battery MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

ENGINE (4G6) – CONTROL SYSTEM (6 M/T)110
1. Supercharging pressure control
The maximum torque has been increased, compared to the 4G63DOHCT/C engine in the current Lancer Evolution VIII, by
installing an additional wastegate solenoid valve (increased from 1 to 2 valves).
By adding a parallel No.2 wastegate solenoid valve to the previous system, provides extra relief capacity for the pressure
applied to the wastegate actuator thus increasing the range of supercharging pressure..
The engine ECU raises the supercharging pressure even further, thus raising the maximum torque, by driving the No.2
wastegate solenoid valve when the engine approaches maximum torque.
The No.1 wastegate solenoid valve is essentially controlled in the same way as previously.
Air flow
sensor
Knock
sensor
Engine
ECUBatterySecondary air
control solenoidvalve
Secondary
air valve
Ignition
switch
Air
intakeBypass valveVacuum tank
Intercooler
Turbocharger
Wastegate
actu
ator No. 1
wastegate
solenoid
valve
No. 2 wastegate
solenoid valve Crank angle
sensor

REFERENCE MA
TERIAL – MAIN SPECIFICATIONS / DETAILED SPECIFICATIONS84
GHCT9AItem
SNDFZSJDFZSJGFZ
Minimum ground clearance m0.140¨¨
Max. speed (estimated) km/h180¨¨
Fuel consumption km/l (10/15 mode)9.69.7¨
Braking distance m (initial speed in
km/h) È49 (100)
[Vehicle with15" brakes]
43 (100)
[Vehicle with17" brakes]¨¨
Performance
Min. turning radius m5.9¨¨
Bore x stroke mm85.0 X 88.0¨¨
Compression ratio8.8 (Unleaded
Premium)¨¨
Max. output net [k/W r.p.m.]206 / 6500
(net)¨¨
Max. torque N•m/rpm.392 / 3500
(net)400 / 3500
(net) Ȩ
OpenBTDC 21˚BTDC 17˚
ȨIntake
ClosedABDC 59˚ABCD 63˚
Ȩ
OpenBBDC 58˚¨¨
Engine
Valve or
port timing
Exhaust
ClosedATDC 18˚¨¨
Fuel tank capacity (litres)50¨55
Type and performance of ignition
equipmentElectronic:
20˚~ 45˚¨¨
Type of spark plugsIGR7A,
IGR7AG,S22PRA7,VW22PRDA7¨¨
Battery capacity Ah34 (5), 48 (5)
or 52 (5)¨¨
Electrical
Equipment
Alternator output VA12 – 58, 90,
100 or 105¨¨
Detailed Specifications
These Detailed Specifications are based on submitted data, and may therefore differ from the actual equipment.
The
symbol indicates specifications which have changed from the previous model.

REFERENCE MATERIAL – MAIN EQUIPMENT87
4WD
RSGSR
Equipment
5M/T6M/T
Seat finishFabriclll
Standard typell
Recaro seatr*1r*1l
SlideAdjustment
mechanism
Reclining
lll
Front
Seat
Headrest
Low back bench seat (fixed)
ll
High back bench seat (fixed)
Rear
Seat
Centre arm rest (with cup
holder)
l
2 ¥ 3point with
ELR
With pretensioner
(driver’s seat &
front passenger
seat)
Front
Adjustable
seatbelt anchor
SRS
airbags
Rear2 ¥ 3point with
ELR / ALR + 1 ¥ 2
point belt
lll
Driver’s seatlllSRS
airbags
Front passenger’s seatrrl
Accessories box (1 DIN)ll
Parcel box (with lid)l
Parcel
boxes
Coin box
Glove box
lll
Standard typell
Large typeWith lidl
Shift boot ringl
Front seatlllAshtray
Rear seatl
Floor
console
Cup holder (front seat)lll
Centre panel (unique type)ll
2 DIN typel
HeadliningClothlll
Moulded type (soft)Front door
trim
Door pocket (driver’s
seat, front passenger’s
seat)
Interior
Rear doorMoulded type (soft)
lll
4WD
RSGSR
Equipment
5M/T6M/T
Boot interior trim
Boot interior
floor carpetNeedle punch
l
¥ 1 (front passenger’s seat)llRetractable
assistance
straps
¥ 3 (front passenger’s seat,
rear seats)l
Driver’s seatlll
Front passenger’s seatrrl
Ticket holder (driver’s seat)lll
Sun
visors
Vanity mirror (with lid)l
Internal
mirrorDay / night switchable
Interior
Foot rests
lll
44B20LlllBattery
55B24Lrrr
Halogen (low and
high beam)ll
Discharge (low
beam)
Halogen (high
beam)
Fog lamps
(halogen)
rrl
Position lightslll
Automatic lightsl
Headlight levellingrrl
Extension (black)rrl
Rear combination
lights
(clear type *2)lll
External
lightsHeadlight
assembly
(Clear
type *2)
Extension (black)rrl
High mount stop
lightRear shelf mounting
(bulb type)
Front cabin lights (with map light)
lll
Rear cabin lightslll
Interior
lights
Boot interior light
Combination meterSpecial type
Electric type analogue
speedometer
Twin type trip meter
Tachometer
Water temperature
Meter
gauge
Fuel
lll
Fog lightsrrl
High beam
Turn signal and hazard lights
Equip
ment
Indicator
lights
ACD
lll
Note : *1: 4point seatbelt asymmetric type seat*2: Turn signal lamps coloured amber

