lights MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

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.

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)

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

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

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-5
Main circuit Name of Circuit Circuit Diagram
J/B -!
J/C -#
Central junction -#
Power supply -#
Start up -!
Ignition -!
Charging -!
Engine control -#
Coolant -!
Headlights (excluding discharge type)!
Headlight (discharge type)!
Tail lights, side lights, licence plate lights, lighting monitor
warning buzzer!
Cabin lights, boot interior light, ignition key cylinder
illumination light, door not closed indicator light *2!
Fog lights!
Lighting
Headlight levelling system
!
Indicator lights, hazard warning lights!
Reversing lights *2!
Stop lights#
Signalling
Horn
!
Meters / Gauges *2!Meters
Remaining fuel warning light, oil pressure warning light,
brake warning light, seatbelt warning light *2
!
Electric windows *2!
Central door locking (vehicle not fitted with keyless entry)!
Door opening control
Central door locking (vehicle fitted with keyless entry)
!
Heater!
Fully automatic air conditioning!
Air conditioning
Manual air conditioning
#
List of Circuit Diagrams
M3000006000169
Notes:
1. This list of circuit diagrams indicates whether each circuit has been modified or added.
2. The “●” symbol indicates a circuit that has been modified or added. Diagrams for these circuits are included in
this supplement.
3. The “


” symbol indicates a circuit that is unchanged. Details of these circuits can be found in the existing
Electrical Wiring Diagram manual (’03-1 No.1036K77).
4. The “X” symbol indicates a circuit that is unrelated to the vehicle referred to in this manual.
5. The “*1” symbol marks circuits whose names have been changed the previous names.
6. The “*2” symbol marks circuits whose J/C terminal numbers have changed. For more information, please refer
to the “Details of Changes” table above.

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
!

3-1
SECTION 3
CIRCUIT DIAGRAMS
CONTENTS
J/C ............................................................3-2
Central Junction .....................................3-8
Power Supply ........................................3-10
Engine Control ......................................3-16
Signalling
Stop lights ........................................................3-24
Air Conditioning
Manual A/C ......................................................3-26
Special Equipment
ABS ..................................................................3-32
ACD (vehicle without AYC) ..............................3-40
ACD, AYC ........................................................3-48
Engine immobiliser system ..............................3-58

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

COMPONENT INSTALLATION POSITIONS - J/C3-3
•Windscreen wiper
& washer
•Indicator lights,
hazard warning
lights
•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer•Fog lights
•Full auto A/C
•Headlights
•Headlight levelling
system
•Manual A/C
•Cooling•Windscreen wiper
& washer
•Electric retractable
remote control
door mirror
•Cabin lights, boot
interior light,
ignition key
cylinder
illumination light,
door not properly
closed indictor light
•Heater
•Full auto A/C
•Manual A/C
•ABS
•ACD
Meter
gauge
Diagnosis
meterVehicle
speed
sensor
General
spare
connector
Power
window
•Windscreen
wiper
& washer
•Indicator lights,
hazard warning
lights•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer
•Fog lights
•Headlights•Ignition key
reminder buzzer
•Windscreen wiper
& washer
•Indicator lights,
hazard warning
lights
•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer•Electric windows
•Fog lights
•Headlights
•Rear wiper /
washer
•Windscreen
wiper &
washer
•Indicator
lights, hazard
warning lights
•Tail lights, side
lights, licence
plate lights,
lighting
monitor
warning
buzzer
•Fog lights
•Headlights
•Rear wiper /
washer
•Reversing light
•Rear wiper /
washer
Rear wiper /
washer
Reversing
lightDiagnosis
connector
J/B
General fuse
()5