Mitsubishi Lancer Evolution VIII MR 2003–2005 Supplement Manual Set (P/N 1036K10)

The design explanations accompany the service, body-repair, and electrical changes, allowing MR-specific construction details to be read alongside the related tests and procedures.

This is a model-change supplement set, not a stand-alone complete workshop manual. It covers differences introduced for the February 2004 build, from CT9A-0300001 onward. Unchanged procedures require the related Lancer Evolution VIII, 4G6 engine, and W5M51/W6MAA transmission publications, which are not included.

PDF Search, Bookmarks and Diagram Detail

Search and drawing labels: The four publications contain searchable text and chapter bookmarks. Some labels within illustrations, including circuit pin numbers and wire codes, are not searchable. Small wiring labels require zooming. The separate cover has no usable text search or bookmarks.

The ZIP download contains five printable PDFs totaling 166 pages. This total includes the separate one-page cover, the publications’ own covers and introductory pages, and six memo/notes pages.

MR Boost Control, 4WD Diagnosis and Body Repair

The following selected content highlights show the main service areas; additional topics include combination-meter changes and cold-climate equipment specifications.

• MPI and boost control: No. 2 wastegate-solenoid fault isolation, engine-ECU terminal checks, turbocharger pressure testing, and boost-control system inspection.

• 4WD diagnosis: MUT-II/III fault charts for wheel-speed inputs, sensors, switches, ABS monitoring, the ACD proportional valve, and electric-pump relay.

• Bilstein suspension: Step-by-step front-strut dismantling and assembly instructions, special-tool references, spring-seat alignment notes, and rear shock-absorber assembly drawings.

• Exterior service: Front-bumper dismantling and assembly, three-diamond badge positioning, and Evolution MR rear-marking installation.

• Aluminum body repair: Roof replacement, roof-out body measurements, service joints, rivet and adhesive locations, panel straightening, welding, finishing, and repair painting.

• Electrical circuits: Revised harness layouts, connector maps, component installation positions, and diagrams for engine control, manual air conditioning, ABS, ACD/AYC, and the immobilizer.

Suited to technicians familiar with workshop electrical testing and MUT-II/III diagnosis; the aluminum-welding sections call for suitable training and practice.

Engine Changes and Boost-Control Diagnosis

The New Vehicle Manual separates changes applying to the 5-speed and 6-speed cars. Its 6M/T 4G63 section explains the five-ply head gasket, revised piston cooling channels and rings, lighter counterbalance shafts, altered intake-cam profile, larger-nozzle 10.5T turbocharger, and sound-absorbing tailpipe.

The dual-solenoid control diagrams identify No. 2 as non-operational on the 5M/T. The service supplement adds the MPI system diagram, No. 2 solenoid fault procedure, ECU terminal references, and the P1500-to-P0622 diagnosis-code change for the 6M/T.

Connector and harness checks help distinguish solenoid, wiring, and ECU faults when tracing boost-control problems. Fuel-filler-neck clamp placement and air-cleaner removal and fitting are also covered where the MR build differs.

Super AYC and 4WD Fault Isolation

The design section explains the Super AYC differential’s aluminum clutch case, revised clutch discs, high-strength hypoid gears, and altered ABS communication strategy.

The diagnostic charts address abnormal tire diameter, TPS, pressure sensors, longitudinal and lateral G sensors, stop-lamp and ACD-mode switches, parking-brake input, and ACD indicator faults. Separate checks cover loss of communication between MUT-II/III and the 4WD-ECU.

The charts distinguish ACD-only and combined ACD/AYC equipment where their wiring or diagnostic paths differ, helping match the checks to the vehicle’s configuration.

Bilstein Struts and Exterior Fittings

The front-strut exploded view is supported by spring-compressor instructions, spring-seat indexing, and special tools MB991367, MB991385, MB991237, and MB991238. The rear shock-absorber drawing identifies the assembly components and refers to existing servicing instructions for dismantling and assembly.

Impact-wrench use can damage the spring compressor or loosen the locknut inside the Bilstein strut piston rod.

Exterior documentation includes front-bumper component breakdowns, badge adhesive locations, and factory positioning data for the three-diamond and Evolution MR rear markings.

Aluminum Roof and Collision Repair

The body publication maps the aluminum roof, added pillar supports, and aluminum front and rear door beams. Roof-replacement documentation includes straight-line measurements with the roof removed, weld symbols, service joints, rivet points, structural-adhesive areas, sealant locations, and replacement-panel fitting requirements.

Separate sections cover panel straightening, distortion correction, MIG repair procedures, TIG and gas-welding guidance, surface preparation, filler work, and repair painting. A body-color chart and rear-spoiler paint breakdown are included.

The roof-removal notes warn that unsupported side structures can spread or lean. Aluminum-repair cautions also identify corrosion from steel-contaminated sanding tools and cracking from unsuitable steel-panel hammers.

Changed Wiring and Connector References

The electrical supplement records revised engine-transmission, instrument-panel, control-harness, and trunk-interior connections. It identifies the added No. 2 wastegate-solenoid connector, relocation of the 4WD-ECU connections to the control harness, and changed immobilizer and solenoid installation positions.

Circuit examples include junction and power-supply distribution, engine control, manual air conditioning, ABS, ACD-only, combined ACD/AYC, and the engine immobilizer. Only modified or added circuits are reproduced; unchanged wiring remains in Electrical Wiring Diagram manual P/N 1036K77.

Observe the manual’s SRS/pretensioner precautions and its two-person, safe-location requirement for full-throttle boost testing.

Examples of 4WD Circuit Test Specifications

For ACD-equipped vehicles, the wheel-speed sensor circuit checks specify 1.2–1.6 kΩ at the harness side of the disconnected C-38 4WD-ECU connector.

The Code 47 pressure-sensor supply diagnosis specifies 4.9–5.1 V between C-37 terminal 43 and ground with the ignition ON.