ABS MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

GENERAL – OVERVIEW OF THE LANCER EVOLUTION VIII MR02
Lancer Evolution VIII MR Lancer Evolution VIII
GHCT9ASNDFZRS (5M/T)GHCT9ASNDFZRS (5M/T)
SJDFZRS (6M/T)SJDFZRS (6M/T)
SJGFZGSRSJGFZGSR
Overview of the Lancer Evolution VIII MR
Differences from the Lancer Evolution VIII
SectionDifference from Lancer Evolution VIIIPage
Change to cam profile (6 M/T)15
Enlarged turbo nozzle diameter (6 M/T)16
Adoption of tail pipe with builtin sound proofing in exhaust main
silencer (6 M/T)17
Addition of wastegate solenoid valve (1 ‡ 2)*118
Change to catalyst volume (2.0 l. ‡ 1.5 l.) (6 M/T)
Engine
Enlarged engine oil cooler
Power trainChange to super AYC differential21
Installation of Bilstein shock absorbers*231
Optional BBS 17inch alloy wheels (new design)31
Drive control
Black finish on spokes of Momo genuine leather steering wheel
(Type A) (GSR)
Aluminium used in roof panel and side door beams41
Change to body colour41
Body
Boot lid opener fitted as standard (RS)
Addition of Evolution MR logo51Exterior
Outer panel on rear spoiler and “Lancer” logo changed to dark grey
Ornamentation added to carbon finish instrument panel
Centre panel changed to black
Shift lever with special Lancer Evolution MR logo plate (6 M/T)
Door trim fabric changed
Interior
Recaro seat fabric changed to suede finish allround (GSR)
Change to combination meter71
Black outs on extensions of headlights (discharge) and rear
combination lamps
Equipment
Adoption of roof aerial (RS)
Notes:*1: The No.2 wastegate solenoid valve does not operate in vehicles with 5 M/T transmission.*2: Joint development of special shock absorbers for the Lancer Evolution VIII MR, with the German firm, Bilstein.

ENGINE (4G6) – INT
AKE / EXHAUST SYSTEM (6 M/T)17
12 Exhaust silencer
A tailpipe with builtin soundabsorbing material has been adopted, in order to increase the silencing effect.
Structural diagram
Main exhaust
silencer
Tailpipe
(with builtin soundabsorbing material)Crosssection
A–A
Sound
absorbing
material

21Power Train – Differential
SECTION 2
POWER TRAIN
CONTENTS
Differential ..............................................21
Differential
The following changes have been made to the Super AYC differential.
• Reduced weight: The weight of the differential has been reduced by building the clutch case from aluminium, rather than
steel, and partially revising the thickness of the clutch discs.
• Improved strength and durability: Strength and durability have been raised by adopting special highstrength steel for the
hypoid gears (pinion gear and drive gear), instead of the cast steel used previously.
• Improved control when ABS is operating: Revisions to the communications with the ABSECU and the control procedure
during ABS operation, as well as active ACD/AYC control in high friction road surfaces, such as circuits, have led to
increased steerability and stability.
Structural Diagram
Hypoid gears
Clutch case
Clutch discs

31DRIVE CONTROL – Front suspension, Rear suspension, Wheels, Tyres
SECTION 3
DRIVE CONTROL
CONTENTS
Front suspension....................................31
Rear suspension .....................................31Wheels and Tyres ...................................31
Front suspension
Roadholding has been improved by the adoption of Bilstein shock absorbers.
(GRS: Standard; RS: Optional)
Notes :
* Bilstein are one of the world’s leading manufacturers of shock absorbers, and their products are used in racing vehicles
worldwide.
Rear suspension
• Roadholding has been improved by the adoption of Bilstein shock absorbers.
(GRS: Standard; RS: Optional)
•The specifications of the coil springs have been changed. (GSR)
Specifications
ItemLancer Evolution VIII MR GSRLancer Evolution VIII GSR
Wire diameter mm12
Average diameter mm88
Free length mm277287
Wheels and Tyres
BBS lightweight forged alloy wheels are provided as an option,
which reduces the unsprung weight. Fitting these BBS lightweight
wheels allows the Bilstein shock absorbers to display their fullrange of performance.
Note:
See “Section 8 Main Equipment” for detailed specifications.

