Mitsubishi Lancer Evolution VIII MR User manual

New Vehicle Manual

LANCER

EVOLUTION VIII

FOREWORD

This manual contains details of the main changes to

the 2004 model Lancer Evolution VIII MR. Only

differences to the current Lancer Evolution VIII are

included, so please use this manual in conjunction with

the related information specified on the next page.

This information relates to the current vehicle (February

2004). Since specifications will change, some of the

information contained here will inevitably be

superseded.

Note that SI units are used in this manual. Old units are

not shown alongside them.

(However, old units are used for some figures we have

taken from existing documents).

Any opinions, requests, or questions concerning

this manual, should be written on the ‘Servicing

Comments Form’ at the end, and sent to us by

fax.

February 2004

MITSUBISHI MOTOR CORPORATION

This manual is printed on recycled paper.

CONTENTS

General..........................................

Engine ...........................................

Power Train...................................

Drive Control ................................

Body ..............................................

Exterior..........................................

Interior...........................................

Equipment.....................................

Reference Materials .....................

There are no changes to the shaded chapter,

so it is not included at all in this manual.

Title

No.

Issue

Date

Title

No.

Issue Date

Body Manuals (Service

Manual)

• Mirage, Lancer

(supplement)

• Lancer Cedia

(supplement)

• Lancer Evolution VII

(supplement)

• Lancer Cedia

(supplement)

• Lancer Evolution VIII MR

(supplement)

1036F52

1036K50

1036K51

1036K52

1036K53

1036K54

Aug 1996

May 2000

July 2000

May 2001

Oct 2001

Feb 2004

Electrical Wiring Diagrams

Service Manual

• Lancer Evolution VIII

• Lancer Evolution VIII MR

(supplement)

1036K77

1036K80

Jan 2003

Feb 2004

New Vehicle Manuals

• Mirage, Lancer

• Lancer

• Mirage, Lancer

• Lancer

• Lancer Cedia

• Lancer Evolution VII

• Lancer Cedia

• Lancer Evolution VII

• Lancer Cedia

• Lancer Evolution VIII

• Lancer

1036F30

1036F31

1036F32

1036F33

1036F34

1036F35

1036F36

1036F37

1036K30

1036K31

1036K32

1036K33

1036K34

1036K35

1036K36

1036K37

1036K38

1036K39

Oct 1995

Jan 1996

Aug 1996

Jul 1997

Jan 1998

Oct 1998

Jan 1999

Dec 1999

May 2000

July 2000

Jan 2001

May 2001

Jan 2002

May 2002

Jan 2003

Feb 2003

Dec 2003

Engine Service Manual

• 4G6 Engine

(supplement)

1039G46

1039G63

Jan 2001

Jan 2003

Service Manuals

• Lancer Cedia

(supplement)

• Lancer Evolution VII

(supplement)

• Lancer Cedia

(supplement)

• Lancer Cedia

(supplement)

• Lancer Evolution VII

(supplement)

• Lancer Cedia

(supplement)

• Lancer Evolution VIII

(supplement)

• Lancer (supplement)

• Lancer Evolution VIII

MR (supplement)

1036K00

1036K01

1036K02

1036K03

1036K04

1036K05

1036K06

1036K07

1036K08

1036K09

1036K10

May 2000

July 2000

Jan 2001

May 2001

Oct 2001

Jan 2002

May 2002

Jan 2003

Feb 2003

Dec 2003

Feb 2004

Transmission Service

Manual

• W5M51 Manual

Transmission

• W5M51 Manual

Transmission

(supplement)

• W6MAA Manual

Transmission

1039M17

1039M22

1039M23

Jan 2001

Jan 2003

Related information

00-1

GENERAL – TECHNICAL FEATURES

SECTION 0

GENERAL

CONTENTS

Vehicle Identification..............................0-1

Implementation Code .............................0-1

Development Aims .................................0-1

Overview of Lancer Evolution VIII MR. 0-2

Model line-up

Note

¡= Continued model

Applied vehicles

GH-CT9A: CT9A-0300001 ~

Development Aims

The launch of the Lancer Evolution VIII MR is the result of our pursuit of further advances and improvements based on the

Lancer Evolution VIII, with the aim of maintaining and strengthening the Mitsubishi Evolution brand.

Model Version ’04 Model Grade Engine Model Transmission Fuel System

GH-CT9A SNDFZ

SJDFZ

SJGFZ

GSR

4G63

(2 000 DOHC 16 valve

intercooler turbo)

W5M51 (4WD, 5M/T)

W6MAA (4WD, 6 M/T)

MPI

GENERAL – OVERVIEW OF THE LANCER EVOLUTION VIII MR

0-2

Lancer Evolution VIII MR Lancer Evolution VIII

GH-CT9A SNDFZ RS (5M/T) GH-CT9A SNDFZ RS (5M/T)

SJDFZ RS (6M/T) SJDFZ RS (6M/T)

SJGFZ GSR SJGFZ GSR

Overview of the Lancer Evolution VIII MR

Differences from the Lancer Evolution VIII

Section

Difference from Lancer Evolution VIII

Page

Change to cam profile (6 M/T)

