ENGINE (4G6) – GENERAL 1-1 SECTION 1 ENGINE CONTENTS Engine (4G6)............................................1-1 Fuel System.............................................1-7 General information................................1-1 1. Fuel tank ........................................................1-8 1. Major specifications .......................................1-1 Control System.......................................1-9 2. Engine Performance Curve ...........................1-2 1. Fuel injection control ....................................1-11 Base Engine ............................................1-2 2. Idle speed control.........................................1-11 1. Timing belt cover............................................1-2 3. Ignition timing and distribution 2. Piston.............................................................1-3 control..........................................................1-12 3. Valve spring ...................................................1-3 4. Other controls ..............................................1-12 4. Delivery pipe ..................................................1-4 5. Diagnosis system.........................................1-12 Cooling Equipment.................................1-5 Emission Control System ....................1-13 Intake and Exhaust Equipment .............1-5 Mount .....................................................1-14 1. Air intake system............................................1-5 Engine (4G6) General information The 4G63-T/C engine of the Lancer Evolution-VIII is basically the same as the 4G63-T/C engine of the Lancer Evolution-VII. The basic structure is the same, but the following improvements and performance upgrades have been implemented. • Changes from a three section split mold to a two section split mold • Changes to piston shape and materials • Beehive-shaped valve springs • Changes to delivery pipe materials 1. Major specifications jp Items Factors Total displacement cc 1,997 Combustion chamber Pentroof type Bore x stroke mm 85.0 x 88.0 Compression ratio 8.8 Camshaft arrangement DOHC 4-valve Fuel used Unleaded premium Maximum output (kW/rpm) 206/6500 Maximum torque (Nm/rpm) 392/3500 Fuel system Electronic controlled multipoint fuel injection Ignition system Electronic controlled two-coil Lash adjuster Equipped 1-2 ENGINE (4G6) – GENERAL INFORMATION AND BASE ENGINE 2. Engine Performance Curve Shaft output (kW) Shaft torque (N-m) Engine r.p.m. AC211451AB Base Engine 1. Timing belt cover The timing belt cover has changed from a three section split mold to a two section split mold. The materials have been changed from aluminium to resin. New Old 6EN2239 ENGINE (4G6) – BASE ENGINE 1-3 2. Piston The skirt has been reinforced in order to reduce friction. A high temperature fatigue resistant alloy has been adopted in order to improve reliability. New Old 6EN2240 3. Valve spring Beehive-shaped valve springs already introduced in Japan, have been adopted. The diameter of the retainer has been reduced and its material has been changed from chrome to abrasion resistant alloy. Retainer New Old Valve spring 6EN2242 1-4 ENGINE (4G6) –ENGINE AND COOLING EQUIPMENT 4. Delivery pipe The material of the delivery pipe has changed from alloy to steel plate to reduce vibration noise. New Old Cooling System The cooling system has changed as follows. ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT 1-5 Intake and Exhaust Equipment 1. Air intake system 1-1 Intercooler It is basically the same as the original Lancer Evolution-VII, but the air guides at the bottom of the intercooler assembly have been discontinued in line with changes to the front bumper. New Old Intercooler assembly Intercooler assembly Air guide AC211453AB 1-6 ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT 1-2 Intercooler water spray It is basically the same as the original Lancer Evolution-VII, but the water spray hose has been changed in line with changes to the front bumper. New Washer tank Intercooler assembly Water spray hose assembly Old Intercooler assembly Washer tank Water spray hose assembly ENGINE (4G6) – FUEL SYSTEM 1-7 Fuel System The fuel system is basically the same as that in the original Lancer Evolution-VII, but the following changes have been made: • The fuel tank assembly has been changed and the tank capacity has been increased in order to extend the range. • A steel plate fuel delivery pipe has been adopted, fuel pulsation has been reduced as have engine vibration and noise. Specifications Items New Old Fuel tank capacity L GSR 55 48 RS 50 48 Construction Diagram New Delivery pipe Fuel tank assembly Old Delivery pipe Fuel tank assembly 1-8 ENGINE (4G6) – FUEL SYSTEM 1. Fuel tank The shape of the fuel tank has been changed. In order to