REFERENCE MATERIAL – MAIN SPECIFICATIONS83
GHCT9AItem
SJDFZ
Classification No. È105
(B,D,W)106
(A,B,D,W)109
(B,D,W)110
(A,B,D,W)113
(B,D,W)
Front axle
weight830840¨850830
Rear axle
weight530¨¨¨540
Vehicle weight
kg
È
Total13601370¨13801370
Number of passengers5
Front axle
weight930940¨950930
Rear axle
weight705¨¨¨715
Weight
Gross vehicle
weight kg È
Total16351645¨16551645
GHCT9AItem
SJDFZSJGFZ
Classification No. È114
(A,B,D,W)117 (B,D,W)118
(A,B,D,W)119
(A,B,D,W)
Front axle
weight840¨850860
Rear axle
weight540¨¨¨
Vehicle weight
kg È
Total1380¨13901400
Number of passengers5
Front axle
weight940¨950960
Rear axle
weight715¨¨715
Weight
Gross vehicle
weight kg È
Total1655¨16651675
Notes :
The symbols after the Classification Numbers indicate the following equipment.
A: Air conditioning B: ABS D: ACD (Active Centre Differential) W: 17inch wheels

REFERENCE MA
TERIAL – MAIN EQUIPMENT86
Main Equipment
The “” symbol indicates standard equipment, and the “” symbol indicates a manufacturer’s option. The equipment may change, depending on the time of manufacture.
4WD
RSGSR
Equipment
5M/T6M/T
Aluminium turbollr
Intercooler water spray systemlll
W/out Intercooler water spray systemrr
Engine
Engine oil coolerlll
5speed manual (short stroke, high gear
ratio)l
6speed manual (short stroke)ll
Gear leverLeather
Front LSDHelical
Rear LSDMechanical
l
lll
Active Centre Differential (ACD)lll
Power
Train
Active Yaw Control Differential (AYC)rll
Bilstein shock absorbersrrl
Front strut tower barslll
205/65R15 94HlTyres
235/45ZR17rll
T125/70D16lSpare
tyre
T125/70D17rll
Steel (5hole)
(Offset : 46 mm)
(PCD:
114.3mm)15inch
¥ 6.0JJ
silverl
17inch
¥ 8.0JJrllSteel (5hole)
(Offset : 38 mm)
(PCD:114.3mm)
17inch
¥ 8.0JJ
(BBS)
rrr
Steel (5hole)
(Offset : 40 mm)
(PCD:
114.3mm)4.0T•
16inchl
Wheel
Steel (5hole)
(Offset : 30 mm)
(PCD:114.3mm)4.0T•
17inch
rll
Centre capBlackl
Power steeringlll
MOMOllSteering wheel (leather
type ; 3spoke; airbag)
MOMO
(black
spokes)
rrl
Tilt steering mechanism
Full cover
lll
Release switch
(gloss)
Parking brake
lever
Leather grip
l
15inch ventilated
disclFront
17inch ventilated
disc (BREMBO)rll
15inch ventilated
disc (drum in)l
Drive
Control
Brake
Rear
16inch ventilated
disc (drum in)(BREMBO)
rll
Note:
In the wheel columns, “PCD” is an abbreviation of “Pitch
Circle Diameter”, referring to the diameter of the pitch circle
of the installation holes.
4WD
RSGSR
Equipment
5M/T6M/T
4 ABS (sports ABS)rll
Pressure control valve (PCV)l
Drive
Control
Electronic Brake Force Distribution
System (EBD)rll
Central door lockingrrl
Boot lid openerlll
Fuel filler flap opener
Child protection
lll
Multimode keyless entryl
BlackllOuter door handles
Body colourl
Inside door handlesColouredlll
Power windows with safety mechanismsrrl
Windscreen (laminated glass)Green
Front door windows (UV absorbing
glass)lll
Greenll
Green, with sun
shadel
Rear window
glass (with
heating element)
Privacy glassr
GreenlllRear door
windows
Privacy glassr
GreenlllRear static
windows
Privacy glassr
BonnetAluminiumAir outlet
WingAluminium
RoofAluminium
lll
Body
Rear end crossbarll
Exclusive
front bumperBody colour
Exclusive
rear bumperBody colour
Windscreen
Rear window
Pillar, roof
Mouldings
(black)
Belt line
lll
Manual type (black)llDoor mirror
Electric stowable
remote control door
mirror (body colour)l
Front air damExclusive
extension
Rear air dam
lll
Exterior
Rear spoiler (large size)lll

