lock MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

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 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

INTAKE – EXHAUST – VEHICLE SERVICING152
1) Wastegate actuator misoperation
2) Wastegate valve misoperation3) Wastegate actuator rubber hose detachment, cracking.
2. Boost pressure control system inspection <6M/T>
Note
The driving test, which is done with the throttle fully open,
must be done in a safe place with two people in the vehicle.
The person sitting in the passenger seat should take thereading of the values on the pressure gauge.
(1) Remove hose (black) from No.1 wastegate solenoid valve, then
connect a threeway coupling between the hose and the
solenoid valve.
(2) Connect a hand vacuum pump to the threeway coupling.
(3)Remove boost hose from the wastegate actuator control boost
nipple on the air outlet fitting, and fit a plug over the nipple.
(4)Apply a vacuum whilst covering and releasing the tip of the
hose to check the vacuum condition.
(5) Ignition switch to “LOCK” (OFF) position.
(6) Remove wastegate solenoid valve connector.
(7) Apply a vacuum whilst covering and releasing the tip of the
hose, to check the vacuum condition (stop the hose tip with a
plug when driving).
Note
When vacuum condition is not normal, it may be assumed that
there is a problem with the wastegate actuator, wastegate solenoid
valve, or hose.
Engine conditionBoost hose tipNormal condition
Stop (ignition
switch:“ON”
position)ReleasedVacuum leaks
CoveredVacuum is maintained
Idle running after
warming up.Vacuum leaks
Engine conditionBoost hose tipNormal condition
Stop (ignition s
witch:
“ON” position)ReleasedV
acuum leaks
CoveredVacuum is maintained
Accelerating with
throttle full open in
2nd gear (at least
3500rpm)Vacuum leaks
Air cleaner
No.1 Wastegate
solenoid valve
No.2 Wastegate
solenoid valve
Wastegate
actuator
Boost hose

MANUAL TRANSMISSION TROUBLESHOOTING2215
Code No.62 ACD mode switch systemAssumed cause of concern
In cases where the ACD mode switch remains ON for 60
seconds or more, code No.61 is output.• ACD mode switch malfunction
• Harness, connector malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.63 ACD mode switch
(1)Press ACD mode switch
OK:ON
(2)Release ACD mode switch
OK:OFF
OK > intermittent malfunction
Check ACD mode switch (refer to P.2253)
*2
NG > replace
Measurement at C134 ACD mode switch connector
• Undo connector, take measurement on harness side
•Ignition switch: ON
• Voltage between 2 – earth
OK:battery voltage
Measurement at C37 4WDECU connector
•Measure ECU terminal voltage
• Ignition switch: OFF
•Voltage between 47 – earth
(1)Press ACD mode switch
OK:battery voltage
(2)Release ACD mode switch
OK:1V or less
Connector check:C37
NG > repair
MUTII/III Service data
• No.63 ACD mode switch
(1)Press ACD mode switch
OK:ON
(2)Release ACD mode switch
OK:OFF
NG > replace 4WDECU
OK > intermittent malfunction
Connector check:C134, C209, C210
NG > repair
Check harness between ACD mode switch – ignition
switch
•Check for broken power supply wire, damage
NG > repair
Check harness between junction block – combi. Meter
•Check power supply wire for earth, damage
NG > repair
Connector check:C134, C133, C37
NG > repair
Check harness between 4WDECU – ACD mode
switch
• Check to see if output wire is broken or damagedNG > repair
NG
NG
NG
OK
OK
OK
OK
OK
OK
OK

FRONT SUSPENSION – STRUT ASSEMBLY33A2
STRUT ASSY
Vehicles fitted with Bilstein shock absorbers
Dismantling and Assembly
NOTE
When applying grease, ensure that
none of it is left on the insulator
rubber as this could lead to insulator
rubber damage.
Dismantling procedure
1.Dust cover
2.Selflocking nut
3. Strut insulator ASSY
4. Upper spring seat5.Bumper rubber6. Dust cover
7. Coil spring8.Lower spring pad
9. Strut ASSY
Important note on dismantling
Procedure remains unchanged, apart from the following point:
Removal of selflocking nut
1. Compress the coil spring using the following special tool
• Spring compressor body (MB991237)
• Arm set (MB991238)
A

A
A
B

FRONT SUSPENSION – STRUT ASSEMBLY33A3
CAUTION
(1) To compress the coil spring securely, ensure that the
special tool is extended as far as the spring will allow,
then fitted evenly to the coil spring.
(2)There is a danger of special tool damage, so do not use
an impact wrench.
2. Using the following special tools, release the selflocking nut.
• Special spanner (MB991367)
• Pin (MB991385)
CAUTION
There is a danger of the lock nut inside the strut piston rodworking loose, so when loosening the selflocking nut, do
not use an impact wrench.
Important note on assembly
Fitting selflocking nut
1. With the coil spring compressed with the special tool,
temporarily tighten the selflocking nut.
2. Match up strut assembly hole in lower spring seat, and hole in
upper spring seat.
Remarks
Using a lever to align the holes can make this job easier.
3. Match both tips of coil spring precisely with the slots on the
spring seats, and release the special tool.
4. Using the special tool, tighten the selflocking nut to the
specified torque.
Tightening tor
que: 60 ± 10N·m
CAUTION
There is a danger of the lock nut inside the strut piston rod
working loose, so when loosening the selflocking nut, do
not use an impact wrench.
A

