Mitsubishi Lancer Evolution VIII MR User manual

New Vehicle Manual

New Vehicle 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.
This information relates to the current vehicle (February
2004). Since specifications will change, some of the
information contained here will inevitably be
superseded.
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..........................................
Engine ...........................................
Power Train...................................
Drive Control ................................
Body ..............................................
Exterior..........................................
Interior...........................................
Equipment.....................................
Reference Materials .....................
There are no changes to the shaded chapter,
so it is not included at all in this manual.
0
1
2
3
4
5
6
7
8

Title
No.
Issue
Date
Title
No.
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
1036K53
1036K54
Aug 1996
May 2000
July 2000
May 2001
Oct 2001
Feb 2004
Electrical Wiring Diagrams
Service Manual
• Lancer Evolution VIII
• Lancer Evolution VIII MR
(supplement)
1036K77
1036K80
Jan 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
1036F33
1036F34
1036F35
1036F36
1036F37
1036K30
1036K31
1036K32
1036K33
1036K34
1036K35
1036K36
1036K37
1036K38
1036K39
Oct 1995
Jan 1996
Aug 1996
Jul 1997
Jan 1998
Oct 1998
Jan 1999
Dec 1999
May 2000
July 2000
Jan 2001
May 2001
May 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Engine Service Manual
• 4G6 Engine
• 4G6 Engine
(supplement)
1039G46
1039G63
Jan 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
1036K02
1036K03
1036K04
1036K05
1036K06
1036K07
1036K08
1036K09
1036K10
May 2000
July 2000
Jan 2001
May 2001
Oct 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004
Transmission Service
Manual
• W5M51 Manual
Transmission
• W5M51 Manual
Transmission
(supplement)
• W6MAA Manual
Transmission
1039M17
1039M22
1039M23
Jan 2001
Jan 2003
Jan 2003
Related information

00-1
GENERAL – TECHNICAL FEATURES
SECTION 0
GENERAL
CONTENTS
Vehicle Identification..............................0-1
Implementation Code .............................0-1
Development Aims .................................0-1
Overview of Lancer Evolution VIII MR. 0-2
Model line-up
Note
¡= Continued model
Applied vehicles
GH-CT9A: CT9A-0300001 ~
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.
Model Version ’04 Model Grade Engine Model Transmission Fuel System
GH-CT9A SNDFZ
SJDFZ
SJGFZ
¡
¡
¡
RS
RS
GSR
4G63
(2 000 DOHC 16 valve
intercooler turbo)
W5M51 (4WD, 5M/T)
W6MAA (4WD, 6 M/T)
MPI

GENERAL – OVERVIEW OF THE LANCER EVOLUTION VIII MR
0-2
Lancer Evolution VIII MR Lancer Evolution VIII
GH-CT9A SNDFZ RS (5M/T) GH-CT9A SNDFZ RS (5M/T)
SJDFZ RS (6M/T) SJDFZ RS (6M/T)
SJGFZ GSR SJGFZ GSR
Overview of the Lancer Evolution VIII MR
Differences from the Lancer Evolution VIII
Section
Difference from Lancer Evolution VIII
Page
Change to cam profile (6 M/T)
1-5
Enlarged turbo nozzle diameter (6 M/T)
1-6
Adoption of tail pipe with built-in sound proofing in exhaust main
silencer (6 M/T)
1-7
Addition of wastegate solenoid valve (1 ‡2)*1
1-8
Change to catalyst volume (2.0 l. ‡1.5 l.) (6 M/T)
-
Engine
Enlarged engine oil cooler
-
Power train
Change to super AYC differential
2-1
Installation of Bilstein shock absorbers*2
3-1
Optional BBS 17-inch alloy wheels (new design)
3-1
Drive control
Black finish on spokes of Momo genuine leather steering wheel
(Type A) (GSR)
-
Aluminium used in roof panel and side door beams
4-1
Change to body colour
4-1
Body
Boot lid opener fitted as standard (RS)
-
Addition of Evolution MR logo
5-1
Exterior
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 all-round (GSR)
-
Change to combination meter
7-1
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.

