Mitsubishi LANCER EVOLUTION-IV, LANCER EVOLUTION-V TECHNICAL INFORMATION MANUAL

ENGINE

CONTENTS
1-1
ENGINE <4G6> 2. . . . . . . . . . . . . . . . . . . . . . . . . .
OVERVIEW 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Specifications <EVOLUTION-IV> 2. . . . .
Major Specifications <EVOLUTION-V> 3. . . . .
ENGINE PERFORMANCE CURVES 4. . . . .
MAIN UNIT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION SYSTEM 6. . . . . . . . . . . . . . . .
COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . .
Intercooler and
Intercooler and
INTAKE AND EXHAUST SYSTEMS 10. . . .
Turbocharger 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNTING 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Roll Stoppers <EVOLUTION-V> 12. . . .
Center Member <EVOLUTION-V> 12. . . . . . .
FUEL SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . .
CONTROL SYSTEM 13. . . . . . . . . . . . . . . . . .
Sensors 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Control 17. . . . . . . . . . . . . . . . . . .
Idle Speed Control 17. . . . . . . . . . . . . . . . . . . . .
Ignition Timing and
Energization Time Control 18. . . . . . . . . . . . . . .
Power Supply and Fuel Pump Control 19. . . Air Conditioner Relay Control; Air Flow
Sensor Filter Reset Control; Fuel Pressure Control; Boost Pressure Control; Exhaust
Temperature Warning Lamp Control 19. . . . . .
Alternator Control 20. . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Output 20. . . . . . . . . . . . . . . . . . .
Fan Motor Relay (Radiator Fan; Air Conditioner Condenser Fan) Control 21. .
Scondary Air Control 22. . . . . . . . . . . . . . . . . . .
Fuel Pump Delivery Rate Control 23. . . . . . . .
Self-diagnosis System 24. . . . . . . . . . . . . . . . . .
EXHAUST EMISSION
CONTROL SYSTEM 26. . . . . . . . . . . . . . . . . .
1-2
ENGINE – Overview

ENGINE <4G6>

OVERVIEW

<EVOLUTION-IV>
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 alignment F Serpentine-belt-driven auxiliary devices F Three-layer cylinder head metal gasket F F High-strength forged pistons f
Higher perfor­mance
Quieter
operation
Cleaner exhaust
emissions
Higher
reliability
Lower
weight
High-strength connecting rods f Steel flywheel f f High-capacity water pump f Straight-port intake manifold F Twin-scroll turbocharger f Throttle body with new type of ISC system F F F New type of compact throttle position sensor F F New type of air flow sensor f Secondary air system f Low-noise fan alternator F Crankshaft mounted crank angle sensor F F F Plug-top ignition coils F F
MAJOR SPECIFICATIONS <EVOLUTION-IV>
Items 4G63-DOHC-T/C Displacement (cc) 1,997 Cylinder bore stroke (mm) 85.0 88.0 Compression ratio 8.8 Valve mechanism DOHC 16-valve Fuel Unleaded premium gasoline Max. output (PS/rpm) 280/6,500 Max. torque (kgf⋅m/rpm) 36.0/3,000 Fuel supply Electronically controlled MPI Ignition timing Electronically controlled
ENGINE – Overview
Revision
1-3
OVERVIEW
<EVOLUTION-V>
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.
Aim (f: Newly adopted item;
F: Item already adopted on other engines)
Higher performance
Crankshaft pins induction hardened f Three-piece crankshaft thrust bearings F Lighter pistons f f Increased turbocharger nozzle area f Higher maximum injector flow rate (MDL510
MDL560) Heater added to O2 sensor F Divided connection of positive crankcase
ventilation (PCV) system to intake manifold
f
Reduced exhaust
emissions
Higher reliability
MAJOR SPECIFICATIONS <EVOLUTION-V>
Items 4G63-DOHC-T/C Displacement (cc) 1,997 Cylinder bore stroke (mm) 85.0 88.0 Compression ratio 8.8 Valve mechanism DOHC 16-valve
F
Fuel Unleaded premium gasoline Max. output (PS/rpm) 280/6,500 Max. torque (kgf⋅m/rpm) 38.0/3,000 Fuel supply Electronically controlled MPI Ignition timing Electronically controlled
1-4
ENGINE – Engine Performance Curves

ENGINE PERFORMANCE CURVES

<EVOLUTION-IV>
4G63 DOHC with Turbocharger 4G63 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)
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.
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
Item Specification
EVOLUTION-IV
Type Drawn-cup
EVOLUTION-IV EVOLUTION-V
EVOLUTION-V
Core dimensions (width height depth) (mm)
Engine oil cooler oil capacity (cc)
Heat release (kW {kcal/h})
200 100 32 200 130 32
160 210
4.7 {4,080} 5.1 {4,380}
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
D Revised radiator cap valve opening pressure (88 kPa {0.9 kgf/cm D Modified radiator fan assembly D Intercooler 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
Item EVOLUTION-IV EVOLUTION-V
Radiator fan motor Manufacturer Calsonic
Type Direct-current ferrite
} 108 kPa {1.1 kgf/cm2})
Rated load torque (Nm
Speed (r/min) LOW: 1,750 " 250 LOW: 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 " 250 HI: 2,200 " 250
HI: 15.5 (or lower) HI: 16.7 (or lower)
<EVOLUTION-V><EVOLUTION-IV>
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
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