diagram MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

TitleNo.Issue
DateTitleNo.Issue Date
Body Manuals (Service
Manual)• Mirage, Lancer
(supplement)
• Lancer Cedia• Lancer Cedia(supplement)• Lancer Evolution VII
(supplement)
• Lancer Cedia(supplement)• Lancer Evolution VIII MR(supplement)
1036F52
1036K50
1036K51
1036K52
1036K531036K54Aug 1996
May 2000
July 2000
May 2001
Oct 2001Feb 2004
Electrical Wiring Diagrams
Service Manual• Lancer Evolution VIII
• Lancer Evolution VIII MR
(supplement)
1036K77
1036K80Jan 2003
Feb 2004
New Vehicle Manuals
• Mirage, Lancer• Mirage, Lancer
• Mirage, Lancer
• Mirage, Lancer• Lancer• Mirage, Lancer• Lancer
• Lancer
• Lancer Cedia• Lancer Cedia• Lancer Evolution VII• Lancer Cedia
• Lancer Cedia
• Lancer Evolution VII• Lancer Cedia• Lancer Evolution VIII• Lancer• Lancer
1036F30
1036F31
1036F32
1036F331036F341036F351036F36
1036F37
1036K301036K311036K321036K33
1036K34
1036K351036K361036K371036K381036K39Oct 1995
Jan 1996
Aug 1996
Jul 1997Jan 1998Oct 1998Jan 1999
Dec 1999
May 2000July 2000Jan 2001May 2001
May 2001
Jan 2002May 2002Jan 2003Feb 2003Dec 2003
Engine Service Manual
• 4G6 Engine• 4G6 Engine(supplement)
1039G46
1039G63Jan 2001
Jan 2003
Service Manuals
• Lancer Cedia• Lancer Cedia(supplement)• Lancer Evolution VII(supplement)• Lancer Cedia
(supplement)
• Lancer Cedia(supplement)• Lancer Evolution VII(supplement)
• Lancer Cedia
(supplement)• Lancer Evolution VIII(supplement)• Lancer (supplement)
• Lancer (supplement)
• Lancer Evolution VIII
MR (supplement)
1036K00
1036K01
1036K021036K031036K041036K051036K06
1036K07
1036K08
1036K09
1036K10May 2000
July 2000
Jan 2001May 2001Oct 2001Jan 2002May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004
Transmission Service
Manual• W5M51 ManualTransmission• W5M51 ManualTransmission(supplement)
• W6MAA Manual
Transmission
1039M17
1039M22
1039M23Jan 2001
Jan 2003
Jan 2003
Related information

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

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)18
Control system (6M/T)
The following changes have been made, based on the control system in the 4G63DOHCT/C engine fitted in the current
Lancer Evolution VIII.
* Addition of wastegate solenoid valve (1 valve –> 2 valves)
System Block Diagram
Air flow sensor (AFS)
Air temperature sensor
Atmospheric pressure sensor
Water temperature sensor
Throttle position sensor (TPS)
A/C switch
A/C load signal
Cam position sensor
Crank angle sensor
Alternator FR terminal
Vehicle speed sensor
Power steering fluid pressure
switch
Knock sensor
Intercooler water spray (auto)
Intercooler water spray (manual)
O
2sensor
Ignition switch –IG
Ignition switch –STPower supplyEngine ECU
Fuel injection control
Idle speed control (ISC)
Ignition timing control
Engine control relay control
Fuel pump relay control
A/C relay control
Fan motor control (radiator)
Fan relay control (A/C
condenser)
Alternator control
Air flow sensor filter reset
control
Fuel pressure control
Supercharging pressure
control
Secondary air controlIntercooler water spay control
Engine warning light control
O
2sensor heater control
Purge control
Diagnosis output
RAM data transmissionNo. 1 indicator
No. 2 indicator
No. 3 indicatorNo. 4 indicator
ISC servo (stepper motor)
Ignition coil A (No.1 – No.4)
Ignition coil B (No.2 – No.3)
Engine control relay
Fuel pump relay 2
Fuel pump relay 3
A/C relay
Fan controller (radiator fan)
Fan motor relay (HI, LOW)
(A/C condenser)
Alternator G terminal
Air flow sensor
Fuel pressure control valve
No. 1 wastegate solenoid valve
No. 2 wastegate solenoid valve
Secondary air control solenoid
valve
Intercooler water spray relay
Intercooler water spray lamp
Tachometer
Engine warning lights O
2sensor heater
Purge control solenoid valve
Diagnosis output terminal
Diagnosis output terminal (for
MUTII)

