transmission 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

001GENERAL – TECHNICAL FEATURES
SECTION 0
GENERAL
CONTENTS
Vehicle Identification ..............................01
Implementation Code .............................01Development Aims .................................01
Overview of Lancer Evolution VIII MR. 02
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
Development Aims
The launch of the Lancer Evolution VIII MR is the result of our pursuit of further advances and improvements based on the
Lancer Evolution VIII, with the aim of maintaining and strengthening the Mitsubishi Evolution brand.
ModelVersion’04 ModelGradeEngine ModelTransmissionFuel System
GHCT9ASNDFZ
SJDFZ
SJGFZ

RS
RS
GSR4G63
(2 000 DOHC 16 valve
intercooler turbo)W5M51 (4WD, 5M/T)
W6MAA (4WD, 6 M/T)MPI

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 – DETAILED SPECIFICATIONS85
GHCT9AItem
SNDFZSJDFZSJGFZ
1st2.7852.909¨
2nd1.9501.944¨
3rd1.4441.434¨
4th1.0961.100¨
5th0.8250.868¨
6th0.693¨
TransmissionGear ratio
Reverse3.4162.707¨
Front4.5294.583¨DifferentialReduction
ratio
Rear3.307¨¨
Power train
TransferReduction
ratio0.302¨¨
Main brake typeHydraulic:
Front : Disc
Rear : Disc¨¨
Parking brake typeMechanical
wheel brake¨¨
FrontMacPherson¨¨
Braking
system
Suspension
RearMultilink¨¨
CO when
unloaded : %,
HC : ppmCO: 0.1,
HC: 100¨¨
10/15 mode
g/kmCO: 0.67,
HC: 0.08,NOx: 0.08¨¨
Emission
gas
suppressionequipmentQuantity or concentration
of exhaust gas
11 mode g/testCO: 19.0,
HC: 2.20,
NOx: 1.40¨¨

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).

01
GENERAL MODEL LINEUP , APPLIED VEHICLES
SECTION 0
GENERAL
CONTENTS
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
Model lineup...........................................01
Applied vehicle numbers .......................01Main specifications.................................02
ModelVersion’04 ModelGradeEngine ModelTransmissionFuel System
GHCT9ASNDFZ
SJDFZ
SJGFZ

RS
RS
GSR4G63
(2 000 DOHC 16 valve
intercooler turbo)W5M51 (4WD, 5M/T)
W6MAA (4WD, 6 M/T)MPI

35CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
ALUMINIUM ALLOY PANELS
Repairing Aluminium Alloy Panels
Precautions when working on sheet metal
1. The main differences to working with sheet steel. (Assuming an ordinary body shop)
OperationAluminium alloy panelSheet steel
HammeringWood or plastic hammerSheet steel hammer
Washer weldingNot possiblePossible
Gas weldingWorkability is poor but possiblePossible
Spot weldingNot possiblePossible
MIG weldingPossible with welder using argon gas and equipment for
aluminium weldingPossible with CO2gas and normal welding
equipment
2. At low temperatures, if subjected to a major impact, strength will deteriorate and it will crack.
3. Coefficient of elasticity is high, so springback (force acting to make material regain original form) is high.
4. Rate of heat transmission is high, and this can cause local thermal expansion.
5. If overheated, it becomes brittle, and strength deteriorates. If heated further, it will melt without discolouration.
(Heat treatment temperature: approx. 250˚C)
MaterialWelding temperature
Aluminium475˚C~660˚C (varies depending on alloy composition)
Sheet steel1500˚C~2500˚C
6. Material is soft, so be careful when selecting polish to use.
Also, since polishing powder is light and easily airborne, wear dust mask and goggles.
7. If strong pressure is used when using a disk sander on the alloy, the friction could cause the aluminium alloy to peel off,
and cause clogging.
8. Disk sanders that become clogged will cause deep scratching on aluminium alloy panels, so replace promptly.
9.Do not use general tools or sanders for sanding sheet steel.
(steel fragments or dust will remain on the sander, causing electrocorrosion with other metal)
10.With MIG welding, shield the local area.Sparks, often difficult to see, can be generated and dispersed over a wide area.
Repairing unevenness
This is basically the same as for sheet steel.However, bear in mind
aluminium alloy characteristics when carrying out this work.
1.Repairing sheet metal
(1) Heat with a torch
Note
a. Heat to the point where heat can be felt on the rear side
of panel with hand wearing a glove.
b. Keep torch moving so as not to overheat one area.

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).