service 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

SERVICE MANUAL
BODY
Supplement

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).

32CHANGING WELDED PANELS – ROOF
SymbolOperation details
Spot welding
MIG plug welding ( : two layers : three layers)
+ + + +MIG spot welding
MIG arc welding (continuous)
Rivet
Areas where rust inhibitor is applied. (Applied using
holes in butt welded locations)
Front pillar
upper supportCentre pillar
upper supportRear pillar upper
support
Note
: these welding points are done by manufacturer (not necessary during repairs).
:
black shading indicates areas where structural adhesive is applied.
AdhesiveTypeProduct name
Epoxy structural adhesiveSumitomo 3M Auto Mix Panel Bond 8115
SERVICE JOINTS

SERVICE MANUAL
Supplement

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

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

151INTAKE, EXHAUST GENERAL, SERVICING STANDARD VALUES, VEHICLE SERVICING
SECTION 15
INTAKE, EXHAUST
CONTENTS
General........................................................1
Servicing standard values ........................1
Vehicle Servicing .......................................11. Turbocharger boost pressure check ..................1
2.Checking boost pressure control system ..........2
Air cleaner ..................................................3
General
The important service points were added as a result of the following changes. Other service points remain the same.
• Change to the turbocharger boost pressure (on 6M/T)
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate on the 5M/T is not functional.
Servicing Standard Values
ITEMSTANDARD VALUE
Turbocharger boost pressure kPa <6M/T>97144
Vehicle servicing
1. Checking turbocharger boost pressure
<5M/T>
Since the No.2 wastegate solenoid valve does not function, the
same check of the No.1 wastegate solenoid valve as before iscarried out.
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 the
reading of the values on the pressure gauge.
(1) Remove the hose (black) from the No.1 wastegate solenoid
valve, and fit the pressure gauge to this hose. Fit a plug to
solenoid valve nipple from which the hose (black) has been
removed.
(2) Remove the No.2 wastegate solenoid valve connector.(3)Accelerate at full throttle in 2nd gear, and then take the boost
pressure measurement when engine speed gets to at least
3,000rpm.
Standard value: 97 – 144kPa
(4) When the boost pressure is lower than the standard value, the
cause could be one of the following:
1. Wastegate actuator misoperation
2. Boost pressure leak
3. Turbocharger NG
(5) When boost pressure is higher than standard value, the boost
pressure control may be faulty, so please check the following
points.
Air cleaner
No.1 Wastegate
solenoid valveNo.2 Wastegate
solenoid valve

MANUAL TRANSMISSION TROUBLESHOOTING222
2. Check procedures by diagnosis code
Remarks
In cases where other diagnosis codes are output, please refer to the relevant item.
Code No.12 Power supply voltage (valve power supply) systemAssumed cause of concern
If the 4WDECU power supply voltage drops below 9V or rises
above 18V, Code No.12 is output, indicating either a broken wire in
the power supply circuit, a short, or a drop in the battery voltage.• battery malfunction
• harness, connector malfunction
• 4WDECU malfunction
Battery inspection
NG > replace
MUTII/III Service data
• No.10 Battery voltage
OK:battery voltage
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•ECU terminal voltage measurement
• Ignition switch: ON
OK:battery voltage
Connector check: C38
NG > repair
MUTII/III Service data
•No.10 battery voltage
OK:battery voltage
NG > replace 4WDECU
OK > intermittent malfunction
Connector check:C38, C133, C212, C210
NG > repair
Check harness between ignition switch – 4WDECU
• Check to see if power supply wire broken, short, or
damage
NG > repair
OK
OK
OK
OK
NG
NG