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NEW MODEL INFORMATION MANUAL LANCER EVOLUTION-VIII CONTENTS General FOREWORD Engine This manual has been prepared as an explanation of the main changes in the 2003 LANCER-EVOLUTION-VIII. It only describes the differences from the LANCER- EVOLUTION-VII. It should be used in conjunction with the Power Train related material in the following pages.
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Related documentation Document name Month and year of publication New model information manuals • Mirage/Lancer 1036F30 October 1995 • Mirage/Lancer 1036F31 January 1996 • Mirage/Lancer 1036F32 August 1996 • Mirage/Lancer 1036F33 July 1997 • Lancer 1036F34 January 1998 • Mirage/Lancer 1036F35 October 1998 •...
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GENERAL – EXTERIOR, VEHICLE IDENTIFICATION AND IMPLEMENTATION NUMBER SECTION 0 GENERAL CONTENTS Exterior ............0-1 Development Aims .........0-2 Vehicle Identification ......0-1 Technical Features .........0-3 Implementation Code ......0-1 Lancer Evolution-VIII Index ....0-4 Model Code and Class Code ....0-2 Exterior AC210961 Vehicle Identification Model Class 2003 Grade...
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Development Aims The Lancer Evolution-VIII is based on the Lancer Evolution-VII, which has proved its high speed capability in all fields of motor sport in Japan and internationally. At the same time, feedback from the actual experience of the Lancer Evolution-VII has been given to the Development team, and the standards for a motor sports based vehicle have been raised.
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GENERAL – TECHNICAL FEATURES Technical Features Exterior • New shape front bumper Accessories • Full carbon-fibre rear boot spoiler • Full-scale 270 km/h speedometer • Newly designed alloy wheels • Immobiliser system • New shape bonnet • Clear rear combination light lens Engine Transmission •...
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GENERAL – LANCER EVOLUTION-VIII INDEX Lancer Evolution-VIII Index Lancer Evolution-VIII Index Lancer Evolution-VIII Base model (Lancer Evolution-VII) GH-CT9A SNDFZ RS (5M/T) GH-CT9A SNDFZ SJDFZ RS (6M/T) SJGFZ SNGFZ Sections that are different from base model Sections that are different from base model...
Engine (4G6) General information The 4G63-T/C engine of the Lancer Evolution-VIII is basically the same as the 4G63-T/C engine of the Lancer Evolution-VII. The basic structure is the same, but the following improvements and performance upgrades have been implemented. • Changes from a three section split mold to a two section split mold •...
ENGINE (4G6) – GENERAL INFORMATION AND BASE ENGINE 2. Engine Performance Curve Shaft output (kW) Shaft torque (N-m) AC211451AB Engine r.p.m. Base Engine 1. Timing belt cover The timing belt cover has changed from a three section split mold to a two section split mold. The materials have been changed from aluminium to resin.
ENGINE (4G6) – BASE ENGINE 2. Piston The skirt has been reinforced in order to reduce friction. A high temperature fatigue resistant alloy has been adopted in order to improve reliability. 6EN2240 3. Valve spring Beehive-shaped valve springs already introduced in Japan, have been adopted. The diameter of the retainer has been reduced and its material has been changed from chrome to abrasion resistant alloy.
ENGINE (4G6) –ENGINE AND COOLING EQUIPMENT 4. Delivery pipe The material of the delivery pipe has changed from alloy to steel plate to reduce vibration noise. Cooling System The cooling system has changed as follows.
ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT Intake and Exhaust Equipment 1. Air intake system 1-1 Intercooler It is basically the same as the original Lancer Evolution-VII, but the air guides at the bottom of the intercooler assembly have been discontinued in line with changes to the front bumper. Intercooler assembly Intercooler assembly Air guide...
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ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT 1-2 Intercooler water spray It is basically the same as the original Lancer Evolution-VII, but the water spray hose has been changed in line with changes to the front bumper. Washer tank Intercooler assembly Water spray hose assembly Intercooler assembly...
ENGINE (4G6) – FUEL SYSTEM Fuel System The fuel system is basically the same as that in the original Lancer Evolution-VII, but the following changes have been made: • The fuel tank assembly has been changed and the tank capacity has been increased in order to extend the range. •...