REFERENCE MA
TERIAL – MAIN EQUIPMENT, COLD CLIMATE SPECIFICATIONS88
4WD
RSGSR
Equipment
5/MT6/MT
ABSrll
SRS airbags
Fuel level
Parking brake
Charge
Brake fluid
Engine check
Warning
lights
Door not properly closed
Lighting monitor warningBuzzer
Ignition key reminder warning
lll
Fixed time
intermittentll
Variable
intermittent(speed
sensitive)l
Windscre
en wipers2 speed
Mist spray
Equip
ment
Windscreen washer (synchronized with
wiper, 4jet)
lll
4WD
RSGSR
Equipment
5/MT6/MT
Rear
windowwiper /
washerFixed time intermittent,
synchronized with (R) gearpositionl
AM/FM tuner radio + MD player
+ DVDMMCS (DVD navigation
Mitsubishi MultiCommunication
System)r
Roof aeriallll
Roof and window aerial (diversity
aerial)r
W/out audiolll
Audio
parts
6 speakers (2 DIN compatible)r*3
Digital clock
Immobiliser system
lll
Manual heater
Air conditioning kit
ll
Equip
ment
Air
conditioning
Fully automatic air
conditioningl
Notes:
*3: Brackets for an aerial and radio are installed as standard.
Cold Climate Specifications
4WD
RSGSR
Equipment
5M/T6M/T
Battery
Weather strip silicon coating
Rear seat heater duct
Cold Climate Specification label
rrr
Door mirrors with heating elementsr

SECTION 22
MANUAL TRANSMISSION
CONTENTS
General........................................................1 Troubleshooting .........................................1
General
The following troubleshooting items have been changed along with the changes to the wiring. Troubleshooting points other than
those mentioned below remain unchanged, and are the same as on the existing Lancer Evolution VII/VIII.
Troubleshooting
1. Diagnosis Code ListMANUAL TRANSMISSION – GENERAL, TROUBLESHOOTING
221
Diagnosis code no.Diagnosis itemPage ref.
12Power supply voltage (valve power supply) systemBroken wire or short222
21Vehicle wheel speed sensor <FR> system <ACD fitted vehicles>Broken wire or short223
22Vehicle wheel speed sensor <FL> system <ACD fitted vehicles>Broken wire or short223
23Vehicle wheel speed sensor <RR> system <ACD fitted vehicles>Broken wire or short223
24Vehicle wheel speed sensor <RL> system <ACD fitted vehicles>Broken wire or short223
25Abnormal diameter tyres <ACD fitted vehicle>225
26Vehicle wheel speed sensor system (output signal abnormal) <ACD fitted vehicles>226
41TPS systemBroken wire or earthing227
42Short227
45Pressure sensor systemBroken wire or earthing228
46Earth wire broken228
47Abnormal power supply229
51Longitudinal G sensor systemBroken wire or short2210
52Sensor malfunction2211
56Lateral G sensor systemBroken wire or short2212
57Sensor malfunction2213
61Stop lamp switch systemBroken wire2214
62ACD mode switch systemSticking2215
63Parking brake switch systemShort or failing to return2216
65ABS monitor system <ACD+AYC fitted vehicles>Broken wire or ABS failure2217
74Proportional control valve <ACD> systemBroken wire or short2218
81Electrical pump relay systemBroken wire or short2218

