2003–2005 Mitsubishi Lancer Evolution VIII MR Service Manual (P/N 1036K55, 1036K40, 1036K10)

• Four Mitsubishi factory publications dated February 2004, supplied as a 166-page PDF set including the separate cover: New Vehicle Manual P/N 1036K40, Service Manual P/N 1036K10, Body Service Manual P/N 1036K55, and Electrical Wiring Diagrams P/N 1036K80.
• Covers the 2004 GH-CT9A Lancer Evolution VIII MR from CT9A-0300001 onward, including SNDFZ RS with W5M51 5-speed, SJDFZ RS with W6MAA 6-speed, and SJGFZ GSR with W6MAA 6-speed manual transmissions.
• Documents the 4G63 6M/T engine and turbo changes, including the revised head gasket, pistons and rings, counterbalance shaft, intake cam, larger-nozzle turbocharger, dual wastegate-solenoid control, the P1500-to-P0622 diagnosis change, and boost-control inspection.
• Provides MUT-II/III fault-isolation charts for the 4WD-ECU and ACD/AYC system, covering wheel-speed inputs, TPS, pressure and G sensors, ACD mode and parking-brake switches, ABS monitoring, the proportional valve, and electric-pump relay.
• Covers Bilstein front-strut dismantling and assembly, rear shock-absorber service, front-bumper work, and MR marking installation, with Mitsubishi special tools identified for the front strut.
• Details aluminum roof and side-door-beam repair, including roof-out measurement points, roof service joints, rivet and adhesive locations, aluminum-panel straightening and welding, finishing, and repair painting.
• Includes changed wiring layouts, connector maps, ECU and solenoid installation positions, and circuit diagrams for junction and power supply, engine control, manual air conditioning, ABS, ACD-only and ACD/AYC systems, and the engine immobilizer.

Component and System Documentation

This is a model-change supplement set, not a stand-alone complete workshop manual. It covers only the differences introduced for the February 2004 Evolution VIII MR build; unchanged procedures must be taken from the related Lancer Evolution VIII, 4G6 engine, and W5M51/W6MAA transmission publications. Its scope is MR-specific construction, controls, diagnosis, and service changes rather than a repeat of every baseline engine or gearbox repair procedure.

The New Vehicle Manual separates the changes that apply to the 5-speed and 6-speed cars. The 6M/T 4G63 section covers the 5-ply cylinder-head gasket, piston cooling-channel and ring revisions, lighter counterbalance shafts, altered intake-cam profile, 10.5T turbocharger, sound-absorbing tailpipe, and second wastegate solenoid. It also identifies the No. 2 solenoid as non-operational on the 5M/T. The service supplement follows those design changes with the related MPI system diagram, 6M/T fault procedure, engine-ECU terminal checks, wastegate-solenoid electrical specifications, turbocharger boost-pressure check, and boost-control system inspection.

Drivetrain coverage centers on the Super AYC differential and 4WD control system. The design section shows the aluminum clutch case, revised clutch discs, high-strength hypoid gears, and altered ABS communication strategy. The service supplement adds diagnosis-code charts and connector-level checks for 4WD-ECU power, all four wheel-speed signals, abnormal tire diameter, TPS, pressure sensor, longitudinal and lateral G sensors, stop-lamp and ACD-mode switches, parking-brake input, ABS monitor, ACD proportional valve, electric-pump relay, and ACD indicator faults. Fuel-filler-neck clamp placement and air-cleaner removal and fitting are also covered where the MR build differs.

Bilstein-equipped suspension work includes a front-strut exploded view, dismantling and assembly notes, spring-compressor use, spring-seat indexing, and the specified tools: MB991367, MB991385, MB991237, and MB991238. Rear shock-absorber assembly information is included, along with revised front-bumper dismantling/assembly and factory positioning data for the three-diamond and Evolution MR rear markings.

Electrical and Specification Preview

The body publication adds collision-repair detail beyond the material-change summary. It maps the aluminum roof, added pillar supports, and aluminum front and rear door beams; supplies straight-line body measurements with the roof removed; and identifies roof service joints, weld types, rivet points, structural-adhesive areas, sealant locations, and replacement-panel fitting requirements. Separate sections cover aluminum-panel straightening, distortion correction, cut-and-tear repair by MIG or TIG methods, surface preparation, filler work, and repair painting. A body-color chart and rear-spoiler paint breakdown are included.

The electrical supplement records revised engine-transmission, instrument-panel, control-harness, and trunk/boot-interior connections. It shows the added No. 2 wastegate-solenoid connector, relocation of the 4WD-ECU connections to the control harness, changed immobilizer arrangement, and updated ECU/solenoid installation positions. Representative diagrams cover junction and power-supply distribution, engine control, manual air conditioning, ABS, ACD-only and combined ACD/AYC systems, and the engine immobilizer. Only modified or added circuits are reproduced; unchanged wiring remains in Electrical Wiring Diagram manual P/N 1036K77.

Factory reference data includes model and grade equipment charts, main and detailed specifications, body measurements, boost service standards, solenoid resistance and ECU terminal references, connector pinouts, and component tightening specifications. The repair notes also flag several MR-specific traps. The body must be supported before roof removal or the side structure can spread or lean; steel-contaminated sanding tools can promote electro-corrosion on aluminum, while steel-type leveling hammers can crack the panel. On the Bilstein front strut, impact-tool use can damage the spring compressor or disturb the internal piston-rod locknut, and the spring ends must be seated in the correct positions. Observe the manual's SRS/pretensioner precautions and its two-person, safe-location requirement for full-throttle boost testing.