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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pistons 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rods 5. . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION SYSTEM 6. . . . . . . . . . . . . . . .

Engine Oil Cooler 6. . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . .

Radiator Fan Assembly 7. . . . . . . . . . . . . . . . . . .

Intercooler and

Intercooler Water Spray System 8. . . . . . . . . . .

Intercooler and

Radiator Water Spray System 9. . . . . . . . . . . . .

Water Pump 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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