ENGINE (4G6) – FUEL SYSTEM 1. Fuel tank The shape of the fuel tank has been changed. In order to extend the range, the tank capacity of the GSR has been increased to 55 litres, and the tank capacity of the RS has been increased to 50 litres taking into consideration the balance between range and the RS’s weight, and motor sport requirements.
ENGINE (4G6) – CONTROL SYSTEM Control System The following changes have been made to the controls of the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII: • MDP (Manifold Differential Pressure) sensor has been discontinued. • EGR control has been discontinued. •...
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1-10 ENGINE (4G6) – CONTROL SYSTEM Control system diagram 1 Injector • Engine control relay 1 Oxygen sensor • Power supply • Fuel pump relay 2, 3 • Ignition switch-IG 2 Air flow sensor 2 Idle speed control • A/C relay •...
ENGINE (4G6) – CONTROL SYSTEM 1-11 1. Fuel injection control This is basically the same as the control system in the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII. System configuration diagram Air flow sensor Intake air temp. sensor Barometric pressure sensor Fuel pressure control solenoid valve Throttle position sensor...
1-12 ENGINE (4G6) – CONTROL SYSTEM 3. Ignition timing and distribution control Basically the same control system has been adopted as in the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII. System configuration diagram Air flow sensor Ignition switch Barometric pressure sensor Ignition coil A Ignition coil B Air intake temp.
ENGINE (4G6) – EMISSION CONTROL SYSTEM 1-13 Emission Control System The following change has been made based on the 4G63-DOHC-Turbocharger engine used in the original Lancer Evolution- VII. • The EGR system has been discontinued. Emission Control System Diagram From fuel tank Canister Check valve...
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1-14 ENGINE (4G6) – MOUNTING Mounting The shape of the transmission mounting has been changed for the new 6-speed manual transmission. Construction diagram Transmission mounting...
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SECTION 2 POWER TRAIN CONTENTS Manual transmission ......2-2 General information .........2-12 Electronic control system .........2-12 General information ...........2-2 Propeller Shaft ........2-13 Description of structure and operations (6-speed manual transmission) ......2-4 Front Axle ..........2-13 Transmission control ..........2-9 Rear Axle ..........2-13 Active Centre Differential (ACD) and Differential ..........2-14 Active Yaw Control (AYC) ....2-12...
Manual Transmission General Information • In accordance with the new additions to the Lancer Evolution-VIII, both the newly developed 6-speed transmission (W6MAA type) and the original 5-speed transmission (W5M51 type) can be installed. • The W6MAA type transmission (6-speed manual gearbox) is mounted in the GSR, and the W5M51 type (5-speed manual gearbox) transmission and the W6MAA type transmission (6-speed manual gearbox) are mounted in the RS.
POWER TRAIN – MANUAL TRANSMISSION Description of structure and operations (6-speed manual transmission) 1. Synchromesh • Triple-cone synchronisers are adopted on the 1 and 2 gears. The gear change feels smooth and lighter. • Reverse gear now has synchromesh, so that reverse can be engaged more smoothly and quietly. 1-1 Triple-cone synchromesh The purpose of the triple-cone synchromesh is to enable smooth gear changes by spreading the cone friction across three surfaces on the same axis.
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POWER TRAIN – MANUAL TRANSMISSION 1-2 Reverse synchromesh A synchroniser hub, coupling sleeve, synchroniser ring and insert spring installed on the reverse idle gear, has created a much smoother reverse gear change. This prevents abnormal grating noises and vibration that can arise when changing rapidly into reverse or when changing into reverse while the engine revolutions are too high.
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POWER TRAIN – MANUAL TRANSMISSION 2. Mechanism to stop two gears being engaged at once. This mechanism prevents engaging two gears at the same time, and is based on the selector forks which are not being used to change a gear being locked in neutral by a shift check sleeve and interlock ball. Operation (When in neutral) With the operation of the mechanism, the shift check sleeve, interlock pin and interlock ball are free when in neutral.
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POWER TRAIN – MANUAL TRANSMISSION 3. Power flow gear gear gear gear...
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POWER TRAIN – MANUAL TRANSMISSION gear gear Reverse...
