exterior MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

New Vehicle Manual
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 theinformation contained here will inevitably be
superseded.
Note that SI units are used in this manual. Old units arenot 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 ..........................................
Engine ...........................................
Power Train ...................................
Drive Control ................................
Body ..............................................Exterior..........................................
Interior ...........................................
Equipment.....................................
Reference Materials .....................
There are no changes to the shaded chapter,
so it is not included at all in this manual.
0
1
2
3
4
5
6
7
8

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.

51EXTERIOR – MARKINGS
SECTION 5
EXTERIOR
CONTENTS
Markings ..................................................53
Markings
An Evolution MR logo has been added.
Evolution MR logo

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

SERVICE MANUAL
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.
Please ensure that proper servicing is carried out
promptly, and that the information contained in the
relevant manuals is carefully read and understood
before doing any servicing work.
This information relates to the current vehicle (February2004).Since specifications will change, some of the
information contained here will inevitably besuperseded.
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 ..........................................
Fuel ................................................
Intake, Exhaust .............................
Manual Transmission ...................
Front Suspension.........................
Rear Suspension ..........................
Exterior..........................................
00
13
15
22
33
34
51

511EXTERIOR – GENERAL
SECTION 51
EXTERIOR
CONTENTS
General........................................................1
Front bumper ..............................................2
Adhesives ..............................................................2Front bumper .........................................................2
Markings .....................................................4
General
Important servicing information has been specified, along with the following changes and additions. Other servicing information,
however, remains the same as the information relating to the Lancer Evolution VIII.
• Changes and additions to front bumper components
• Changes to the position of the 3 diamonds badge, and addition to the EVOLUTION MR mark.

EXTERIOR – FRONT BUMPER512
Front bumper
Adhesives
Locations usedBrand
Three diamonds badgeDoublesided tape: ordinary tape, widely available on the market (width 20mm, thickness 0.8mm)
Front Bumper
Dismantling · Assembling
Locations where doublesided tape is applied
Doublesided tape: ordinary tape, widely available
on the market (width 20mm,thickness 0.8mm)
Crosssection AA Crosssection BB
Clip Clip

EXTERIOR – FRONT BUMPER513
Dismantling procedure
1.Three diamonds badge
2. Licence plate garnish
3. Licence plate bracket
4. Licence plate bracket ASSY5.Front bumper plate
6. Cover7.Front air dam panel
8. Front bumper lower plate ASSY
9. Front bumper lower reinforcement
ASSY
10. Front bumper upper plate ASSY11. Bumper net
12. Front bumper side cover
13. Bumper side net (LH)
14.Oil cooler duct
15. Bumper side net (RH)
• Water spray hose and nozzle (ref.
Section 15)
16.Front bumper side plate ASSY
17. Front bumper upper reinforcement
ASSY
18. Front bumper facing
AA
Important notes on dismantling
Front bumper side plate removal
Same as for existing front bumper rivet removal.
Important notes on assembly
Fitting front bumper side plate
Same as for existing front bumper rivet fitting.A
A

EXTERIOR MARKINGS514
Markings
Removal and fixing
1. Three diamonds badge 2. EVOLUTION MR mark
Important fitting notes
Fixing the markings
1. Positions
(1) Three diamonds badge
Boot lid press line
Vehicle centre point
AA

A

EXTERIOR MARKINGS515
(2) EVOLUTION MR MARK
Boot lid end line
Boot lid end line
2.Important fixing notes
(1) Clean and remove any grease from the body surface where markings will be
affixed, using unleaded petrol.
(2) Remove the paper backing on the rear of the markings, and fix in position.
(3) Remove the ‘application’ tape.
Note
• Do this job in an ambient temperature of 20 38
˚C in a dust free location.
•If temperature is less than 20
˚C,warm up the markings and the body where
they will be fitted to between 20 – 30
˚C.
•Stick the markings on and press firmly so that no air bubbles get trapped.
RJSY402025–46