heating MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

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

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).

36CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
(2) When hammering, note that the panels stretch easily, so use a
wooden or plastic hammer.
Note
Reduce stretching and process hardening, and do not
leave hammer marks.
2. Check for distortion
Polish with #80 ~ #120 grade sandpaper, checking for any
distortion.
3. Removing distortions
Remove any distortions Using a levelling hammer and a torch,
correct any distortions.
Note
(1) Heat to about 250˚C to do this work.(2) Be careful when heating so as not to cause
discolouration when welding.
(3) Use a damp cloth to prevent heat increases which
could result in heat affecting heated area (distortion
etc.)
(4) Do not use drawing hammers which are used for
sheet steel,as this could result in cracking.
4. Polishing
Polish with a disk or a double action sander.
• Disk sander: #100 ~ #120
• Double action sander: #150 ~ #180
Note
Since the material is softer than sheet steel, choose a
polishing material that does not scour the surface deeply.
Repairing cuts and tears
When sheet steel panels are cut, torn, or have holes, repair using
CO
2MIG welding.However, with aluminium alloy panels, use MIG
or TIG welder and use argon gas (inert gas) as shield gas.
Extent of distortion from welding
Gas welding (large distortion) > TIG welding > MIG welding (little
distortion).
Here we explain the MIG welding process, where distortion
resulting from welding is small.

37CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
MIG welding procedure
1.Repairing sheet metal
These should be repaired by heating the damaged part gently,
and lightly hammering. The areas stretched by hammering out
should be cut away using an air saw.
Note
(1) Take care not to overstretch or damage the panel.
(2) The gaps at the joint areas should be as narrow as
possible.
2. Welding
This work should be done using equipment designed for
aluminium welding or equipment that can be used for bothaluminium and steel plate welding.
• Welding wire: 5356, 5556, 5183 (JIS classifications)
• Wire dia.: 0.8 or 1.0mm
(1) Remove any grease from welding areas using white spirit
or similar.
(2) Immediately prior to welding, remove any oxidation film
with a stainless steel wire brush (including the rear side), and
carry out the work immediately after cleaning.
Note
To minimize distortion and material melting and coming
away, weld a little at a time, rather than welding long
stretches.
3.Inspecting welded areas
After finishing off areas sanded with #100 disk sander, check
that there are no inadequately welded parts (red check).
Note
The panel surface should not be excessively sanded away.
4.Checking for distortions
Polish with #80 ~ #120 sandpaper, and check for distortion.
5. Removing distortions
Remove any distortions by pressing out using a levelling
hammer and a torch.
Note
(1) Heat to approx. 250˚C to do this work
(2) Take care when heating so that welding can be done
without heating causing any discolouration

38CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
(3) Use a damp cloth to prevent temperature rising and
causing distortion or other effects in the area beingheated.
(4) Do not use levelling hammers which are used for sheet
steel as they can cause cracking.
6. Finishing
Finish off with #100~#120 grade disk sander.
Note
As spark marks and carbon adhesion can have an
adverse effect during painting,remove completely using a
stainless steel wire brush.
Other welding
1. TIG welding
The process is basically the same as MIG welding, using the
same arc welder, but instead of using an electrode wire, a rodcoated with flux is used.
To help prevent distortion from the heat generated in welding,
and poor quality welding, this job should be done by someone
with suitable training and practice.
• Welding rod: 5356, 5556, 5183 (JIS classification)
• Diameter: 1.6mm
2. Gas welding (oxyacetylene)
In essence, if gas welding can be done, then a welding rod
and flux (for cleaning and reducing oxide inclusions) can beused.
To help prevent distortion from the heat generated in welding,
and poor quality welding, this job should be done by someone
with suitable training and practice.
• Welding rod: 5356, 5556, 5183 (JIS classification)
• Diameter: 1.6mm
(1) Flux is made to adhere by heating the welding rod.

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).

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-6
Main circuit Name of Circuit Circuit Diagram
Windscreen wipers, washers *2!
Rear wiper, washer!
Demister (vehicle not fitted with fully automatic A/C)!
Demister, door mirror heating elements (vehicle fitted with
fully automatic A/C)!
Safety / Visibility
Electric retractable remote control door mirrors *2
!
Spare Audio connectors *1,2!
DVD-MMCS X
Clock *1,2!
Accessories
Cigar lighter, ashtray illumination light
!
ABS#
ACD (vehicle not fitted with AYC)#
ACD, AYC#
SRS airbags, seatbelt pre-tensioners (vehicle not fitted
with side airbags)!
SRS airbags, seatbelt pre-tensioners (vehicle fitted with
side airbags)!
Sun roof X
Ignition key reminder buzzer!
Intercooler water spray *2!
Engine immobiliser system#
Security alarm!
Spare connectors for fog lights!
Special Equipment
Spare general connectors *2
!

COMPONENT INSTALLATION POSITIONS - J/C3-2
J/C
Note :
In an actual vehicle, any of the terminals connected in the J/C
may be used. Therefore, the terminal numbers given in the
circuit diagrams may not coincide with the terminal arrangement
in the actual vehicle.
• Windscreen wiper
& washer
• Indicator lights,
hazard warning
lights
• Tail lights, side
lights, licence
plate lights,
lightning monitor
warning buzzer• Fog lights
• Headlights
• Headlight levelling
system
• Rear wiper /
washer
Full auto
A/C
General
spare
connector
Clock
Spare audio
connector
• Warning
lights
• Meter
gauge
• ACD
• Engine
control
J/B
General fuse
()18
General
spare
connector
Fog light
Spare audio
connector
• Demister (Vehicle
w/out full auto A/C)
• Demister, door
mirror heating
element (vehicle
with full auto A/C)
• Heater
• Full auto A/C
• Manual A/C
Cigar lighter
Ashtray
illumination
light
Clock
ACD
Headlight
levelling
system
Indicator light
Hazard
warning lights
Intercooler
water spray
General fuse15
• Meter gauge
• Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer

CIRCUIT DIAGRAMS - J/C3-4
J/C (cont’d)
•Ignition key
reminder buzzer
•Windscreen wiper
& washer
•Security alarm
•Central door
locking
•Indicator lights,
hazard warning
lights•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer
•Electric
retractable
remote control
door mirror
•Electric windows
•Heater
•Fog lights•Full auto A/C
•Headlights
•Manual A/C
•Rear wiper /
washer
•Cabin lights, boot
interior light,
ignition key
cylinder
illumination light,
door not properly
closed indictor
light
•Ignition key reminder
buzzer
•Intercooler water
spray
•Security alarm
•Central door locking
(vehicle with keyless
entry)
•Cabin lights, boot
interior light, ignition
key cylinder
illumination light,
door not properly
closed indictor light
Fog lights
•Clock
•Indicator
lights,
hazard
warning
lights
•ABS
•ACD
Headlight
levelling
systemElectric
retractable
remote
control door
mirror•Warning lights
•Starter
Headlight
levelling
system
Fog lights
Cigar lighter
Ashtray illumination light
•Demister
(vehicle
w/out full
auto A/C)
•Demister,
door
mirror
heating
element
(vehicle
with full
auto A/C)
•Heater
•Full auto
A/C
•Manual
A/C
ACD
Intercooler
water spray
Indicator
lights,
hazard
warning
lights
Meter gauge