This is basically the same as for the original Lancer Evolution-VII, but the following changes have been made: • A spherical gear knob is adopted only for the Lancer Evolution-VIII. • A 6-speed gear lever assembly is adopted with the addition of 6-speed transmission (basically the same as for the original Lancer Evolution-VII in the case of 5-speed transmission) •...
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2-10 POWER TRAIN – MANUAL TRANSMISSION Gear lever assembly (6 M/T) 6M/T Shift pattern The 6-speed gear lever assembly has a 6 gear position in the reverse Neutral position position of the 5-speed shift lever assembly, and the reverse gear is Reverse located further to the right.
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POWER TRAIN – MANUAL TRANSMISSION 2-11 Reverse Gear protection when changing into 5 or 6 gear The lock moves against the base bracket when shifting to 5 or 6 gear, thus preventing a change into reverse. Engaging to Engaging to gear gear Lock...
Lancer Evolution-VIII, it becomes AYC control defect, and Diagnosis Code No. 65 appears 60 seconds after Ignition is switched ON and the ACD and AYC systems stop. (the same applies if the 4WD-ECU for the Lancer Evolution-VIII is...
POWER TRAIN – PROPELLER SHAFT, FRONT AXLE AND REAR AXLE 2-13 Propeller Shaft Propeller Shaft The specifications of the propeller shaft have changed as follows for the 6M/T mounting. Specifications Item New 6M/T New and old 5M/T Universal joint Journal diameter mm 18.3 16.3 Front Axle...
2-14 POWER TRAIN – DIFFERENTIAL Differential The differential has changed as follows. • Optimisation and weight saving of the differential carrier wall thickness (RS) • Installation of super AYC (standard for GSR; optional for RS) Super AYC The performance in track competitions such as rally cross and circuit races has improved significantly with AYC, where the torque differential has increased by 1.6 compared to the original by changing the design of the AYC torque transfer differential.
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POWER TRAIN – DIFFERENTIAL 2-15 New: Super AYC (Shaft to shaft system) Old: AYC (Case to shaft system) Differential Differential mechanism mechanism (bevel gear (planetary gear system) system)
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DRIVE-CONTROL – FRONT SUSPENSION AND REAR SUSPENSION 3-1 SECTION 3 DRIVE-CONTROL CONTENTS Front Suspension ........3-1 Wheel and Tyre ........3-2 Rear Suspension ........3-1 Steering ...........3-2 Front Suspension • Traction, response and damping have been improved by optimizing strut damping response. • Ride comfort and driving stability have been improved by adjusting the spring rates Specifications Item...
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DRIVE-CONTROL – WHEEL AND TYRE, STEERING Wheel and Tyre New design 17-inch alloy wheels are fitted. (standard for GSR and RS (6M/T); optional for RS (5M/T)) Note For the specifications please refer to Section 8 – Main Accessories. Steering 1. Steering shaft •...
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DRIVE-CONTROL – STEERING 2. Oil line Noise has been reduced by improving suspension insulation and by fitting rubber mountings to the oil reservoir tank and pressure hose assembly. Rubber Mounting A view A view Rubber Mounting B view Rubber Mounting B view Rubber Mounting AC106940AB...
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BODY - MAIN BODY SECTION 4 BODY CONTENTS Main Body..........4-1 Coating ............4-4 Features of the Body Structure.....4-1 Body colour chart ..........4-4 Bonnet .............4-4 Front body............4-1 Side body ............4-2 Door ............4-5 Under body ............4-3 Keyless Entry System ........4-5 Main Body – Features of the Body Structure Front body Front deck...
BODY - MAIN BODY Side Body Side structure • Body rigidity has been improved by increasing the size of the rear door hinge reinforcement. • Suspension rigidity has been improved by adding a rear spring housing brace to the upper surface of the rear wheel housing and by adding wheel housing inner reinforcement to the side surface.
BODY MAIN BODY Underbody Rear floor • Rigidity of the rear floor seatbelt reinforcement has been improved by changing its shape. • Body rigidity has been improved by increasing the size of the seat back plate extension and the rear seat back reinforcement.
