charging MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

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) – 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

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)18
Control system (6M/T)
The following changes have been made, based on the control system in the 4G63DOHCT/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)
O
2sensor
Ignition switch –IG
Ignition switch –STPower supplyEngine 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 controlIntercooler water spay control
Engine warning light control
O
2sensor heater control
Purge control
Diagnosis output
RAM data transmissionNo. 1 indicator
No. 2 indicator
No. 3 indicatorNo. 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 O
2sensor heater
Purge control solenoid valve
Diagnosis output terminal
Diagnosis output terminal (for
MUTII)

ENGINE (4G6) – CONTROL SYSTEM (6 M/T)110
1. Supercharging pressure control
The maximum torque has been increased, compared to the 4G63DOHCT/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
ECUBatterySecondary air
control solenoidvalve
Secondary
air valve
Ignition
switch
Air
intakeBypass valveVacuum tank
Intercooler
Turbocharger
Wastegate
actu
ator No. 1
wastegate
solenoid
valve
No. 2 wastegate
solenoid valve Crank angle
sensor

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-5
Main circuit Name of Circuit Circuit Diagram
J/B -!
J/C -#
Central junction -#
Power supply -#
Start up -!
Ignition -!
Charging -!
Engine control -#
Coolant -!
Headlights (excluding discharge type)!
Headlight (discharge type)!
Tail lights, side lights, licence plate lights, lighting monitor
warning buzzer!
Cabin lights, boot interior light, ignition key cylinder
illumination light, door not closed indicator light *2!
Fog lights!
Lighting
Headlight levelling system
!
Indicator lights, hazard warning lights!
Reversing lights *2!
Stop lights#
Signalling
Horn
!
Meters / Gauges *2!Meters
Remaining fuel warning light, oil pressure warning light,
brake warning light, seatbelt warning light *2
!
Electric windows *2!
Central door locking (vehicle not fitted with keyless entry)!
Door opening control
Central door locking (vehicle fitted with keyless entry)
!
Heater!
Fully automatic air conditioning!
Air conditioning
Manual air conditioning
#
List of Circuit Diagrams
M3000006000169
Notes:
1. This list of circuit diagrams indicates whether each circuit has been modified or added.
2. The “●” symbol indicates a circuit that has been modified or added. Diagrams for these circuits are included in
this supplement.
3. The “


” symbol indicates a circuit that is unchanged. Details of these circuits can be found in the existing
Electrical Wiring Diagram manual (’03-1 No.1036K77).
4. The “X” symbol indicates a circuit that is unrelated to the vehicle referred to in this manual.
5. The “*1” symbol marks circuits whose names have been changed the previous names.
6. The “*2” symbol marks circuits whose J/C terminal numbers have changed. For more information, please refer
to the “Details of Changes” table above.

CIRCUIT DIAGRAMS - POWER SUPPLY3-10
Power Supply
Battery
Fusible link
Special fuse
Starter
Charging•Full auto A/C
•Manual A/C
•Cooling
•Full auto A/C
•Manual A/C
•CoolingEngine
control•Security alarm
•Central door
locking
(vehicles with
keyless entry)
•Turn signal
lights, hazard
warning lightsCharging•Full auto
A/C
•Manual
A/C
•Cooling•ABS
•ACD
•Stop
lights•Heater
•Full auto
A/C
•Manual
A/C

CIRCUIT DIAGRAMS - POWER SUPPLY3-12
Power supply (cont’d)
Fusible link4
Ignition
switch
Special
fuse
Intercooler
water spray
•Engine control
•Starter
•ABS
•ACD
•SRS airbags, seat
pre-tensioners
•Ignition key reminder
buzzer
•Intercooler water
spray
•Windscreen wiper /
washer
•Warning lights
•Engine control
•Meter gauge
•Charging
•Security alarm
•Central door locking•Turn signal lights,
hazard warning lights
•Tail lights, position
lights, licence plate
lights, lighting monitor
warning buzzer
•Electric stowable
remote control door
mirrors
•Power windows
•General spare
connectors
•Fog lamps
•Headlights
•Rear wiper / washer
•Cabin lights, boot
interior light, ignition
key cylinder
illumination light, door
not properly closed
indicator lamp•SRS airbags, seatbelt
pre-tensioners
•Reversing lights
•Rear wiper / washerEngine controlIgnition