1-5

Enlarged turbo nozzle diameter (6 M/T)

1-6

Adoption of tail pipe with built-in sound proofing in exhaust main

silencer (6 M/T)

1-7

Addition of wastegate solenoid valve (1 ‡2)*1

1-8

Change to catalyst volume (2.0 l. ‡1.5 l.) (6 M/T)

Engine

Enlarged engine oil cooler

Power train

Change to super AYC differential

2-1

Installation of Bilstein shock absorbers*2

3-1

Optional BBS 17-inch alloy wheels (new design)

3-1

Drive control

Black finish on spokes of Momo genuine leather steering wheel

(Type A) (GSR)

Aluminium used in roof panel and side door beams

4-1

Change to body colour

4-1

Body

Boot lid opener fitted as standard (RS)

Addition of Evolution MR logo

5-1

Exterior

Outer panel on rear spoiler and “Lancer” logo changed to dark grey

Ornamentation added to carbon finish instrument panel

Centre panel changed to black

Shift lever with special Lancer Evolution MR logo plate (6 M/T)

Door trim fabric changed

Interior

Recaro seat fabric changed to suede finish all-round (GSR)

Change to combination meter

7-1

Black outs on extensions of headlights (discharge) and rear

combination lamps

Equipment

Adoption of roof aerial (RS)

Notes:

*1: The No.2 wastegate solenoid valve does not operate in vehicles with 5 M/T transmission.

*2: Joint development of special shock absorbers for the Lancer Evolution VIII MR, with the German firm, Bilstein.

1-1

ENGINE (4G6) – GENERAL

SECTION 1

ENGINE (4G6)

CONTENTS

General ....................................................1-1

1. Major Specifications....................................1-1

2. Engine Performance Curve.........................1-2

Base Engine (6 M/T) ...............................1-2

1. Cylinder head gasket...................................1-2

2. Pistons..........................................................1-3

3. Piston rings (2nd) ........................................1-3

4. Oil rings ........................................................1-4

5. Counterbalance shaft .................................1-4

6. Camshaft.......................................................1-5

Intake / Exhaust System (6 M/T)............1-6

1. Exhaust system ...........................................1-6

Control system (6 M/T)...........................1-8

1. Supercharging pressure control..............1-10

General

The 4G63-T/C engine fitted in the Lancer Evolution VIII MR is basically the same as the 4G63-T/C engine used in the Lancer

Evolution VIII.

The basic structure is the same in both the 6M/T (6-speed) and 5M/T (5-speed) versions, but the following improvements have

been made to the 6M/T version, in order to achieve higher performance.

• Adoption of 5-ply cylinder head gasket

• Addition of V-shaped groove in piston , and modified shape in cooling channel

• Reduced oil consumption by increasing tension in piston rings and reducing end-to-end 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/T 5M/T

Total Displacement cc 1997

Combustion chamber Pentroof type

Bore x stroke (mm) 85.0 x 88.0

Compression ratio 8.8

Camshaft arrangement DOHC-4 valve

Fuel Premium unleaded

Max. output (kW/rpm) 206/6500

Max. torque (Nm/rpm) 400/3500 392/3500

Fuel system Electronic controlled multipoint fuel injection

Ignition system Electronic controlled two-coil

Lash adjuster Equipped

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)

1-2

2. Engine performance curve (6 M/T)

Base Engine (6 M/T)

1. Cylinder head gasket

A5-ply metal gasket has been introduced, in order to improve sealing properties.

Shaft output (kW) Shaft torque (N•m)

Engine r.p.m.

ENGINE (4G6) – BASE ENGINE (6 M/T) 1-3

2. Pistons

• Addition of V-shaped groove.

A V-shaped 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 channel

V-shaped

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.

Item Evolution VIII MR Evolution VIII

Tension 10.5 N 7.0 N

End to end gap 0.30 – 0.45 mm 0.35 – 0.50 mm

End to end gap

ENGINE (4G6) – BASE ENGINE (6 M/T)

1-4

4. Oil Rings

The outer circumference of the side rail has been treated with chrome nitride. The thickness of the side rail has also been

reduced from 1.7 mm to 1.63 mm, with a view to increasing durability and reducing oil consumption.

(Evolution VII MR) (Evolution VIII)

Chrome nitride

5. Counterbalance shaft

The shape of the shaft was changed in order to reduce weight.

Counterbalance shaft (right)

Counterbalance shaft (left)

Thickness

reduced

Thickness

reduced

ENGINE (4G6) – BASE ENGINE (6 M/T) 1-5

6. Camshaft

Output at high engine speeds has been improved by altering the cam profile of the intake camshaft, and optimizing the valve

timing.

Evolution VIII MR Evolution VIII

Cam height mm 35.96 35.79

Evolution VIII MR Evolution VIII

T.D.C (top dead centre) T.D.C (top dead centre)

Intake valve open

Intake valve

closed

Exhaust

valve closed

Exhaust

valve open

Intake valve open

Intake valve

closed

Exhaust

valve closed

Exhaust

valve open

B.D.C (Bottom dead centre) B.D.C (Bottom dead centre)

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