BODY – COATING, BONNET Coating Body colour chart Colour name Colour Colour Colour (paint) Coating Maintenance Name of paint (former colour symbol code number ingredient symbol manufacturer name) Cool Silver CMA10031 Alloy Kansai Paint Metallic Medium Purple CMV10005 Alloy Kansai Paint Mica Black Mica AC11342...
BODY - DOOR Door Security against theft has been improved by adding a security alarm function to the keyless entry system. Keyless entry system General information The security alarm function controls locking and unlocking by a keyless entry transmitter, and the system raises the alarm if the door is opened by a control other than the keyless entry transmitter.
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EXTERNAL PARTS – FRONT BUMPER SECTION 5 EXTERNAL PARTS CONTENTS Front Bumper ..........5-1 Rear Spoiler..........5-2 Underbody Protection ......5-2 Indication marks ........5-3 Front Bumper The front bumper has been redesigned to reflect the new Mitsubishi image, and has the following features. •...
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EXTERIOR PARTS – UNDERBODY PROTECTION Exterior Parts – Underbody protection Aerodynamic and drive line cooling efficiencies have been improved by changing the shape of the underbody protection. Front bumper Underbody protection AC210652AK Rear Spoiler The rear spoiler adopts a carbon construction of a new design that looks like the tail fin of an aeroplane. It has the following features: •...
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EXTERIOR PARTS – IDENTIFICATION MARKS Identification marks The EVOLUTION identification mark on the boot lid has changed EVOLUTION identification mark Boot lid...
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EXTERNAL PARTS – FRONT BUMPER SECTION 6 INTERNAL PARTS CONTENTS Floor Console..........6-1 SRS Air Bag and Pretensioner with Seatbelt ...........6-2 Floor Console The “Evolution indication mark” is affixed to the front floor console shift lever panel. Front floor console Evolution indication mark AAC211121...
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INTERNAL PARTS – SRS AIR BAG AND PRETENSIONER WITH SEATBELT SRS Air Bag and Pretensioner with Seatbelt The following changes have been made to the Supplemental Restraint System of the Lancer Evolution-VII. • In the case of the sports-specific model RS, weight saving has been achieved by making the passenger-side airbag optional equipment instead of standard equipment.
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INTERNAL PARTS – SRS AIR BAG AND PRETENSIONER WITH SEATBELT 6-3 Seatbelt with pretensioner Passenger restraint has been improved by changing the structure of the Lancer Evolution-VIII pretensioner. Note Please refer to the June 2001 Airtrek New Model Instruction Manual (No. 1036R30) for the structure and operation of the seatbelt with pretensioner.
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EQUIPMENT - MAIN BODY SECTION 7 EQUIPMENT CONTENTS Engine Immobiliser System....7-1 General Information........7-3 Exterior Lights ........7-2 Functions and Controls of Combination Meter .........7-2 SWS ECUs ..........7-3 Smart Wiring System (SWS)....7-3 Adjustment Functions (User Mode)..7-17 Adjustment Functions (Supplier Mode) .............7-17 Engine Immobiliser System The engine immobiliser system is anti-theft equipment that inhibits the engine’s fuel injection and disables starting if someone tries to start the engine with an ignition key other than that which is registered for the car.
EQUIPMENT - EXTERIOR LIGHTS AND COMBINATION METER Exterior lights • The appearance of the headlights has been improved by darkening the entire inside of the light except for the reflector. • The appearance of the rear combination lights has been improved by making the outer lenses clear (the colour of the turn signal light is amber) and by darkening the entire inside of the light except for the reflector.
EQUIPMENT - SMART WIRING SYSTEM (SWS) Smart Wiring System (SWS) General Information The SWS version has changed (changed from the original Ver. 0 to Ver. 3) Functions and controls of SWS ECUs The following functions are controlled by the SWS ECUs Function Control ECU Ignition key still inserted reminder function...
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EQUIPMENT - SMART WIRING SYSTEM (SWS) Light still ON reminder function Tail lights, fog lights or headlights If the ignition key is still in when the driver’s door is opened and a tail (Key light, fog light or headlight is ON, a buzzer will sound continuously to Key still in removed) reminder...
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EQUIPMENT - SMART WIRING SYSTEM (SWS) Central door lock control function Lock switch When the driver’s door is locked (the lock switch is turned ON after the unlock switch in the driver’s door actuator is turned OFF), the ETACS- ECU will activate the lock relay output for 0.25 seconds and lock all the Unlock switch doors.
