The engine of the EVOLUTION-IV is based on the 4G63 DOHC turbocharged unit used in the EVOLUTION-III.
Its right/left alignment has been reversed and its structure simplified and optimized. In addition, it incorporates
the revisions shown below for increased output and durability.
Aim (f: Newly adopted item;
F: Item already adopted on other engines)
Revision
Revised engine mounting alignmentF
Serpentine-belt-driven auxiliary devicesF
Three-layer cylinder head metal gasketFF
High-strength forged pistonsf
Higher
performance
Quieter
operation
Cleaner
exhaust
emissions
Higher
reliability
Lower
weight
High-strength connecting rodsf
Steel flywheelff
High-capacity water pumpf
Straight-port intake manifoldF
Twin-scroll turbochargerf
Throttle body with new type of ISC systemFFF
New type of compact throttle position sensorFF
New type of air flow sensorf
Secondary air systemf
Low-noise fan alternatorF
Crankshaft mounted crank angle sensorFFF
Plug-top ignition coilsFF
The engine of the EVOLUTION-V is based on the 4G63 DOHC turbocharged unit used in the EVOLUTION-IV .
It incorporates the revisions shown below for increased output and durability.
4G63 DOHC with Turbocharger4G63 DOHC with Turbocharger
Output (PS)
Output (PS)
Torque (kgf.m)
<EVOLUTION-V>
Torque (kgf.m)
Engine speed (rpm)
Fuel consumption rate (g/PS.h)
Engine speed (rpm)
Fuel consumption rate (g/PS.h)
Page 5
ENGINE – Main Unit
1-5
Alumite-treated
54.65 mm ← 61.65 mm
MAIN UNIT
PISTONS
(1) A revised production method enhances the pistons’ fatigue
strength.
(2) The No. 1 ring grooves are alumite-treated.
<EVOLUTION-V>
Reduced weight enhances engine responsiveness.
CONNECTING RODS
Shot blasting is performed again after coining, giving the connecting rods approximately 15% more fatigue strength than
the connecting rods used in the EVOLUTION-III.
Steel flywheel
Cast iron flywheel
FLYWHEEL
For lightness, the flywheel is made from steel instead of the
earlier cast iron.
Page 6
1-6
ENGINE – Lubrication System
LUBRICATION SYSTEM
ENGINE OIL COOLER
<EVOLUTION-IV>
A corrugated-fin-type air-cooled engine oil cooler is utilized.
<EVOLUTION-V>
The oil cooler core has increased dimensions, and an air
duct has been added to the front bumper to improve the efficiency with which the engine oil is cooled.
Specifications
ItemSpecification
EVOLUTION-IV
TypeDrawn-cup←
EVOLUTION-IVEVOLUTION-V
EVOLUTION-V
Core dimensions (width
height depth) (mm)
Engine oil cooler oil
capacity (cc)
Heat release
(kW {kcal/h})
200 100 32200 130 32
160210
4.7 {4,080}5.1 {4,380}
Page 7
ENGINE – Cooling System
{kgf⋅m})
1-7
COOLING SYSTEM
As compared with the EVOLUTION-IV’s cooling system, the EVOLUTION-V’ system incorporates the following
modifications for further enhancement of cooling performance:
2
DRevised radiator cap valve opening pressure (88 kPa {0.9 kgf/cm
DModified radiator fan assembly
DIntercooler water spray system plus new radiator water spray system
RADIATOR FAN ASSEMBLY
For improved cooling performance, the radiator fan’s shape has been modified and the motor specifications
have been revised.
Specifications
ItemEVOLUTION-IVEVOLUTION-V
Radiator fan motorManufacturerCalsonic←
TypeDirect-current ferrite←
} → 108 kPa {1.1 kgf/cm2})
Rated load torque (Nm
Speed (r/min)LOW: 1,750 " 250LOW: 1,900 " 250
Current (A)LOW: 12.0 (or lower)LOW: 13.3 (or lower)
LOW: 43.1 {4.4}LOW: 31.4 {3.2}
HI: 53.2 {5.4}HI: 53.9 {5.5}
HI: 2,100 " 250HI: 2,200 " 250
HI: 15.5 (or lower)HI: 16.7 (or lower)
<EVOLUTION-V><EVOLUTION-IV>
Page 8
1-8
ENGINE – Cooling System
INTERCOOLER AND INTERCOOLER WATER SPRAY SYSTEM
A large intercooler is utilized to improve cooling performance. An intercooler water spray system sprays
water from the washer tank onto the intercooler’s front surface to lower the intercooler’s temperature.
