2004 MITSUBISHI LANCER EVOLUTION VIII Workshop Manual

MANUAL TRANSMISSION TROUBLESHOOTING2220
The ACD mode injector lamp does not come on when the ignition
switch is ON (engine stopped)Assumed cause of concern
ACD mode indicator lamp circuit or 4WDECU malfunctions are possible.• Harness, connector malfunction
• ACD mode indicator lamp ASSY malfunction
• 4WDECU malfunction
Measurement at C106, combi. meter connector.
• Undo connector, take measurement on harness side
• Ignition switch ON
OK:battery voltage
Measurement at C37 4WDECU connector
• Undo connector, take measurement on harness side
• Ignition switch ON
• Earth 40, 51, 52 to body earth
OK:indicator lamp on
Connector check:C37
NG > repair
Fault confirmation Replace 4WDECU
Connector check:C106, C212, C210
NG > repair
Fault confirmation
Check harness between ignition switch – ACD mode
indicator lamp ASSY
• Check power supply wire to see if broken or
damaged
•NG > repair
Check ACD mode indicator lamp ASSY
NG > replace
Connector check:C37, C133, C106
NG > repair
Fault confirmation
Check harness between ACD mode indicator lamp
ASSY 4WDECU
• Check output wire to see if broken or damaged
When C37 4WDECU connector is undone, do all
ACD mode indicator lamps all go out?
Replace 4WDECU
Check connector:C37, C133, C106
NG > repair
Fault confirmation Check harness between ACD mode indicator ASSY
4WDECU
• Check output wire for earthing, shorting
NG > repair
Replace ACD mode indicator ASSY
Checking procedure 3
Checking procedure 4
Even after engine starts, at least 2 ACD mode indicator lamps
remain litAssumed cause of concern
ACD mode indicator lamp output circuit malfunction is possible.•Harness, connector malfunction
• 4WDECU malfunction
• ACD mode indicator lamp ASSY malfunction
Remarks
This phenomenon is limited to when communication with MUTII/III is possible (4WDECU power supply normal), and diagnosis
code is normal/correct.
OK
NG
NG
NO
OK
OK
NG
NG
OK
OK
OK
NG
YESOK
NG
OK

33A1FRONT SUSPENSION – GENERAL, SPECIAL TOOLS
SECTION 33A
FRONT SUSPENSION
CONTENTS
General........................................................1
Special tools ...............................................1Strut Assembly...........................................2
General
Important servicing information has been added along with the adoption of Bilstein shock absorbers. However, apart from the
information below, other servicing information remains unchanged.
Special Tools
ToolNumberNameDetails
MB991367Special spannerDismantling and assembly of strut ASSY.
Vehicles fitted with Bilstein shock absorbers
MB991385Pin

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

511EXTERIOR – GENERAL
SECTION 51
EXTERIOR
CONTENTS
General........................................................1
Front bumper ..............................................2
Adhesives ..............................................................2Front bumper .........................................................2
Markings .....................................................4
General
Important servicing information has been specified, along with the following changes and additions. Other servicing information,
however, remains the same as the information relating to the Lancer Evolution VIII.
• Changes and additions to front bumper components
• Changes to the position of the 3 diamonds badge, and addition to the EVOLUTION MR mark.

EXTERIOR – FRONT BUMPER512
Front bumper
Adhesives
Locations usedBrand
Three diamonds badgeDoublesided tape: ordinary tape, widely available on the market (width 20mm, thickness 0.8mm)
Front Bumper
Dismantling · Assembling
Locations where doublesided tape is applied
Doublesided tape: ordinary tape, widely available
on the market (width 20mm,thickness 0.8mm)
Crosssection AA Crosssection BB
Clip Clip

EXTERIOR – FRONT BUMPER513
Dismantling procedure
1.Three diamonds badge
2. Licence plate garnish
3. Licence plate bracket
4. Licence plate bracket ASSY5.Front bumper plate
6. Cover7.Front air dam panel
8. Front bumper lower plate ASSY
9. Front bumper lower reinforcement
ASSY
10. Front bumper upper plate ASSY11. Bumper net
12. Front bumper side cover
13. Bumper side net (LH)
14.Oil cooler duct
15. Bumper side net (RH)
• Water spray hose and nozzle (ref.
Section 15)
16.Front bumper side plate ASSY
17. Front bumper upper reinforcement
ASSY
18. Front bumper facing
AA
Important notes on dismantling
Front bumper side plate removal
Same as for existing front bumper rivet removal.
Important notes on assembly
Fitting front bumper side plate
Same as for existing front bumper rivet fitting.A
A