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EQUIPMENT - SMART WIRING SYSTEM (SWS) Electric window timer function (Initial Setting: 30 seconds) Ignition switch (1G1) When the ignition switch is turned to the ON position, the ETACS-ECU Driver’s door (Open) will turn on the electric window relay and electric window switch switch reception permission signal (SWS signal sent from the ETACS-ECU).
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EQUIPMENT - SMART WIRING SYSTEM (SWS) 2. The front ECU decides the intermittent time T1 according to the incoming SWS data signal, and turns on the windscreen wiper drive Windscreen signal. The windscreen wiper stop signal will go off when the wiper is in wiper auto- stop signal the stop position, and the windscreen wiper drive signal will be turned...
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EQUIPMENT - SMART WIRING SYSTEM (SWS) • Low speed wiper, high speed wiper control If the windscreen low speed wiper switch of the column switch is turned on when the ignition switch is in the ACC or ON position, the front ECU will turn on the windscreen wiper drive signal, turn off (LO) the windscreen wiper speed relay, and move the windscreen wiper at low speed.
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EQUIPMENT - SMART WIRING SYSTEM (SWS) Rear wiper and washer control function (Initial Setting: 8 seconds; continuous movement OFF) 1. If the rear wiper switch of the column switch is turned on when the ignition switch is in the ACC or ON position, the ETACS- ECU will carry out intermittent movement in 8 second cycles from 7.4 seconds after the rear wiper drive signal has been on for 3 seconds (moves approximately twice).
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7-10 EQUIPMENT - SMART WIRING SYSTEM (SWS) Electric retractable door mirror control function • Electric retractable mirror timer function If the retract / return switch of the electric remote control switch is turned on when the ignition switch is in the ACC or ON position, the electric retractable mirror relay (retract or return) will be on for 16 seconds, and retract or return will be operated.
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EQUIPMENT - SMART WIRING SYSTEM (SWS) 7-11 2. Ignition synchronized retract and return function It returns by switching on the ignition switch, and retracts when the ignition switch is in the OFF (LOCK) position and the driver’s door is opened. Ignition switch Driver’s door switch...
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7-12 EQUIPMENT - SMART WIRING SYSTEM (SWS) Headlight auto-cut function (Initial setting: Function ON (no auto-cut when the ignition switch is in the LOCK (OFF) position and the tail lights have been put on)) If the lighting switch (tail light switch or the headlight switch) is on, the headlights (including the tail light etc.) will automatically go off in the following conditions to prevent the battery from discharging.
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EQUIPMENT - SMART WIRING SYSTEM (SWS) 7-13 Fog light function By turning the fog light switch ON when the tail lights or headlights have been turned on (tail light switch or headlight switch ON), the fog light relay goes ON and the fog lights are turned on. If the tail lights and headlights are turned off by turning OFF the lighting switch while the fog lights are on, the fog lights will also go off at the same time, preventing the fog lights being left on.
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7-14 EQUIPMENT - SMART WIRING SYSTEM (SWS) Dimmer type interior light function (Initial Setting: 15 seconds) When the interior light switch is in the door position, the ETACS-ECU controls the turning on of the interior light as follows: 1. When a door is opened to get in or out of the vehicle (when the ignition switch is OFF), the light respectively goes on when opened (100%), dims when closed (75%) and goes off after 15 seconds.
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EQUIPMENT - SMART WIRING SYSTEM (SWS) 7-15 Interior light auto-cut function (Initial Setting: Automatic switch off - 15 seconds) If they have been left on, interior lights (interior light, map light, luggage interior light and ignition key cylinder illumination light) that have interior light fuses, will turn off automatically in the following conditions, and battery leakage will be avoided.
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7-16 EQUIPMENT - SMART WIRING SYSTEM (SWS) Security alarm function (Initial Setting: Function OFF) When locking the door with the transmitter (but not when locking by key), a “beep, beep” sound is emitted as an initial warning. It changes to warning status after 20 seconds, and an interior warning signal is given by a “beep, beep, beep” sound if there is a warning status caused by a door being improperly open (or a door being unlocked by the transmitter or the tailgate or bonnet is open).