1-1
ENGINE (4G6) – GENERAL
SECTION 1
ENGINE (4G6)
CONTENTS
General ....................................................1-1
1. Major Specifications....................................1-1
2. Engine Performance Curve.........................1-2
Base Engine (6 M/T) ...............................1-2
1. Cylinder head gasket...................................1-2
2. Pistons..........................................................1-3
3. Piston rings (2nd) ........................................1-3
4. Oil rings ........................................................1-4
5. Counterbalance shaft .................................1-4
6. Camshaft.......................................................1-5
Intake / Exhaust System (6 M/T)............1-6
1. Exhaust system ...........................................1-6
Control system (6 M/T)...........................1-8
1. Supercharging pressure control..............1-10
General
The 4G63-T/C engine fitted in the Lancer Evolution VIII MR is basically the same as the 4G63-T/C engine used in the Lancer
Evolution VIII.
The basic structure is the same in both the 6M/T (6-speed) and 5M/T (5-speed) versions, but the following improvements have
been made to the 6M/T version, in order to achieve higher performance.
• Adoption of 5-ply cylinder head gasket
• Addition of V-shaped groove in piston , and modified shape in cooling channel
• Reduced oil consumption by increasing tension in piston rings and reducing end-to-end gap
•Extra durability and reduced oil consumption by using new treatment on outer surface of oil ring side rail, and altering
thickness
•Lighter counterbalance shaft
• Increased output at high engine speeds by modifying intake cams
Major Specifications
Item 6 M/T 5M/T
Total Displacement cc 1997
Combustion chamber Pentroof type
Bore x stroke (mm) 85.0 x 88.0
Compression ratio 8.8
Camshaft arrangement DOHC-4 valve
Fuel Premium unleaded
Max. output (kW/rpm) 206/6500
Max. torque (Nm/rpm) 400/3500 392/3500
Fuel system Electronic controlled multipoint fuel injection
Ignition system Electronic controlled two-coil
Lash adjuster Equipped

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)
1-2
2. Engine performance curve (6 M/T)
Base Engine (6 M/T)
1. Cylinder head gasket
A5-ply metal gasket has been introduced, in order to improve sealing properties.
Shaft output (kW) Shaft torque (N•m)
Engine r.p.m.

ENGINE (4G6) – BASE ENGINE (6 M/T) 1-3
2. Pistons
• Addition of V-shaped groove.
A V-shaped groove has been formed in the second land, with a view to reducing oil consumption.
•Modification of cooling channel.
The shape of the cooling channel, which recycles the oil, has been modified in order to improve recycling efficiency.
Modified shape of
cooling channel
V-shaped
groove added
3. Piston Rings (2nd)
To increase the tension in the piston rings, they have been changed
to ductile cast iron, from the standard cast iron used previously.
The end to end gap in the rings was also reduced.
These modifications are designed to reduce oil consumption.
Item Evolution VIII MR Evolution VIII
Tension 10.5 N 7.0 N
End to end gap 0.30 – 0.45 mm 0.35 – 0.50 mm
End to end gap

ENGINE (4G6) – BASE ENGINE (6 M/T)
1-4
4. Oil Rings
The outer circumference of the side rail has been treated with chrome nitride. The thickness of the side rail has also been
reduced from 1.7 mm to 1.63 mm, with a view to increasing durability and reducing oil consumption.
(Evolution VII MR) (Evolution VIII)
Chrome nitride
5. Counterbalance shaft
The shape of the shaft was changed in order to reduce weight.
Counterbalance shaft (right)
Counterbalance shaft (left)
Thickness
reduced
Thickness
reduced