The intercooler water spray system is basically the same as that used on the EVOLUTION-III.
Construction
Washer tank
Water spray nozzle
Intercooler
Bumper
Water
spray
Water
Intercooler
Floor console
Water spray
switch
Page 9
ENGINE – Cooling System
1-9
INTERCOOLER AND RADIATOR WATER SPRAY SYSTEM
<EVOLUTION-V>
The EVOLUTION-V is provided with a new radiator water spray system in addition to the intercooler water
spray system.
Radiator
Nozzle assembly
Nozzle assembly
(for radiator)
Air conditioner
condenser
Bumper face
for radiator
Nozzle assembly
(for intercooler)
WATER PUMP
The water pump’s inlet diameter and impeller diameter have
been increased to improve cooling performance.
Page 10
1-10
ENGINE – Intake and Exhaust Systems
INTAKE AND EXHAUST SYSTEMS
TURBOCHARGER
Low-speed performance and responsiveness are improved
by a twin-scroll turbocharger with a dual passage arrangement
from the exhaust manifold to the turbine.
Twin scroll
Dual exhaust
manifold
<EVOLUTION-V>
The nozzle cross-sectional area has been increased for improved performance at mid-range and high
speeds.
Section A-A
Nozzle cross-sectional area
Page 11
ENGINE – Intake and Exhaust Systems
1-11
EXHAUST PIPE
EVOLUTION-IV
The exhaust pipe is constructed in three parts. It has the following key features:
DLarge, sound-absorbing pre-mufflers that reduce the high-frequency components of exhaust noise;
DA stainless steel main muffler that is highly resistant to corrosion;
DA heat-retaining cover on the front pipe that enhances the catalytic converter’s effectiveness.
Construction
Main muffler
Catalytic converter
Pre-muffler
EVOLUTION-V
DIn accordance with revised safety regulations, the high temperature sensor and heat protectors have
been eliminated.
DIn accordance with the addition of a front cross member bar (see “Suspension” in Group 3) the front
exhaust pipe has been provided with an indent to prevent interference <vehicles with 17-inch wheels>.
High temperature sensor (eliminated)
<Vehicles with 17-inch wheels>
Front exhaust pipe
Indent
Front cross
member bar
Heat protector (eliminated)
Page 12
1-12
ENGINE – Mounting
Rear roll
stopper
Insulator diameter reduced
from φ70 mm to φ60 mm
MOUNTING
REAR ROLL STOPPERS <EVOLUTION-V>
Front of
vehicle
Center member
The insulator diameter has been reduced from φ70 mm to
φ60 mm to reduce engine roll.
CENTER MEMBER <EVOLUTION-V>
DRigid mounting of the center member (achieved using added spacers) decreases engine roll.
DIn accordance with the addition of a front cross member bar (see “Suspension” in Group 3) a bracket
has been added to the lower reinforcement to protect the heads of the front cross member bar’s
mounting bolts and a front cross member bar mounting nut has been added <vehicles with 17-inch
wheels>.
Center Member Mounting
<EVOLUTION-V><EVOLUTION-IV>
Collar
Upper bushing
Lower bushing
Center member
Center member
NOTE:
This drawing shows the front mounting. The rear mounting is similar.
Rigid mounting spacer (added)
Front cross member bar
mounting nut (added)
Front of
vehicle
Bracket added to lower reinforcement to protect
heads of front cross member bar mounting bolts
<vehicles with 17-inch wheels>
Rigid mounting spacer (added)
Page 13
ENGINE – Fuel System / Control System
1-13
FUEL SYSTEM
The fuel system is basically the same as that of the 4G63 DOHC turbocharged engine used in the EVOLUTIONIII.
