brake MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

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 – DETAILED SPECIFICATIONS85
GHCT9AItem
SNDFZSJDFZSJGFZ
1st2.7852.909¨
2nd1.9501.944¨
3rd1.4441.434¨
4th1.0961.100¨
5th0.8250.868¨
6th0.693¨
TransmissionGear ratio
Reverse3.4162.707¨
Front4.5294.583¨DifferentialReduction
ratio
Rear3.307¨¨
Power train
TransferReduction
ratio0.302¨¨
Main brake typeHydraulic:
Front : Disc
Rear : Disc¨¨
Parking brake typeMechanical
wheel brake¨¨
FrontMacPherson¨¨
Braking
system
Suspension
RearMultilink¨¨
CO when
unloaded : %,
HC : ppmCO: 0.1,
HC: 100¨¨
10/15 mode
g/kmCO: 0.67,
HC: 0.08,NOx: 0.08¨¨
Emission
gas
suppressionequipmentQuantity or concentration
of exhaust gas
11 mode g/testCO: 19.0,
HC: 2.20,
NOx: 1.40¨¨

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 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

MANUAL TRANSMISSION TROUBLESHOOTING2213
Code No.57 Lateral G sensor systemAssumed cause of concern
At 10kph or over, with ABS and brakes not applied, code No.
57 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.15 longitudinal sensor voltage
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Lateral G sensor check (refer to P.2220)
*2
NG > replace
Measurement at C38 4WDECU connector
•ECU terminal voltage measurement
• Ignition switch: ON
•Voltage between 11 – earth
OK:2.4 – 2.6V (when vehicle is standing on flat
ground)
Connector check:C38
NG > repair
MUTII/III Service data
•No.15 lateral sensor voltage
OK:P.2232 Refer to (Service Data List)*2
NG > Replace 4WDECU
OK > Intermittent malfunction
Connector check:C38, D31, C20, B109
<ACD+AYC fitted vehicles> C38, C20, D31 <ACD
fitted vehicles> NG > repair
Check harness between lateral G sensor – 4WDECU
•Check to see if output wire is broken, earth, or
damaged
Check harness between lateral G sensor – ABSECU
• Check to see if output wire earth or damaged
NG > repair
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 replace 4WDECU
OK > intermittent malfunction
NG
NG
OK
OK
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING2214
Code No.61 Stop lamp switch systemAssumed cause of concern
In cases where, at 15kph or over, the stop lamp switch stays
ON for 15 minutes or longer, code No.61 is output.• Brake pedal malfunction
•Stop lamp switch malfunction
• Harness, connector malfunction
•4WDECU malfunction
Remarks*1: Refer to ’005 Lancer Sedia Service Manual (No.1036K00)
Check height of brake pedal
(Refer to Group 35A – Vehicle Servicing)
*1
NG > Adjust
MUTII/III Service data
• No.56 Stop lamp switch
(1)Depress brake pedal
OK:ON
(2)Release brake pedal
OK:OFF
OK > Intermittent malfunction
Check connector:C118
NG > repair
Check stop lamp switch
(Refer to Group 35A – Brake pedal)
*1
NG > replace
Measurement at C118 stop lamp switch connector
• Undo connector, measure on harness side
•Voltage between 2 – earth
OK:battery voltage
Measurement at C37 4WDECU connector
• ECU terminal voltage measurement
•
Voltage between 38 earth
(1)Depress brake pedal
OK:battery voltage
(2)Release brake pedal
OK:1V or less
Connector check:C118, C22, C23, C37
NG > repair
Check harness between 4WDECU stop lamp
switch
• Check for broken or damaged output wire
NG > repair
Check harness between stop lamp switch – stop lamp.
• Check for broken or damaged output wireNG > repair
Connector check:C118, C31
NG > repair
Check harness between stop lamp switch – battery
•Check power supply wire to see if broken or
damaged
NG > repair
Connector check:C37
NG > repair
MUTII/III Service data
•No.56 Stop lamp switch
(1)Depress brake pedal
OK:ON
(2)Release brake pedal
OK:OFF
NG > replace 4WDECU
OK > Intermittent malfunction
NG
OK
OK
NG
OK
OK
OK
NG
OK
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING2216
Code No.63 Parking brake switchAssumed cause of concern
In cases where, at 15kph or over, the parking brake switch
remains ON for 15 minutes or more, code No.63 is output.• Parking brake switch malfunction
•Harness, connector malfunction
• ABSECU malfunction, <ACD+AYC fitted vehicles>
•4WDECU malfunction
Remarks*1: Refer to ’005 Lancer Sedia Service Manual (No.1036K00)
MUTII/III Service data
• No.62 Parking brake switch
(1)Apply parking brake lever
OK:ON
(2)Release parking brake lever
OK:OFF
OK > intermittent malfunction
When parking brake lever is
released, does the brake
warning lamp go off?
Measurement at D25, parking
brake switch connector
•Undo connector, take
measurement on harness side
•Ignition switch: ON
• Voltage between 1 – earth
OK:battery voltage
Connector check:D25
NG > repair
Check, and if necessary adjust,
the play in the parking brake
lever
(refer to Group 36 – Vehicle
Servicing)
*1
NG > Adjust
Check parking brake switch
(refer to Group 36 – Vehicle
Servicing)
*1
NG > adjust
Connector check:C37, D25,
C20NG > repair
Connector check:D25, C37,
C20, B109 <ACD + AYC fitted
vehicles>
D25, C20, C37 <ACD fitted
vehicles>
NG > repair
(1)Check harness between
parking brake switch – 4WD
ECU
• Check output wire for
earth, damage
(2)Check harness between
parking brake switch –
combi.meter
• Check power supply wire
for earth, damage
(3) Check harness between
parking brake switch – ABS
ECU.
<ACDAYC fitted vehicles>
• Check output wire forearth, damage
NG > repair
Replace hydraulic unit, ABS
ECUCheck harness between
parking break switch – 4WD
ECU
• Check output wire to see if
broken or damaged
NG > repair
MUTII/III Service data
• No.62 Parking brake switch
(1)Apply parking brake lever
OK:ON
(2)Release parking brake lever
OK:OFF
NG > replace 4WDECU
OK > intermittent malfunction
Check brake warning lamp bulb
NG > replace
Replace combi. meter
YESOK
(1) OK
(2) OK
NG
NG
NO
OK
OK
OK
(3) OK
OK
OK
OK

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