ENGINE (4G6) – BASE ENGINE (6 M/T) 1-5
6. Camshaft
Output at high engine speeds has been improved by altering the cam profile of the intake camshaft, and optimizing the valve
timing.
Evolution VIII MR Evolution VIII
Cam height mm 35.96 35.79
Evolution VIII MR Evolution VIII
T.D.C (top dead centre) T.D.C (top dead centre)
Intake valve open
Intake valve
closed
Exhaust
valve closed
Exhaust
valve open
Intake valve open
Intake valve
closed
Exhaust
valve closed
Exhaust
valve open
B.D.C (Bottom dead centre) B.D.C (Bottom dead centre)

ENGINE (4G6) – INTAKE / EXHAUST SYSTEM (6 M/T)
1-6
Intake / Exhaust System (6 M/T)
1. Exhaust system
1-1 Turbocharger
A large-nozzle 10.5T turbo has been adopted in order to improve mid to high-range torque. Optimum control of the
supercharging pressure has ensured good torque and response at medium engine speeds.
The positions of the turbine housing and the wastegate holes have also been changed to achieve smoother outflow and
increase low-speed torque. Along with these modifications, the wastegate valve has been changed from an oval to a circular
valve.
(Evolution VIII MR) (Evolution VIII)
Turbine housing Turbine housing
Wastegate holes
Wastegate holes
Oval valve
Circular valve

ENGINE (4G6) – INTAKE / EXHAUST SYSTEM (6 M/T) 1-7
1-2 Exhaust silencer
A tailpipe with built-in sound-absorbing material has been adopted, in order to increase the silencing effect.
Structural diagram
Main exhaust
silencer
Tailpipe
(with built-in sound-
absorbing material)
Cross-section A–A
Sound-
absorbing
material

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)
1-8
Control system (6M/T)
The following changes have been made, based on the control system in the 4G63-DOHC-T/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)
O2sensor
Ignition switch –IG
Ignition switch –ST
Power supply
Engine 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 control
Intercooler water spay control
Engine warning light control
O2sensor heater control
Purge control
Diagnosis output
RAM data transmission
No. 1 indicator
No. 2 indicator
No. 3 indicator
No. 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
O2sensor heater
Purge control solenoid valve
Diagnosis output terminal
Diagnosis output terminal (for
MUT-II)

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T) 1-9
★1. O2 sensor
★2. Air flow sensor
★3. Air intake sensor
★4. Throttle position
sensor
★5. Cam position sensor
★6. Crack angle sensor
★7. Atmospheric 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. Injector
✩2. 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 valve
Canister
✩7. Secondary air
control solenoid valve
From fuel tank
Secondary
air valve
By-pass
valve
★1. O2sensor
✩3. Fuel pressure
control solenoid valve
★4. Throttle
position
sensor
★7. Atmospheric pressure
sensor ★3. Air intake
sensor
★2. Air flow sensor
✩4. No.1
wastegate
solenoid valve
✩5. No.2 wastegate
solenoid valve
Only operates on 6M/T
Wastegate actuator
Fuel pressure
regulator
✩1. Injector
★5.Cam position sensor
★8.Water temperature sensor
★9.Knock sensor
Crack angle sensor
Catalytic converter
Air
intake
Check
valve
✩2. ISC servo Vacuum
tank
From fuel
pump
To fuel
tank
Control system diagram

ENGINE (4G6) – CONTROL SYSTEM (6 M/T)
1-10
1. Supercharging pressure control
The maximum torque has been increased, compared to the 4G63-DOHC-T/C engine in the current Lancer Evolution VIII, by
installing an additional wastegate solenoid valve (increased from 1 to 2 valves).
By adding a parallel No.2 wastegate solenoid valve to the previous system, provides extra relief capacity for the pressure
applied to the wastegate actuator thus increasing the range of supercharging pressure..
The engine ECU raises the supercharging pressure even further, thus raising the maximum torque, by driving the No.2
wastegate solenoid valve when the engine approaches maximum torque.
The No.1 wastegate solenoid valve is essentially controlled in the same way as previously.
Air flow
sensor
Knock
sensor
Engine
ECU
Battery Secondary air
control solenoid
valve
Secondary
air valve
Ignition
switch
Air
intake
Bypass valve
Vacuum tank
Intercooler
Turbocharger
Wastegate
actu-
ator
No. 1
wastegate
solenoid
valve
No. 2 wastegate
solenoid valve
Crank angle
sensor