Fuel filter
Intake manifold
Delivery pipe
Injector
Injector
Engine
Injector
Injector
Fuel pressure control
solenoid valve
Fuel pressure
regulator
(regulated pressure:
294 kPa {3.00 kgf/cm
Fuel tank
2
})
Filter
Fuel pump
CONTROL SYSTEM
The control system is based on that of the 4G63 DOHC turbocharged engine used in the EVOLUTION-III.
For enhanced torque and output, it incorporates the following improvements:
(1) A new type of air flow sensor significantly reduces air intake resistance.
(2) A flow-limiter-type idle speed control system provides superior control over the engine’s idle speed
during warm-up.
(3) The crank angle sensor is attached directly to the crankshaft to enhance accuracy.
(4) A stick-type cam position sensor is used.
(5) The ignition system utilizes plug-top coils with built-in power transistors for enhanced ignition performance.
(6) An alternator control system enhances fuel efficiency while the engine is idling.
(7) A high/low two-speed fan control relay is utilized.
(8) The engine control relay and fuel pump control relay are located separately to enable simpler circuitry.
(9) A secondary air system has been added to enhance acceleration response.
(10)The ignition timing adjustment connector has been eliminated.
(11)The air conditioner refrigerant medium pressure switch has been eliminated.
Page 14
1-14
ENGINE – Control System
Air flow sensor (AFS)
Intake temperature sensor
Atmospheric pressure sensor
Coolant temperature sensor
Throttle position sensor (TPS)
Idle switch
Cam position sensor
Crank angle sensor
O2 sensor
Vehicle speed sensor
Air conditioner switch
Power steering fluid pressure switch
Engine ECU
[1] Fuel injection control
[2] Idle speed control (ISC)
[3] Ignition timing control
[4] Control relay control
(supply of power to sensors and actuators)
[5] Fuel pump control
[6] Air conditioner relay con-
Fan motor relay (radiator; air conditioner condenser)
Fuel pressure control valve
Wastegate solenoid valve
Alternator FR terminal
Ignition switch IG terminal
Ignition switch ST terminal
Knock sensor
Power supply
High temperature sensor
Diagnosis control terminal
[12] Secondary air control
[13] Fuel pump delivery rate
control
[14] Exhaust temperature warning
lamp control
[15] Engine warning lamp control
[16] Diagnosis output
[17] Engine speed output
[18] RAM data transmission
Secondary air control solenoid
valve
Fuel pump relay No. 2
Exhaust temperature warning
lamp
Engine warning lamp
Diagnosis output terminal
Tachometer
Diagnosis output terminal (MUT -II)
Page 15
<4G63 DOHC with Turbocharger>
Vehicle speed sensor
Air conditioner switch
Power steering fluid pressure switch
Alternator FR terminal
Ignition switch IG terminal
Ignition switch ST terminal
Power supply
Cam position sensor
Crank angle sensor
High temperature sensor
Coolant temperature sensor
Knock sensor
O
Atmospheric pressure sensor
Air flow sensor
Intake temperature sensor
Idle switch
Throttle position sensor
ENGINE – Control System
Engine ECU
Injectors
sensor
2
Fuel pressure control valve
ISC servo
Wastegate solenoid valve
Secondary air control solenoid valve
1-15
Ignition coils (power transistors)
Control relays
Fuel pump relay
Air conditioner relay
Alternator G terminal
Fan motor relay
Exhaust temperature warning lamp
Engine warning lamp
Diagnosis output terminal
Tachometer
Secondary
air valve
Page 16
1-16
ENGINE – Control System
Air flow sensing
element
Air
Air deflector
Bypass
passage
Air
Vortex-inducing
pillar
Air flow sensing circuitry
Vortex-inducing pillar
Bypass passage
Shape of
conventional
sensor
Air from
bypass
passage
Kármán
vortex
SENSORS
Air Flow Sensor (Incorporating Atmospheric Pressure
Sensor)
To reduce pressure losses and thus improve performance,
Mitsubishi Motors developed a new air flow sensor known
as MUKAS. In contrast with a conventional sensor, which
senses Kármán vortices downstream of a vortex-inducing pillar
using a pressure-sensitive element, the MUKAS sensor counts
Kármán vortices in a bypass passage using a hot-wire arrangement.
