Mitsubishi MOTORS Lancer Evolution-VIII Manual

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LANER
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TECHNICAL INFORMATION
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NEW MODEL
INFORMATION MANUAL
LANCER
EVOLUTION-VIII
FOREWORD
This manual has been prepared as an explanation of the
main changes in the 2003 LANCE -EVOLUTION-VIII. It
only describes the differences from the LANCE -
EVOLUTION-VII. It should be used in conjunction with the
related material in the following pages. This manual is
based on the current model as of January 2003. Please
note that its content may not conform to that of future
models due to specification changes etc. Please also note
that the units described in this manual are based on SI
units, which is the International System of Units, and
conventional units are not included.
(However, old units are used for some figures taken from
existing documents)
January 2003
MITSUBISHI MOTOR CORPORATION
CONTENTS
General
Engine
Power Train
Drive Control Co ponents
Body
Exterior
Interior
Equip ent
Reference Materials
0
1
2
3
4
5
6
7
8
Any opinions, requests, or questions concerning this
manual, should be written on the ‘Servicing Comment
Form’ at the end, and sent to us by fax.

Related docu entation
Document name No. Month and year of publication
New model information manuals
• Mirage/Lancer
• Mirage/Lancer
• Mirage/Lancer
• Mirage/Lancer
• Lancer
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1036F35
1036F36
1036F37
1036K30
1036K31
1036K32
1036K33
1036K34
1036K35
1036K36
October 1995
January 1996
August 1996
July 1997
January 1998
October 1998
January 1999
December 1999
May 2000
July 2000
January 2001
May 2001
May 2001
January 2002
May 2002
Maintenance manuals
• Lancer Sedia
• Lancer Sedia (supplement)
• Lancer Evolution-VII (supplement)
• Lancer Sedia (supplement)
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• Lancer Evolution-VII (supplement)
• Lancer Sedia (supplement)
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May 2001
October 2001
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Body maintenance manuals
• Mirage/Lancer (supplement)
• Lancer Sedia
• Lancer Sedia (supplement)
• Lancer Evolution-VII (supplement)
• Lancer Sedia (supplement)
1036F52
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1036K52
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Electrical wiring diagrams - maintenance manual
• Lancer Evolution-VII 1036K77 January 2003
Engine service maintenance manuals
• 4G6 Engine
• 4G6 Engine (supplement) 1039G46 1039G63 January 2001 January 2003
Transmission maintenance manuals
• W5M51 Manual Transmission
• W5M51 Manual Transmission (supplement)
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January 2003

GENERAL – EXTERIOR, VEHICLE IDENTIFICATION AND IMPLEMENTATION NUMBER 0-1
SECTION 0
GENERAL
CONTENTS
Exterior
Note [] indicates new additional model [] indicates continuation model [X] indicates discontinued model
I ple entation Code
GH-CT9A: CT9A-0200001 ~
Model
code Class code 2003 code Grade Engine model Transmission model Fuel supply
system
S DFZ RS W5M51 (4WD,
5M/T)
SYGFZ X GT-A W5A51 [4WD,
I VECS –II Sports
Mode 5A/T
(Steering shift
switch included)]
SJDFZ RS
GH-CT9A
SJGFZ GSR
4G63
(2,000 cc DOHC 16
valve intercooler turbo)
W6MAA (4WD,
6M/T)
MPI
Exterior ....................................................0-1
Vehicle Identification..............................0-1
I ple entation Code.............................0-1
Model Code and Class Code.................0-2
Develop ent Ai s .................................0-2
Technical Features .................................0-3
Lancer Evolution-VIII Index ...................0-4
AC210961
Vehicle Identification
✕

