MITSUBISHI LANCER EVOLUTION VIII 2004 Repair Manual

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).

001GENERAL – MODEL COMPOSITION, APPLIED VEHICLE NUMBERS
SECTION 00
GENERAL
CONTENTS
Model composition ....................................1 Applied vehicle numbers ..........................1
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
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

13A1
SECTION 13A
MPI (Multipoint Fuel Injection)
CONTENTS
General........................................................2 Troubleshooting .........................................3

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

MPI – Troubleshooting13A3
Connector inspection : B32
Change No.2 wastegate solenoid valve.
Check connector:B19X
Inspect, repair harness between No.2 wastegate
solenoid valve and engine control relay.
• Check for broken wire and shorting.
Check connector:C49
Replace engine ECU
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check output wire to see if broken or shorting.
Check connector: C49
Replace engine ECU.
B32 No.2: measure at wastegate solenoid valve
connector
• Undo connector and take measurement on
solenoid valve side
• Resistance between 1 and 2
OK:29 35Ω(at 20˚C)
Measure at B32 No.2 waste gate solenoid valve
connector.
• Undo connector and take measurement on
harness side.
• Ignition switch ON:
• Resistance between 1 – earth
OK:battery voltage
Measurement at C49 engine ECU connector
•Engine ECU terminal voltage measurement
• Ignition switch: ON
• Voltage between 6 – Earth
OK:battery voltage
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check for damage to output wire.
Check harness between No.2 wastegate
solenoid valve and engine control relay.
•Check for damage to power supply cable.
TROUBLESHOOTING
1.Inspection procedures for different types of malfunction
Inspection procedure 37
No.2 Wastegate solenoid valve system <6M/T>
The No.2 wastegate solenoid valve controls excess pressure
introduced via the turbocharger wastegate actuator.
Assumed cause of concern
• No.2 wastegate solenoid valve malfunction
• Engine ECU malfunction
Repair
Repair
Repair
Repair
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NGRepair
NGRepair
Repair
OK OK OK

MPI – TROUBLESHOOTING13A4
2.ENGINE ECU CHECKS
21 List of terminal voltages
22 List of resistances and conductance between harness side connector – terminal
Terminal No.Check itemCheck item (engine condition)Normal value
41No.1 wastegate
solenoid valveIgnition switch ONBattery voltage
Engine: warm, idling (using premium petrol)1V or less
6No.2 wastegate
solenoid valve
<6M/T>Ignition switch: ONBattery voltage
Accelerating in 2nd gear with throttle full open (at least 3500 rpm)Voltage decrease
Terminal No.Check itemStandard value, normal condition (check condition)
4147No.1 wastegate solenoid valve2935Ω(at 20˚C)
647No.2 wastegate solenoid valve <6 M/T>2935 Ω(at 20˚C)

13B1FUEL SUPPLY GENERAL, FUEL TANK
SECTION 13B
FUEL SUPPLY
CONTENTS
General........................................................1 Fuel tank .....................................................1
General
As well as changing the filler neck hose clamp from an M6 x 39 to M6 x 49, the mounting position has been changed. There
were no changes other than the following.
Fuel Tank
Removal and fitting
Cross section A – A
Rear cross member
NOTE
Fit the filler neck hose clamp so that it does not interfere with the rear cross member.

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

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

INTAKE, EXHAUST – AIR CLEANER153
Air Cleaner
Removal and Fitting
Note
The parts marked with a symbol are plastic components which contain recycled paper. Please note the following:
•When fixing or removing, or after fitting parts, be careful not to knock or apply force to these components.
• When assembling, fix the air cleaner body ASSY securely to the air cleaner cover using the clamp on the body.
Remarks
Parts marked with a
symbol use plastic that may contain recycled paper, so when scrapped are burnable.
Removal procedure
1.Battery
2. Air duct
3. Air flow sensor connector4.Air cleaner assembly
5.Air flow sensor
6. Gasket
7. Air cleaner cover8.Air cleaner element
9.Air cleaner body assembly
10. Vacuum hose• Air pipe E, air hose D, air bypass valve
assembly, air bypass hose.
• Oil level gauge assembly11.Air intake hose
12.Wastegate solenoid valve connector
13. Vacuum hose connection
14. Wastegate solenoid valve assembly15.Air cleaner bracket