MANUAL TRANSMISSION TROUBLESHOOTING2210
Code No.51 Longitudinal G sensor systemAssumed cause of concern
Code No.51 is output when the longitudinal G sensor signal
falls below 0.5V or rises above 4.5V.• Harness, connector malfunction
• Longitudinal G sensor malfunction
• ABSECU malfunction <AYC fitted vehicles>
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.14 longitudinal G sensor power voltage
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Measurement at D29 longitudinal G sensor connector
• Undo connector and measure on harness side
• Ignition switch: ON
(1) Voltage between 1 earth
OK:battery voltage
(2) Resistance between 3 – earth
OK:2Ω or less
D29
Harness side
connector
• Remove longitudinal G sensor
• Connect the special tool between D29 longitudinal
G sensor connector harness side connector and
longitudinal G sensor.
• Ignition switch: ON
• Voltage between 2 – body earth (when longitudinal
G sensor is set on a flat surface)
OK:2.4 – 2.6V
• Voltage between 2 – body earth (when longitudinal
G sensor is placed so that the label surface facesside
ways)
OK:3.3 – 3.7V
Connector check:D29, C38, C20, B109 <ACD +
AYC fitted vehicles> D29, C20, C38 <ACD fitted
vehicles>
NG > repair
Check harness between longitudinal G sensor – 4WD
ECU
• Check for broken output wire, earth, damage
Check harness between longitudinal G sensor – ABSECU <ACD+AYC fitted vehicles>
•Check output wire for earth, damage
NG > repair
Connector check:D29, C212, C210
NG > repair
Check harness between longitudinal G sensor –
ignition switch.
• Check for broken power supply wire, earth, damage
• NG > repair
Connector check:D29, C20, B109 <ACD + AYC
fitted vehicles> D29, C20, C38, <ACDfitted vehicles>
NG > repair
Check harness between longitudinal G sensor – ABS
ECU <ACD+AYC fitted vehicles>
•Check to see if earth wire broken or damaged
NG > repair
Check harness between longitudinal G sensor – 4WD
ECU <ACD fitted vehicles>
• Check to see if earth wire broken or damaged
NG > repair
MUTII/III Service data
• No.14 longitudinal G sensor voltage
OK:Refer to P.2232 (Service Data List)*2
NG > Refer to Group 35C – Troubleshooting*2
<ACD+AYC fitted vehicles> or 4WDECU <ACD fitted
vehicles> Replace
OK > intermittent malfunction
Replace longitudinal G sensor
MUTII/III Service data• No.14 longitudinal G sensor voltage
OK:Refer to P.2232 (Service Data List)*2
NG > Refer to Group 35C – Troubleshooting*2
<ACD+AYC fitted vehicles> or 4WDECU <ACD fitted
vehicles> Replace
OK > intermittent malfunction
label label
OK
NG
(1) NG
NG
(2) NG
OK
OK
OK
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING2211
Code No.52 Longitudinal G sensor systemAssumed cause of concern
At 10kph or over, with ABS and brakes not applied, code No.
52 is output in cases where G sensor indicates higher than
specified value.• Harness, connector malfunction
• Longitudinal G sensor malfunction
• ABSECU malfunction <ACD+AYC fitted vehicles>
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.14 longitudinal sensor voltage
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Longitudinal G sensor check (refer to P.2232)
*2
NG > replace
Measurement at C38 4WDECU connector
• ECU terminal voltage measurement
• Ignition switch: ON
• Voltage between 23 – earth
OK:2.4 – 2.6V (when vehicle is standing on flat
ground)
Connector check:C38
NG > repair
MUTII/III Service data
• No.14 longitudinal sensor voltage
OK:P.2232 Refer to (Service Data List)*2
NG > Replace 4WDECU
OK > Intermittent malfunction
Connector check:C38, D29, C20, B109
<ACD+AYC fitted vehicles> C38, C20, D29 <ACD
fitted vehicles> NG > repair
Check harness between longitudinal G sensor – 4WD
ECU
•Check to see if output wire is broken, earth, or
damaged
Check harness between longitudinal G sensor – ABS
ECU
<ACD+AYC fitted vehicles>
MUTII/III Service data
• No.14 longitudinal G sensor voltage
OK:Refer to P.2232 (Service Data List)*2
NG > Refer to Group 35C – Troubleshooting*2
<ACD+AYC fitted vehicles> or replace 4WDECU
OK > intermittent malfunction
NG
OK
OK
OK
NG
OK
OK