Engine MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop 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 theinformation contained here will inevitably be
superseded.
Note that SI units are used in this manual. Old units arenot 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

TitleNo.Issue
DateTitleNo.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
1036K531036K54Aug 1996
May 2000
July 2000
May 2001
Oct 2001Feb 2004
Electrical Wiring Diagrams
Service Manual• Lancer Evolution VIII
• Lancer Evolution VIII MR
(supplement)
1036K77
1036K80Jan 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
1036F331036F341036F351036F36
1036F37
1036K301036K311036K321036K33
1036K34
1036K351036K361036K371036K381036K39Oct 1995
Jan 1996
Aug 1996
Jul 1997Jan 1998Oct 1998Jan 1999
Dec 1999
May 2000July 2000Jan 2001May 2001
May 2001
Jan 2002May 2002Jan 2003Feb 2003Dec 2003
Engine Service Manual
• 4G6 Engine• 4G6 Engine(supplement)
1039G46
1039G63Jan 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
1036K021036K031036K041036K051036K06
1036K07
1036K08
1036K09
1036K10May 2000
July 2000
Jan 2001May 2001Oct 2001Jan 2002May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004
Transmission Service
Manual• W5M51 ManualTransmission• W5M51 ManualTransmission(supplement)
• W6MAA Manual
Transmission
1039M17
1039M22
1039M23Jan 2001
Jan 2003
Jan 2003
Related information

001GENERAL – TECHNICAL FEATURES
SECTION 0
GENERAL
CONTENTS
Vehicle Identification ..............................01
Implementation Code .............................01Development Aims .................................01
Overview of Lancer Evolution VIII MR. 02
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
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.
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

GENERAL – OVERVIEW OF THE LANCER EVOLUTION VIII MR02
Lancer Evolution VIII MR Lancer Evolution VIII
GHCT9ASNDFZRS (5M/T)GHCT9ASNDFZRS (5M/T)
SJDFZRS (6M/T)SJDFZRS (6M/T)
SJGFZGSRSJGFZGSR
Overview of the Lancer Evolution VIII MR
Differences from the Lancer Evolution VIII
SectionDifference from Lancer Evolution VIIIPage
Change to cam profile (6 M/T)15
Enlarged turbo nozzle diameter (6 M/T)16
Adoption of tail pipe with builtin sound proofing in exhaust main
silencer (6 M/T)17
Addition of wastegate solenoid valve (1 ‡ 2)*118
Change to catalyst volume (2.0 l. ‡ 1.5 l.) (6 M/T)
Engine
Enlarged engine oil cooler
Power trainChange to super AYC differential21
Installation of Bilstein shock absorbers*231
Optional BBS 17inch alloy wheels (new design)31
Drive control
Black finish on spokes of Momo genuine leather steering wheel
(Type A) (GSR)
Aluminium used in roof panel and side door beams41
Change to body colour41
Body
Boot lid opener fitted as standard (RS)
Addition of Evolution MR logo51Exterior
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 allround (GSR)
Change to combination meter71
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.

11ENGINE (4G6) – GENERAL
SECTION 1
ENGINE (4G6)
CONTENTS
General ....................................................11
1. Major Specifications ....................................11
2. Engine Performance Curve.........................12
Base Engine (6 M/T) ...............................12
1. Cylinder head gasket...................................12
2. Pistons ..........................................................13
3. Piston rings (2nd) ........................................134. Oil rings ........................................................14
5. Counterbalance shaft .................................14
6. Camshaft.......................................................15
Intake / Exhaust System (6 M/T)............16
1. Exhaust system ...........................................16
Control system (6 M/T) ...........................18
1. Supercharging pressure control ..............110
General
The 4G63T/C engine fitted in the Lancer Evolution VIII MR is basically the same as the 4G63T/C engine used in the Lancer
Evolution VIII.
The basic structure is the same in both the 6M/T (6speed) and 5M/T (5speed) versions, but the following improvements have
been made to the 6M/T version, in order to achieve higher performance.
• Adoption of 5ply cylinder head gasket
• Addition of Vshaped groove in piston , and modified shape in cooling channel
• Reduced oil consumption by increasing tension in piston rings and reducing endtoend 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/T5M/T
Total Displacement cc1997
Combustion chamberPentroof type
Bore x stroke (mm)85.0 x 88.0
Compression ratio8.8
Camshaft arrangementDOHC4 valve
FuelPremium unleaded
Max. output (kW/rpm)206/6500
Max. torque (Nm/rpm)400/3500392/3500
Fuel systemElectronic controlled multipoint fuel injection
Ignition systemElectronic controlled twocoil
Lash adjusterEquipped

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)12
2. Engine performance curve (6 M/T)
Base Engine (6 M/T)
1. Cylinder head gasket
A5ply 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)13
2. Pistons
• Addition of Vshaped groove.
A Vshaped 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 channelVshaped
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.
ItemEvolution VIII MREvolution VIII
Tension10.5 N7.0 N
End to end gap0.30 – 0.45 mm0.35 – 0.50 mm
End to end gap

ENGINE (4G6) – BASE ENGINE (6 M/T)14
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)15
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 MREvolution VIII
Cam height mm35.9635.79
Evolution VIII MR Evolution VIII
T.D.C (top dead centre) T.D.C (top dead centre)
Intake valve open
Intake valve
closedExhaust
valve closed
Exhaust
valve openIntake valve open
Intake valve
closedExhaust
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)16
Intake / Exhaust System (6 M/T)
1. Exhaust system
11 Turbocharger
A largenozzle 10.5T turbo has been adopted in order to improve mid to highrange 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 lowspeed torque. Along with these modifications, the wastegate valve has been changed from an oval to a circular
valve.
(Evolution VIII MR) (Evolution VIII)
Turbine housingTurbine housing
Wastegate holes Wastegate holes
Oval valve Circular valve