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

MPI – Troubleshooting13A3
Connector inspection : B32
Change No.2 wastegate solenoid valve.
Check connector:B19X
Inspect, repair harness between No.2 wastegate
solenoid valve and engine control relay.
• Check for broken wire and shorting.
Check connector:C49
Replace engine ECU
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check output wire to see if broken or shorting.
Check connector: C49
Replace engine ECU.
B32 No.2: measure at wastegate solenoid valve
connector
• Undo connector and take measurement on
solenoid valve side
• Resistance between 1 and 2
OK:29 35Ω(at 20˚C)
Measure at B32 No.2 waste gate solenoid valve
connector.
• Undo connector and take measurement on
harness side.
• Ignition switch ON:
• Resistance between 1 – earth
OK:battery voltage
Measurement at C49 engine ECU connector
•Engine ECU terminal voltage measurement
• Ignition switch: ON
• Voltage between 6 – Earth
OK:battery voltage
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check for damage to output wire.
Check harness between No.2 wastegate
solenoid valve and engine control relay.
•Check for damage to power supply cable.
TROUBLESHOOTING
1.Inspection procedures for different types of malfunction
Inspection procedure 37
No.2 Wastegate solenoid valve system <6M/T>
The No.2 wastegate solenoid valve controls excess pressure
introduced via the turbocharger wastegate actuator.
Assumed cause of concern
• No.2 wastegate solenoid valve malfunction
• Engine ECU malfunction
Repair
Repair
Repair
Repair
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NGRepair
NGRepair
Repair
OK OK OK

MPI – TROUBLESHOOTING13A4
2.ENGINE ECU CHECKS
21 List of terminal voltages
22 List of resistances and conductance between harness side connector – terminal
Terminal No.Check itemCheck item (engine condition)Normal value
41No.1 wastegate
solenoid valveIgnition switch ONBattery voltage
Engine: warm, idling (using premium petrol)1V or less
6No.2 wastegate
solenoid valve
<6M/T>Ignition switch: ONBattery voltage
Accelerating in 2nd gear with throttle full open (at least 3500 rpm)Voltage decrease
Terminal No.Check itemStandard value, normal condition (check condition)
4147No.1 wastegate solenoid valve2935Ω(at 20˚C)
647No.2 wastegate solenoid valve <6 M/T>2935 Ω(at 20˚C)

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 TROUBLESHOOTING222
2. Check procedures by diagnosis code
Remarks
In cases where other diagnosis codes are output, please refer to the relevant item.
Code No.12 Power supply voltage (valve power supply) systemAssumed cause of concern
If the 4WDECU power supply voltage drops below 9V or rises
above 18V, Code No.12 is output, indicating either a broken wire in
the power supply circuit, a short, or a drop in the battery voltage.• battery malfunction
• harness, connector malfunction
• 4WDECU malfunction
Battery inspection
NG > replace
MUTII/III Service data
• No.10 Battery voltage
OK:battery voltage
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•ECU terminal voltage measurement
• Ignition switch: ON
OK:battery voltage
Connector check: C38
NG > repair
MUTII/III Service data
•No.10 battery voltage
OK:battery voltage
NG > replace 4WDECU
OK > intermittent malfunction
Connector check:C38, C133, C212, C210
NG > repair
Check harness between ignition switch – 4WDECU
• Check to see if power supply wire broken, short, or
damage
NG > repair
OK
OK
OK
OK
NG
NG

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 TROUBLESHOOTING2212
Code No.56 Longitudinal G sensor systemAssumed cause of concern
Code No.56 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 <ACD+AYC fitted vehicles>
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.15 longitudinal G sensor power voltage
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Measurement at D31 lateral 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 D31 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 surf
ace faces
sideways)
OK:3.3 – 3.7V
Connector check:D31, C38, C20, B109 <ACD +
AYC fitted vehicles> D31, C20, C38 <ACD fitted
vehicles>
NG > repair
Check harness between lateral G sensor – 4WDECU
• Check for broken output wire, earth, damage
Check harness between lateral G sensor – ABSECU<ACD+AYC fitted vehicles>
•Check output wire for earth, damage
NG > repair
Connector check:D31, C212, C210
NG > repair
Check harness between lateral G sensor – ignition
switch.
• Check for broken power supply wire, earth, damage
NG > repair
Connector check:D31, C20, B109 <ACD + AYC
fitted vehicles> D31, C20, C38, <ACDfitted
vehicles>
NG > repair
Check harness between lateral G sensor – ABSECU
<ACD+AYC fitted vehicles>
MUTII/III Service data
•No.15 lateral 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 lateral G sensor
MUTII/III Service data
• No.15 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
(1) NG
NG
OK
(2) NG
NG
OK
OK
OK
OK
OK
OK