EQUIPMENT - SMART WIRING SYSTEM (SWS) 7-17 Adjustment Functions (User Mode) Security alarm function ON / OFF and warning signal output can be adjusted by the adjustment mode entry conditions according to each switch operation. Information that is being adjusted will be remembered even if the battery is disconnected. Adjustment mode entry conditions 1.
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7-18 EQUIPMENT - SMART WIRING SYSTEM (SWS) • Turn signal light operation sound function This function gives a buzzer sound signal in synchronization with a hazard light and turn signal light. • Keyless entry hazard feedback function This function can confirm whether a vehicle is locked or unlocked even when away from the vehicle by making a hazard light flash when locking or unlocking with the keyless entry transmitter.
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7-19 FUNCTION OFF Function OFF DOOR MIRROR Electric retractable VEHICLE SPEED Vehicle speed response function (initial setting) door mirror RESPONSE FUNCTION ON automatic return function IG SYNC FUNCTION ON Ignition synchronization KEYLESS SYNC Keyless entry synchronization FUNCTION ON FUNCTION OFF Function OFF KEYLESS Keyless entry...
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7-20 PW/KEY OFF Operation NORMAL OPERATION Normal operation even while timer is on TIMER adjustment while power window key off timer is on MAIN S/W OPERATION While timer is on, operation of each power window (except the driver’s seat power window) from the power window main switch is prohibited KEYLESS TIMER Timer lock time...
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REFERENCE MATERIALS – 4-ASPECT DIAGRAM 4-aspect Diagram The 4-aspect Diagram is included in the application materials and there are some differences from the actual equipment. Please refer to the Schedule of Lighting Devices for details of lighting devices. 1425 (Interior width) Units: mm Auxiliary brake light...
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The Outline Specification is included in the application materials and there are some differences from the actual equipment. indicates sections where there are changes compared to the original vehicle. Vehicle name and type Mitsubishi GH-CT9A Chassis name and type Mitsubishi CT9A Name of manufacturer Mitsubishi Motors Corporation Type Normal Passenger Body shape Box shaped Engine type...
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REFERENCE MATERIALS – OUTLINE SPECIFICATION Weight Chart ITEM GH-CT9A SNDFZ 040(A, CLASSIFICATION NO. B,C,D, (D,E) (A,D, (D,E, (1,D, (A,B, (D,E, (D,E, (A,D, A, D, E,W) E,W) C,D, E,J) E, W E,W) VEHICLE Front axle WEIGHT weight Rear axle weight Total 1 320 1 330 1 340...
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REFERENCE MATERIALS – DETAILED SPECIFICATION Detailed Specification The Detailed Specification is included in the application materials and there are some differences from the actual equipment. indicates sections where there are changes or additions compared to the original vehicle. ITEM GH-CT9A SNDFZ SNDFZ SNDFZ...
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REFERENCE MATERIALS – OUTLINE EQUIPMENT Outline Equipment indicates standard equipment, ∆ indicates manufacture option. There are no changes by the time of manufacture. EQUIPMENT 5M/T 6M/T ∆ Aluminium turbo Intercooler water spray system ∆ ∆ Intercooler water spray systemless Engine oil cooler 5-speed manual (short stroke type, high gear) 6-speed manual (short stroke type) Gear lever...
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REFERENCE MATERIALS – OUTLINE EQUIPMENT EQUIPMENT 5M/T 6M/T Rear spoiler (large size) ∆ ∆ ∆ Sunroof Seat material Fabric Standard type Recaro type ∆ ∆ Adjustment Slide mechanism Reclining Headrest Low back bench seat (fixed) High back bench seat (fixed) Centre arm rest (with cup holder) Seat belts Front...
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8-10 REFERENCE MATERIALS – OUTLINE EQUIPMENT, COLD CLIMATE SPECIFICATIONS, PERIODIC INSPECTION EQUIPMENT 5M/T 6M/T ∆ ∆ Warning light SRS air bag Fuel level Parking brake Charge Brake fluid Engine charge Seat belt on Door not properly closed Buzzer Lighting monitor warning Ignition key LEFT IN warning Windscreen Fixed time type intermittent...
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