Pressure losses
reduced by 50%
Size and weight
reduced by 20%
Improved resistance
to contamination and
noise
Increased sensitivity at low air flow
rates enables the use of a larger air
inlet. Thus, pressure losses are reduced.
A more condensed circuit layout
and a new, compact connector enable a significant reduction in overall length.
Only a small amount of air flows
through the bypass passage, so
contamination is greatly reduced.
Also, Kármán vortices are mea-
sured digitally in accordance with
the difference in signals received
from left and right hot-wire arrangements, so the sensor is resistant to
noise and to changes in the components that occur over time.
From air
intake hose
ACTUATORS
Secondary Air Control Solenoid Valve
The secondary air control valve is an ON/OFF solenoid valve.
It switches the pressure applied to the secondary air valve
between the intake manifold vacuum pressure and the atmospheric pressure.
When the coil is not energized, continuity exists between the
X-nipple and ambient air. When the coil is energized, continuity
exists between the X-nipple and Y-nipple.
Secondary Air Valve
The secondary air valve turns ON and OFF the secondary
air supply by opening and closing in accordance with the vacuum pressure applied to the diaphragm chamber.
To exhaust
manifold
Page 17
FUEL INJECTION CONTROL
Fuel pressure
regulator
To fuel tank
To cam
rear side
From fuel
pump
ENGINE – Control System
Fuel pressure
control valve
Engine ECU
Injectors
Air flow sensor
Intake temperature sensor
Atmospheric pressure sensor
Throttle position sensor
Idle switch
Ignition switch ST terminal
sensor
O
2
Vehicle speed sensor
Crank angle sensor
Knock sensor
Coolant temperature sensor
Cam position sensor
1-17
IDLE SPEED CONTROL
Bimetallic limiter
To intake manifold
ISC servo
(stepper motor)
Speed adjusting
screw (SAS)
From air cleaner
Engine ECU
Ignition switch IG terminal
Ignition switch ST terminal
Power steering fluid pressure switch
Air conditioner switch
Vehicle speed sensor
Crank angle sensor
Coolant temperature sensor
Atmospheric pressure sensor
Air flow sensor
Intake temperature sensor
Throttle position sensor
Idle switch
Alternator FR terminal
Page 18
1-18
ENGINE – Control System
IGNITION TIMING AND ENERGIZATION TIME CONTROL
Air flow sensor
Intake temperature sensor
Atmospheric pressure sensor
Coolant temperature sensor
Idle switch
Cam position sensor
Crank angle sensor
Vehicle speed sensor
Ignition switch ST terminal
Knock sensor
Engine ECU
Tachometer
Ignition coil B
Cylinders
Ignition
switch
Ignition coil A
Battery
Page 19
ENGINE – Control System
POWER SUPPLY AND FUEL PUMP CONTROL
Battery
1-19
Ignition
switch
Fuel
pump
relay
Fuel pump control
Engine ECU
To fuel
pump
Ignition switch
IG signal
To injectors, ISC
servo, etc.
Control
relay
Power
supply
Backup
power
Power
control
AIR CONDITIONER RELAY CONTROL; AIR FLOW SENSOR FILTER RESET CONTROL;
FUEL PRESSURE CONTROL; BOOST PRESSURE CONTROL; EXHAUST TEMPERATURE WARNING LAMP CONTROL
The control arrangement is the same as that used with the 4G63 DOHC turbocharged engine of the EVOLUTION-III.
Page 20
1-20
ALTERNATOR CONTROL
ENGINE – Control System
Coolant temperature sensor
Crank angle sensor
Air conditioner switch
Power steering fluid pressure
switch
Ignition switch ST terminal
Engine ECU
Alternator G terminal
Alternator FR terminal
Alternator
ENGINE SPEED OUTPUT
Engine speed signals are issued in synchronization with crank angle sensor signals.