341REAR SUSPENSION GENERAL – SHOCK ABSORBER ASSY
SECTION 34
REAR SUSPENSION
CONTENTS
General........................................................1 Shock Absorber Assy................................1
General
Important servicing information has been specified along with.the adoption of Bilstein shock absorbers.
Shock Absorber Assy
Vehicles fitted with Bilstein shock absorbers
Dismantling and Assembly
Dismantling procedure
1. Selflocking nut
2.Washer
3. Bush B
4. Bracket ASSY5.Spring upper pad6. Collar
7.Bush A
8. Cup ASSY
9. Dust cover10.Coil spring
11. Bumper rubber
12. Shock absorber
Remarks
Carry out dismantling and assembly following existing servicing instructions
A
D

C

B
A

Related documentation
Cautionary Note regarding servicing of vehicles fitted with SRS airbags and/or seatbelts with
pre-tensioner systems.
Warnings:
1. Incorrect inspection or servicing of a component part of the SRS airbag system or seatbelt pre-tensioner system, or
a part relating to these systems, may cause accidental operation (deployment) of the SRS airbag or seatbelt pre-
tensioners, or may cause these systems to be disabled, leading in either case the risk of serious injury.
2. If parts may be affected by heat during painting operations, then those parts must be removed in advance. This
applies to the SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors, and pre-tensioner seatbelts.
• 93ºC or above : SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors
• 90ºC or above : Pre-tensioner seatbelts
3. The component parts of the SRS airbag system or seatbelt pre-tensioner system, and parts relating to these
systems, must always be inspected and serviced by a Mitsubishi dealer.
4. Service personnel must read the relevant service manuals (particularly, Section 52B – SRS Airbags) carefully and
thoroughly, before inspecting or servicing the component parts of the SRS airbag system or seatbelt pre-tensioner
system, and parts relating to these systems.
Title of Document No. Date of
IssueTitle of Document No. Date of
Issue
Body Manuals (Service Manual)
• Mirage, Lancer (supplement)
• Lancer Cedia
• Lancer Cedia (supplement)
• Lancer Evolution VII
(supplement)
• Lancer Cedia (supplement)
• Lancer (supplement)
• Lancer Evolution VIII MR
(supplement)1036F52
1036K50
1036K51
1036K52
1036K53
1036K54
1036K55Aug 1996
May 2000
July 2000
May 2001
Oct 2001
Feb 2003
Feb 2004
Electrical Wiring Diagrams
Service Manual
• Lancer Evolution VIII 1036K77 Jan 2003
New Vehicle Manuals
• Mirage, Lancer
• Mirage, Lancer
• Mirage, Lancer
• Mirage, Lancer
• Mirage
• 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
• Lancer Evolution VIII MR1036F30
1036F31
1036F32
1036F33
1036F34
1036F35
1036F36
1036F37
1036K30
1036K31
1036K32
1036K33
1036K34
1036K35
1036K36
1036K37
1036K38
1036K39
1036K40Oct 1995
Jan 1996
Aug 1996
Jul 1997
Jan 1998
Oct 1998
Jan 1999
Dec 1999
May 2000
July 2000
Jan 2001
May 2001
Oct 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004Engine 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
1036K02
1036K03
1036K04
1036K05
1036K06
1036K07
1036K08
1036K09
1036K10May 2000
July 2000
Jan 2001
May 2001
Oct 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004Transmission Service Manual
• W5M51 Manual Transmission
• W5M51 Manual Transmission
(supplement)
• W6MAA Manual Transmission1039M17
1039M22
1039M23Jan 2001
Jan 2003
Jan 2003

GENERAL INFORMATION - DETAILS OF CHANGES0-4
Main circuit Name of circuit Page Details of change
Spare Audio connectors -• Change to terminal number in J/C(1)
(C-07) on line inking J/B (general fuse
No.18) and spare audio connector.
(No.3 " No.7)Accessories
Clock -• Change to terminal number in J/C(1)
(C-07) on line inking J/B (general fuse
No.18) and clock. (No.2 " No.6)
Special
EquipmentABS p.3-32
ACD (Vehicles not fitted with
AYC)p.3-40• Circuit changed due to change in
branching point of connector for
4WD-ECU (C-37) (C-38) (from
instrument panel harness to control
harness).
• J/C(6) (C-23) added between ABS-
ECU and 7
th terminal of junction
connector (C-20) between instrument
panel harness and control harness.
• J/C(6) (C-23) added between ABS-
ECU and 22
nd terminal of junction
connector (C-22) between instrument
panel harness and control harness.
ACD, AYC p.3-48• Circuit changed due to change in
branching point of connector for
4WD-ECU (C-37) (C-38) (from
instrument panel harness to control
harness).
• Earth No.13 added
• J/C(6) (C-23) added between 4WD-
ECU and 7
th terminal of junction
connector (C-20) between instrument
panel harness and control harness.
• J/C(6) (C-23) added between 4WD-
ECU and 22
nd terminal of junction
connector (C-22) between instrument
panel harness and control harness.
Intercooler water spray -• Change to terminal number in J/C(1)
(C-07). (No.12 " No.21).
Engine immobiliser system p.3-58• Partial changes due to removal of
DVD-MMCS.
• Partial changes to circuit, due to
change in installation point of
immobiliser ECU.
Spare general connectors -• Change to terminal numbers in J/C(1)
(C-07) on line linking J/B (general
fuse No.18) / special fuse No.15, and
general spare connectors. (No.7 "
No.5), (No.21 " No.12).