2-1
Power Train – Differential
SECTION 2
POWER TRAIN
CONTENTS
Differential ..............................................2-1
Differential
The following changes have been made to the Super AYC differential.
• Reduced weight: The weight of the differential has been reduced by building the clutch case from aluminium, rather than
steel, and partially revising the thickness of the clutch discs.
• Improved strength and durability: Strength and durability have been raised by adopting special high-strength steel for the
hypoid gears (pinion gear and drive gear), instead of the cast steel used previously.
• Improved control when ABS is operating: Revisions to the communications with the ABS-ECU and the control procedure
during ABS operation, as well as active ACD/AYC control in high friction road surfaces, such as circuits, have led to
increased steerability and stability.
Structural Diagram
Hypoid gears Clutch case
Clutch discs

3-1 DRIVE CONTROL – Front suspension, Rear suspension, Wheels, Tyres
SECTION 3
DRIVE CONTROL
CONTENTS
Front suspension....................................3-1
Rear suspension.....................................3-1
Wheels and Tyres ...................................3-1
Front suspension
Road-holding has been improved by the adoption of Bilstein shock absorbers.
(GRS: Standard; RS: Optional)
Notes :
* Bilstein are one of the world’s leading manufacturers of shock absorbers, and their products are used in racing vehicles
worldwide.
Rear suspension
• Road-holding has been improved by the adoption of Bilstein shock absorbers.
(GRS: Standard; RS: Optional)
•The specifications of the coil springs have been changed. (GSR)
Specifications
Item Lancer Evolution VIII MR GSR Lancer Evolution VIII GSR
Wire diameter mm 12 ←
Average diameter mm 88 ←
Free length mm 277 287
Wheels and Tyres
BBS lightweight forged alloy wheels are provided as an option,
which reduces the unsprung weight. Fitting these BBS lightweight
wheels allows the Bilstein shock absorbers to display their full
range of performance.
Note:
See “Section 8 Main Equipment” for detailed specifications.

4-1
BODY – MAIN BODY
SECTION 4
BODY
CONTENTS
Main Body................................................4-1
Body Panels .....................................................4-1
Paintwork.................................................4-1
Body colour chart ............................................4-1
Main Body
Body Panels
Vehicle weight has been reduced by using aluminium for the roof panels and the side door beams, in addition to the bonnet
panel and front wing panels, as previously.
: Parts made from aluminium
Paintwork
Body colour chart
Colour name
(Former name)
Colour
symbol
Colour
code
Colour (paint)
number
Coating ingredient Maintenance
symbol
Name of paint
manufacturer
Cool Silver Metallic CL A31 CMA10031 Aluminium MKansai Paint
Medium Purplish Grey Mica ES A39 CMA10039 Aluminium +
interference mica
2P Nippon Paint
Solid White (Scotia White) 2E W83 AC10983 –– SKansai Paint
Solid Red (Palma Red) JW P85 AC11185 –– SKansai Paint
Note :
• The maintenance code is only for the top coat. S = Solid; M = Metallic; 2P = 2-coat pearl
• The name of the paint manufacturer is the name of the manufacturer of the paint used at the time of production.

5-1 EXTERIOR – MARKINGS
SECTION 5
EXTERIOR
CONTENTS
Markings ..................................................5-3
Markings
An Evolution MR logo has been added.
Evolution MR logo

7-1
EQUIPMENT – COMBINATION METER
SECTION 7
EQUIPMENT
CONTENTS
Combination meter.................................7-1
Combination meter
The combination meter has been changed as illustrated below.
(Lancer Evolution VIII MR) (Lancer Evolution VIII)
Marking changed