17
MAIN SPECIFICATIONS
Notes
1. *1 in the case of vehicles fitted with 17 inch tyres *2 in the case of vehicles fitted with 15 inch tyres
2.*3 it is possible to select from 3 types of camber. This is be set to 1˚ 00´ ±30´ when shipped from the factory.

11BODY CONSTRUCTION – GENERAL, BODY CONSTRUCTION SPECIAL FEATURES
SECTION 1
BODY CONSTRUCTION
CONTENTS
Summary .................................................11
Body construction ..................................11Roof..........................................................11
Doors........................................................12
Summary
• The roof and side door beams have been changed from steel to aluminium.
Body Construction Special Features
ROOF
Body is now lighter as a result of changing the roof panels to aluminium.
The body is also more rigid now as a result of additional support in pillar areas.
:shaded areas indicate parts that are the same as those used on current vehicle.
a
Roof panel
Rear pillar upper support
Centre pillar upper support
Front pillar upper support

12BODY CONSTRUCTION – BODY CONSTRUCTION SPECIAL FEATURES
DOORS
The body has been lightened as a result of using aluminium for the side door beams.
FRONT DOOR
Front door side door beam
Rear door side door beam
REAR DOOR
:shaded areas indicate parts that are the same as those used on current vehicle.a

21STANDARD DIMENSIONS – GENERAL, B TYPE (straight line measurements)
SECTION 2
STANDARD DIMENSIONS
CONTENTS
General ....................................................21
B type (straight line measurements) ....22Roof..........................................................22
General
Together with the changes relating to roof panel replacement, dimensions without the roof in place are specified.
B Type (straight line measurements)
ROOFunits mm
Diagram shows roof assembly removed condition.
NumberMeasurement pointsHole shapes – Sizes (mm)NumberMeasurement pointsHole shapes – Sizes (mm)
90Side roof rail inner corner91Side roof rail inner corner

31CHANGING WELDED PANELS GENERAL
SECTION 3
CHANGING WELDED PANELS
CONTENTS
Summary .................................................31
Body construction ..................................32
Aluminium alloy panels..........................35Repairing aluminium alloy panels ........35
Painting aluminium alloy panels .........310
General
Along with the change to an aluminium roof, important roof replacement details have been specified.

32CHANGING WELDED PANELS – ROOF
SymbolOperation details
Spot welding
MIG plug welding ( : two layers : three layers)
+ + + +MIG spot welding
MIG arc welding (continuous)
Rivet
Areas where rust inhibitor is applied. (Applied using
holes in butt welded locations)
Front pillar
upper supportCentre pillar
upper supportRear pillar upper
support
Note
: these welding points are done by manufacturer (not necessary during repairs).
:
black shading indicates areas where structural adhesive is applied.
AdhesiveTypeProduct name
Epoxy structural adhesiveSumitomo 3M Auto Mix Panel Bond 8115
SERVICE JOINTS

33CHANGING WELDED PANELS – ROOF
(Front pillar upper support (Rear pillar upper support
removed condition) removed condition)
IMPORTANT POINTS TO OBSERVE WHEN DOING THE
WORK
REMOVAL
1.When removing the roof, use a support to prevent the side
panels opening out or leaning in.
2. To cut weld the front or rear roof rail, remove the front pillar
upper support and rear pillar upper support.
3. Using a drill (
5mm), make a hole in through the centre of the
rivet, crack it, and remove. Normally, selfpiercing rivets are
used, but blind rivets may also be used.
For areas where there is adhesive, use a cold chisel or similar
tool to free and remove the roof.Selfpiercing rivetBlind rivet
Drill
Rivet
Roof panel