extend the range, the tank capacity of the GSR has been increased to 55 litres, and the tank capacity of the RS has been increased to 50 litres taking into consideration the balance between range and the RS’s weight, and motor sport requirements. New Fuel pump and gauge assembly Cut-off valve assembly Gauge and pump assembly Fuel tank Old Fuel pump and gauge assembly Gauge and Cut-off valve assembly pump assembly Fuel tank ENGINE (4G6) – CONTROL SYSTEM 1-9 Control System The following changes have been made to the controls of the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII: • MDP (Manifold Differential Pressure) sensor has been discontinued. • EGR control has been discontinued. • Diagnostic control terminal has been discontinued. System block diagram Air flow sensor No.1 injector Engine ECU No.2 injector Intake air temperature sensor Fuel injection control No.3 injector No.4 injector Barometric pressure sensor Idle speed control Idle speed control servo (stepper motor) Engine coolant temperature sensor Ignition timing control No.1, No. 4 ignition coil No.2, No.3 ignition coil Throttle position sensor Engine control relay control Engine control A/C switch Fuel pump relay control Fuel pump relay 2 A/C load signal A/C relay control Fuel pump relay 3 A/C relay Camshaft position sensor Fan motor control (radiator) Fan controller (radiator) Crank angle sensor Fan relay control (A/C condenser) Fan motor relay (HI, LOW) (A/C condenser) Alternator FR sensor Alternator control Alternator G terminal Air flow sensor Vehicle speed sensor Air flow sensor filter reset control Fuel pressure control solenoid Power steering fluid pressure switch Fuel pressure control valve Turbocharger Waste gate solenoid valve Detonation sensor Secondary air control Secondary air control solenoid valve Intercooler water spray (auto) Intercooler water spray control Intercooler water spray relay Intercooler water spray (manual) Engine warning light control Intercooler water spray light Tachometer Oxygen sensor Oxygen sensor heater control Engine warning light (check engine light) Ignition switch-IG Purge control Oxygen sensor heater Purge control solenoid valve Ignition switch-ST Diagnosis output Diagnosis output terminal Power supply RAM data transmission Diagnosis output terminal (for MUT - II) 1-10 ENGINE (4G6) – CONTROL SYSTEM Control system diagram ★ 1 Oxygen sensor • Power supply ✩ 1 Injector • Engine control relay ★ 2 Air flow sensor • Ignition switch-IG ✩ 2 Idle speed control • Fuel pump relay 2, 3 ★ 3 Intake air temperature • Ignition switch-ST servo • A/C relay sensor • Vehicle speed sensor ✩ 3 Fuel pressure control • Ignition control ★ 4 Throttle position • A/C switch solenoid valve • Fan controller Sensor • A/C load signal ✩ 4 Waste gate solenoid • Condenser fan relay (HI) • Condenser fan relay ★ 5 Camshaft position • Power steering fluid ➩ Engine ➩ valve sensor pressure switch -ECU ✩ 5 Purge control solenoid (LOW) ★ 6 Crank angle sensor • Alternator FR terminal valve • Engine warning light • Intercooler water spray • Diagnosis output ★ 7 Barometric pressure ✩ 6 Secondary air control switch (Auto) • Alternator G terminal sensor solenoid valve • Intercooler water spray • Intercooler water spray ★ 8 Engine coolant switch (Manual) relay temperature sensor • Intercooler water spray ★ 9 Detonation sensor light Canister ✩ 2 Idle From fuel speed control ✩ tank 5 Purge control solenoid valve servo Check Vacuum ★ valve By-pass valve 4 Throttle tank ✩ 6 Secondary air position Sensor control solenoid valve ✩ 3 Fuel pressure control Secondary air valve solenoid valve ★ 1 Oxygen To From sensor fuel Fuel pressure fuel tank regulator pump ★ 7 Barometric pressure sensor ★ 3 Intake ★ 2 Air flow sensor air temp. sensor Air ✩ 1 Injector inlet ★ 5 Camshaft position sensor ★ 8 Engine coolant temperature sensor ★ 9 Detonation sensor Waste gate actuator ★ ✩ 4 Waste gate 6 Crank angle sensor solenoid valve Catalytic converter ENGINE (4G6) – CONTROL SYSTEM 1-11 1. Fuel injection control This is basically the same as the control system in the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII. System configuration diagram Air flow sensor Intake air temp. sensor Fuel pressure control Barometric pressure sensor solenoid valve Throttle position sensor Fuel pressure Ignition switch-ST regulator From Engine fuel Oxygen sensor pump ECU Vehicle speed sensor To fuel tank Injector Crank angle sensor Detonation sensor Engine coolant temp. sensor Camshaft position sensor 6FU2823 2. Idle speed control This is basically the same as the control system in the 4G63-DOHC-Turbocharger engine installed in the original Lancer Evolution-VII. System configuration diagram Air flow sensor Barometric pressure sensor Air intake temp. sensor Engine coolant temp.