cooling 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) – 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

COMPONENT INSTALLATION POSITIONS - J/C3-3
•Windscreen wiper
& washer
•Indicator lights,
hazard warning
lights
•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer•Fog lights
•Full auto A/C
•Headlights
•Headlight levelling
system
•Manual A/C
•Cooling•Windscreen wiper
& washer
•Electric retractable
remote control
door mirror
•Cabin lights, boot
interior light,
ignition key
cylinder
illumination light,
door not properly
closed indictor light
•Heater
•Full auto A/C
•Manual A/C
•ABS
•ACD
Meter
gauge
Diagnosis
meterVehicle
speed
sensor
General
spare
connector
Power
window
•Windscreen
wiper
& washer
•Indicator lights,
hazard warning
lights•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer
•Fog lights
•Headlights•Ignition key
reminder buzzer
•Windscreen wiper
& washer
•Indicator lights,
hazard warning
lights
•Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer•Electric windows
•Fog lights
•Headlights
•Rear wiper /
washer
•Windscreen
wiper &
washer
•Indicator
lights, hazard
warning lights
•Tail lights, side
lights, licence
plate lights,
lighting
monitor
warning
buzzer
•Fog lights
•Headlights
•Rear wiper /
washer
•Reversing light
•Rear wiper /
washer
Rear wiper /
washer
Reversing
lightDiagnosis
connector
J/B
General fuse
()5

CIRCUIT DIAGRAMS - J/C3-6
J/C (cont’d)
Diagnosis
connector
Security
alarm
•Security alarm
•Horn
Full auto A/C
•ABS
•ACD
Horn
•Ignition key
reminder
buzzer
•Windscreen
wiper &
washer
•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
•Fog lamps
•Headlights
•Rear wiper /
washer•Cabin lights,
boot interior
light, ignition
key cylinder
illumination
light, door not
properly
closed
indicator light
Engine
control•Engine
control
•IgnitionMeter gauge•Engine control
•Meter gauge
•Ignition
•Engine immobiliser
system
•Engine control
•Full auto A/C
•Cooling
Engine
control
•Engine
immobiliser
system
•Engine
control
•Full auto A/C
•Cooling
Engine
immobiliser
system

CIRCUIT DIAGRAMS - CENTRAL JUNCTION3-8
Central Junction
M3030000300552
Fusible link (Relay box inside engine space)
No.CircuitTypeHousing colourRated current (A)
2Full auto air conditioning;
manual air conditioning;
coolingConnector typeRed50
Forward
direction of
vehicle

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 SUPPLY3-13
•ABS
•ACD
•Intercooler water spray
•Windscreen wiper /
washer
•Turn signal lights,
hazard warning lights
•Tail lights, position
lights, licence plate
lights, lighting monitor
warning buzzer
•Heater
•Fog lamps
•Full auto A/C
•Headlights
•Headlight levelling
system
•Manual A/C
•Cooling
•ABS
•ACDWindscreen
wiper / washerCigar lighter,
ashtray
illumination lampElectric
stowable
remote
control door
mirrors•Spare audio
connector
•Clock
•General spare
connector
•Cabin lights,
boot interior
light, ignition
key cylinder
illumination
light, door not
properly closed
indicator lamp•Rear wiper/
washer
•Cabin lights,
boot interior
light, ignition
key cylinder
illumination
light, door
not properly
closed
indicator
lamp

CIRCUIT DIAGRAMS - AIR CONDITIONING3-30
Manual Air Conditioning (cont’d)
Battery
J/C(2)
(General fuse)5Radiator fan
controller
A/C
compressor
relay
General fuse
A/C
compressor
Cooling
temperature
switch
Magnetic
switch
Dual
pressure
switchLow pressure side
ON
OFF
: 196kPa
OFF
ON
: 221kPa
High pressure side
ON
OFF
: 3138kPa
OFF
ON
: 2550kPa
Engine ECU