2004 MITSUBISHI LANCER EVOLUTION VIII transmission

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).

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

SECTION 22
MANUAL TRANSMISSION
CONTENTS
General........................................................1 Troubleshooting .........................................1
General
The following troubleshooting items have been changed along with the changes to the wiring. Troubleshooting points other than
those mentioned below remain unchanged, and are the same as on the existing Lancer Evolution VII/VIII.
Troubleshooting
1. Diagnosis Code ListMANUAL TRANSMISSION – GENERAL, TROUBLESHOOTING
221
Diagnosis code no.Diagnosis itemPage ref.
12Power supply voltage (valve power supply) systemBroken wire or short222
21Vehicle wheel speed sensor system Broken wire or short223
22Vehicle wheel speed sensor system Broken wire or short223
23Vehicle wheel speed sensor system Broken wire or short223
24Vehicle wheel speed sensor system Broken wire or short223
25Abnormal diameter tyres 225
26Vehicle wheel speed sensor system (output signal abnormal) 226
41TPS systemBroken wire or earthing227
42Short227
45Pressure sensor systemBroken wire or earthing228
46Earth wire broken228
47Abnormal power supply229
51Longitudinal G sensor systemBroken wire or short2210
52Sensor malfunction2211
56Lateral G sensor systemBroken wire or short2212
57Sensor malfunction2213
61Stop lamp switch systemBroken wire2214
62ACD mode switch systemSticking2215
63Parking brake switch systemShort or failing to return2216
65ABS monitor system Broken wire or ABS failure2217
74Proportional control valve systemBroken wire or short2218
81Electrical pump relay systemBroken wire or short2218

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

MANUAL TRANSMISSION TROUBLESHOOTING223
Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor
•No.02 Vehicle speed sensor
• No.03 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
• Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor )
(2) Resistance between 6 19 (vehicle speed sensor )
(3) Resistance between 7 20 (vehicle speed sensor )
(4) Resistance between 8 – 21 (vehicle speed sensor )
OK:1.2 – 1.6 kΩ
To next pageVehicle wheel speed sensor check
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Replace
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG > Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
MUTII/III Service data
•No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK: Speed shown on speedometer and MUTII/III agreeNG > Replace 4WDECU
OK > Intermittent malfunction
Code No.21 Vehicle wheel speed sensor systems
Code No.22 Vehicle wheel speed sensor systems
Code No.23 Vehicle wheel speed sensor systems
Code No.24 Vehicle wheel speed sensor systemsAssumed cause of concern
When one of the vehicle wheel speed sensors detects a
vehicle speed of 15kph or more, and when even one of the
remaining 3 sensors cannot detect vehicle speed, the
diagnosis code for wheel speed sensor broken wire or short is
output.• Wheel speed sensor malfunction
• Rotor malfunction
•Wheel bearing malfunction
• Harness, connector malfunction
• 4WDECU malfunction

Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK
OK
NG
NG

MANUAL TRANSMISSION TROUBLESHOOTING224
From previous page
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector: C38
NG > Repair
MUTII/III Service data
• No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle speed sensor and rotor check
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
NG
OK
OK
OK

Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor
• No.02 Vehicle speed sensor
• No.03 Vehicle speed sensor
• No.04 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor
)
(2) Resistance between 6 19 (vehicle speed sensor
)
(3) Resistance between 7 20 (vehicle speed sensor
)
(4) Resistance between 8 – 21 (vehicle speed sensor
)
OK:1.2 – 1.6kΩ
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector:C38
NG > repair
MUTII/III Service data
• No.1 Vehicle speed sensor
• No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle wheel speed sensor
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG: Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
• Check output wire for broken wire, earthing, short
• Check earth wire to see if broken or damaged
NG:repair
MUTII/III Service data
•No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunction
Vehicle wheel speed sensor and rotor check
(Refer to Group 35B – Vehicle Wheel Speed Sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
MANUAL TRANSMISSION TROUBLESHOOTING225
Code No.25 Abnormal tyre diameterAssumed cause of concern
Abnormal tyre Code No. 25 is output in cases where, when
the steering wheel is in a central position, and vehicle speed
is 20kph or more, there is a discrepancy between one of the
vehicle wheel speed sensors and the average of the 4 wheel
speed sensors, in that it is outside the specified range.However, the warning lamp does not come on.• Tyre malfunction
•Vehicle speed sensor malfunction
• Rotor malfunction
• Wheel bearing malfunction
• Harness, connector malfunction

Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK NG
NG
OK
NG
OK
OK
OK