Engine ECU
Crank angle
sensor signals
To tachometer
Engine speed
signals
Page 21
ENGINE – Control System
1-21
F AN MOTOR RELA Y (RADIA TOR FAN; AIR CONDITIONER CONDENSER FAN) CONTROL
Battery
Ignition switch
Radiator fan
motor relay
(HI)
Radiator
fan motor
Radiator fan
motor relay (LO)
Condenser
fan motor
relay (HI)
Condenser
fan motor
Engine ECU
High-speed side
Condenser fan
motor relay (LO)
Coolant temperature
sensor
Throttle position sensor
Idle switch
Crank angle sensor
Air conditioner switch
During deceleration from a high speed, secondary air is introduced upstream of the turbocharger. This
operation prevents the turbine’s speed from dropping and thus enhances responsiveness when the driver
next wishes to accelerate. For maximum effectiveness, secondary air is introduced into the exhaust manifold
immediately downstream of each cylinder.
Engine ECU
Secondary air
control solenoid
valve
Secondary air
valve
Control relay
Battery
Vacuum
tank
Secondary air is introduced for approximately three minutes when both of the following conditions are
satisfied:
DThe engine speed is 4,000 rpm or higher.
DThe engine speed drops sharply after at least three seconds of full-throttle acceleration.
Page 23
Control
relay
Ignition
switch
Fuel pump
relay No. 2
Engine ECU
Battery
ENGINE – Control System
FUEL PUMP DELIVERY RATE CONTROL
1-23
Fuel
pump
Resistor
Page 24
1-24
ENGINE – Control System
SELF-DIAGNOSIS SYSTEM
Engine Warning Lamp (Check Engine Lamp) Control
The engine warning lamp illuminates in the event of an abnormality in any of the items shown in the
following table.
Air flow sensorAtmospheric pressure sensor
Intake temperature sensorKnock sensor
Throttle position sensorInjectors
Coolant temperature sensorIgnition coils; power transistor units
Crank angle sensorEngine ECU
Cam position sensor
Diagnosis Function
Diagnosis items are shown in the following table.
Code No.Diagnosis itemMain fault(s) diagnosed
12Air flow sensorOpen/short circuit in sensor-related circuitryNo
13Intake temperature sensorOpen/short circuit in sensor-related circuitryNo
14Throttle position sensorAbnormal sensor outputNo
21Coolant temperature sensorD Open/short circuit in sensor-related circuitry
D Increased contact resistance in connector
22Crank angle sensorAbnormal sensor outputNo
23Cam position sensorAbnormal sensor outputNo
24Vehicle speed sensorOpen/short circuit in sensor circuitryNo
25Atmospheric pressure sensorOpen/short circuit in sensor-related circuitryNo
31Knock sensorAbnormal sensor outputNo
41InjectorsOpen/short circuit in injector-related circuitryNo
44Ignition coils; power transistor unitsAbnormality in ignition system (failure in one out
of two coils)
64Alternator FR terminalOpen circuit in sensor circuitryNo
—Normal state——
Dealer mode
diagnosis
No
No
Page 25
ENGINE – Control System
Service Data Output
Service data output items are shown in the following table.
Item No.Service data itemUnit
11O2 sensormV
12Air flow sensor outputHz
13Intake temperature sensor output°C
14Throttle position sensor outputmV
16Battery voltageV
18Cranking signal (ignition switch ST terminal)ON-OFF
21Coolant temperature sensor output°C
22Crank angle sensor outputRPM
25Atmospheric pressure sensor outputkPa
26Idle switchON-OFF
27Power steering fluid pressure switchON-OFF
28Air conditioner switchON-OFF
Actuator test items are shown in the following table.
Item No.Actuator test item
01No. 1 injector: OFF
02No. 2 injector: OFF
03No. 3 injector: OFF
04No. 4 injector: OFF
07Fuel pump: ON
09Fuel pressure control valve: ON
12Wastegate solenoid valve: ON
13Fuel pump relay No. 2: ON (current supplied via resistor)
17*Ignition timing: 5°BTDC
20Radiator fan (high), air conditioner condenser fan (high): high-speed operation
21Radiator fan (low), air conditioner condenser fan (low): low-speed operation
30*ISC servo: locked in reference step during SAS adjustment
*: Continues for 27 minutes unless cancelled by depression of clear key.
Page 26
1-26
ENGINE – Exhaust Emission Control System
EXHAUST EMISSION CONTROL SYSTEM
System Diagram
Canister
Check valve
O
sensor
2
PCV valve
Fuel pressure
regulator
Injector
Intake air
High temperature sensor
Three-way catalytic converter
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