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)19
1. O2 sensor2. Air flow sensor3. Air intake sensor4. Throttle position
sensor
5. Cam position sensor6. Crack angle sensor7. Atmospheric pressure
sensor
8. Water temperature
sensor
9. Knock sensor•Power supply
• Ignition switch IG
•Ignition switch ST
•Vehicle speed sensor
• A/C switch
1. Injector2. ISC servo (stepper
motor)
3. Fuel pressure control
solenoid valve
4. No.1 wastegate solenoid
valve
5. No.2 wastegate solenoid
valve
6. Purge control solenoid
valve
7. Secondary air control
solenoid valve•Engine control relay
•Fuel pump relay 2, 3
•A/C relay
•Ignition coil
• Fan controller
Engine ECU
6. Purge control
solenoid valveCanister
7. Secondary air
control solenoid valveFrom fuel tank
Secondary
air valveBypass
valve
1. O2sensor
3. Fuel pressure
control solenoid valve
4. Throttle
position
sensor
7. Atmospheric pressure
sensor
3. Air intake
sensor2. Air flow sensor
4. No.1
wastegate
solenoid valve
5. No.2 wastegate
solenoid valve
Only operates on 6M/TWastegate actuatorFuel pressure
regulator
1. Injector5.Cam position sensor8.Water temperature sensor
9.Knock sensor
Crack angle sensor
Catalytic converter Air
intakeCheck
valve
2. ISC servo
Vacuum
tank
From fuel
pump To fuel
tank
Control system diagram

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

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).

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

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)
•Lancer Evolution VIIIMR (supplement)1036K53
1036K5410/2001
2/2004
•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 VIII
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 Sedia1036K005/2002•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 VIII
(supplement)1036K071/2003•W6MAA Manual
transmission1039M231/2003
•Lancer (supplement)1036K082/2003
•Lancer (supplement)1036K0912/2003
Related information
Precautions to be taken when servicing vehicles with seatbelts fitted with SRS Airbag and Pretensioners:
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 seatbelts
3.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).

MPI General13A2
General
Service information issued contains the changes noted below. Other service details remain unchanged.
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate solenoid valve on the 5 M/T is not
functional.
• Diagnosis code No. P1500 changed to P0622. <6M/T>
MPI system diagram
1.O2 sensor2. Air flow sensor3. Air intake sensor4. Throttle position
sensor
5. Cam position sensor6. Crack angle sensor7.Barometric pressure
sensor
8. Water temperature
sensor
9. Knock sensor•Power supply
• Ignition switch IG
• Ignition switch ST
•Vehicle speed sensor
• A/C switch
• A/C load signal
•Power steering fluid
pressure switch
•Alternator FR signal
•Intercooler water spray
switch (auto)
•Intercooler water spray
switch (manual)
1.Injector2. ISC servo (stepper
motor)
3.Fuel pressure control
solenoid valve
4.No.1 wastegate solenoid
valve
5. No.2 wastegate solenoid
valve
6. Purge control solenoid
valve
7. Secondary air control
solenoid valve•Engine control relay
•Fuel pump relay 2, 3
• A/C relay
•Ignition coil
• Fan controller
• Condenser fan relay (HI)
•Condenser fan relay
(LOW)
•Engine warning lamp
•Diagnosis output
• Alternator G terminal
•Intercooler water spray
relay
•Intercooler water spray
lamp
Engine ECU
6.Purge control
solenoid valveCanister
7.Secondary air
control solenoid valveFrom fuel tank
Secondary
air valveBypass
valve
1. O2sensor
3.Fuel pressure
control solenoid valve
4.Throttle
position
sensor
7. Barometric pressure
sensor
3. Air intake
sensor2. Air flow sensor
4. No.1
wastegate
solenoid valve
5.No.2 wastegate
solenoid valve
Only operates on 6M/TWastegate actuatorFuel pressure
regulator
1. Injector5.Cam position sensor8.Water temperature sensor
9.Knock sensor
Crack angle sensor
Catalytic converter Air
intakeCheck
valve
2.ISC servo
Vacuum
tank
From fuel
pump To fuel
tank