GENERAL – MODEL CODE AND CLASS CODE
0-2
Model Code and Class Code
Develop ent Ai s
The Lancer Evolution-VIII is based on the Lancer Evolution-VII, which has proved its high speed capability in all fields of motor
sport in Japan and internationally. At the same time, feedback from the actual experience of the Lancer Evolution-VII has been
given to the Development team, and the standards for a motor sports based vehicle have been raised. In addition to the
pursuit of further speed, improvements have been made to its performance and appearance through investment in new
equipment such as a 6-speed manual transmission and changes to its interior and exterior appearance.
o Items Contents
1 Gas Emission
conformity G HConforms to Gas Emission Regulations 2000 (passenger vehicles fuelled by gasoline or LPG for carriage of passengers with a
passenger capacity of 10 persons or less)
2 Development C
TLancer Evolution Series
3 Engine type 9 2,000 cc (4G63)
4 Sort A Passenger car
5 Body style S 4-door saloon
5-speed manual transmission6 Transmission type J 6-speed manual transmission
DRS7 Trim level G GSR
8 Specification engine
feature F DOHC-MPI-intercooler turbo
9 Special feature Z 4WD

GENERAL – TECHNICAL FEATURES 0-3
Technical Features
Exterior
• New shape front bumper
• Full carbon-fibre rear boot spoiler
• Newly designed alloy wheels
• New shape bonnet
• Clear rear combination light lens
Accessories
• Full-scale 270 km/h speedometer
• Immobiliser system
Engine Trans ission
• Improved engine reliability by
strengthening the pistons and
connecting rods
• Increased fuel tank capacity
• 6-speed manual transmission
• Super AYC

GENERAL – LANCER EVOLUTION-VIII INDEX
0-4
Lancer Evolution-VIII Index
Lancer Evolution-VIII Base model (Lancer Evolution-VII)
SNDFZ S (5M/T)
SJDFZ S (6M/T) SNDFZ S
GH-CT9A
SJGFZ GS
GH-CT9A
SNGFZ GS
Sections that are different from base model
Group Sections different from base model Page
reference
Changes to piston shape and materials 1-3
Beehive-shaped valve springs 1-3
Changes to delivery pipe materials 1-4
Engine
Increase in fuel tank capacity 1-7
6-speed manual transmission 2-2
Changes to rear gear knob 2-9
Changes to propeller shaft specifications 2-13
Changes to front drive shaft wheel constant velocity joints 2-13
Changes to rear drive shaft wheel constant velocity joints 2-13
Power Train
Super AYC (GS ; optional for S) 2-14
Changes to front spring specifications 3-1
Changes to rear spring specifications 3-1
Newly designed 17-inch alloy wheels 3-2
Changes to steering shaft 3-2
Drive Control
Components
ubber mounting of power steering oil reservoir tank and pressure hose 3-3
Improvement to body rigidity by additional reinforcement etc. 4-1
Changes to body colour 4-4
Changes to bonnet shape 4-4
Body
Additional security functions to keyless entry system 4-5
Changes to shape of front bumper 5-1Exterior Full carbon-fibre rear boot spoiler 5-2
Evolution logo on floor console 6-1
Changes to optional setting of front passenger’s air bag ( S) 6-2
Interior
Changes to structure of seat belt pre-tensioner 6-3
Immobiliser system 7-1
Changes to rear combination light lens colours and lens intrinsic colours 7-2
Full-scale 270 km/h speedometer 7-2
Equipment
Changes to SWS functions 7-3
Lancer Evolution-VIII Index
Sections that are different fro base odel

ENGINE (4G6) – GENERAL 1-1
SECTION 1
ENGINE
CONTENTS
Engine (4G6)............................................1-1
General infor ation................................1-1
1. Major specifications .......................................1-1
2. Engine Performance Curve ...........................1-2
Base Engine............................................1-2
1. Timing belt cover............................................1-2
2. Piston.............................................................1-3
3. Valve spring ...................................................1-3
4. Delivery pipe..................................................1-4
Cooling Equip ent.................................1-5
Intake and Exhaust Equip ent.............1-5
1. Air intake system............................................1-5
Fuel Syste .............................................1-7
1. Fuel tank........................................................1-8
Control Syste .......................................1-9
1. Fuel injection control....................................1-11
2. Idle speed control.........................................1-11
3. Ignition timing and distribution
control..........................................................1-12
4. Other controls ..............................................1-12
5. Diagnosis system.........................................1-12
E ission Control Syste ....................1-13
Mount.....................................................1-14
Engine (4G6)
General infor ation
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

ENGINE (4G6) – GENERAL INFORMATION AND BASE ENGINE
1-2
2. Engine Perfor ance Curve
Base Engine
1. Ti ing 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.
Shaft torque (N-m)
Shaft output (kW)
New Old
6EN2239
Engine r.p.m. AC211451AB

ENGINE (4G6) – BASE ENGINE 1-3
New Old
Retainer
Valve spring
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.
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
6EN2242

ENGINE (4G6) –ENGINE AND COOLING EQUIPMENT
1-4
4. Delivery pipe
The material of the delivery pipe has changed from alloy to steel plate to reduce vibration noise.
New Old
Cooling Syste
The cooling system has changed as follows.

ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT 1-5
Intake and Exhaust Equip ent
1. Air intake syste
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
Intercooler assembly Intercooler assembly
Old
Air guide AC211453AB

ENGINE (4G6) – INTAKE AND EXHAUST EQUIPMENT
1-6
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.
Water spray hose
assembly
Washer tank
Intercooler assembly
Intercooler assembly Washer tank
Water spray hose
assembly
New
Old

ENGINE (4G6) – FUEL SYSTEM 1-7
Fuel Syste
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
Delivery pipe
Delivery pipe
Construction Diagra
Old
Fuel tank assembly
Fuel tank assembly
New
Items New Old
Fuel tank capacity L GS
S 55 50 48 48

ENGINE (4G6) – FUEL SYSTEM
1-8
1. Fuel tank
The shape of the fuel tank has been changed. In order to extend the range, the tank capacity of the GS has been increased
to 55 litres, and the tank capacity of the S has been increased to 50 litres taking into consideration the balance between
range and the S’s weight, and motor sport requirements.
New
Gauge and
pump assembly
Fuel pump and gauge assembly
Cut-off valve assembly
Fuel tank
Old
Gauge and
pump assembly
Fuel tank
Fuel pump and gauge assembly
Cut-off valve assembly

ENGINE (4G6) – CONTROL SYSTEM 1-9
Control Syste
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.
• EG control has been discontinued.
• Diagnostic control terminal has been discontinued.
Syste block diagra
Air flow sensor
Intake air temperature sensor
Barometric pressure sensor
Engine coolant temperature sensor
Throttle position sensor
A/C switch
A/C load signal
Camshaft position sensor
Crank angle sensor
Alternator F sensor
Vehicle speed sensor
Power steering fluid pressure switch
Detonation sensor
Intercooler water spray (auto)
Intercooler water spray (manual)
Oxygen sensor
Ignition switch-IG
Ignition switch-ST
Power supply
Fuel injection control
Idle speed control
Ignition timing control
Engine control relay control
Fuel pump relay control
A/C relay control
Fan motor control (radiator)
Fan relay control (A/C condenser)
Alternator control
Air flow sensor filter reset control
Fuel pressure control
Turbocharger
Secondary air control
Intercooler water spray control
Engine warning light control
Oxygen sensor heater control
Purge control
Diagnosis output
AM data transmission
No.1 injector
No.2 injector
No.3 injector
No.4 injector
Idle speed control servo (stepper
motor)
No.1, No. 4 ignition coil
No.2, No.3 ignition coil
Engine control
Fuel pump relay 2
Fuel pump relay 3
A/C relay
Fan controller (radiator)
Fan motor relay (HI, LOW) (A/C
condenser)
Alternator G terminal
Air flow sensor
Fuel pressure control solenoid
valve
Waste gate solenoid valve
Secondary air control solenoid
valve
Intercooler water spray relay
Intercooler water spray light
Tachometer
Engine warning light (check
engine light)
Oxygen sensor heater
Purge control solenoid valve
Engine ECU
Diagnosis output terminal
Diagnosis output terminal (for
MUT - II)

ENGINE (4G6) – CONTROL SYSTEM
1-10
✩1 Injector
✩2 Idle speed control
servo
✩3 Fuel pressure control
solenoid valve
✩4 Waste gate solenoid
valve
✩5 Purge control solenoid
valve
✩6 Secondary air control
solenoid valve
• Engine control relay
• Fuel pump relay 2, 3
• A/C relay
• Ignition control
• Fan controller
• Condenser fan relay (HI)
• Condenser fan relay
(LOW)
• Engine warning light
• Diagnosis output
• Alternator G terminal
• Intercooler water spray
relay
• Intercooler water spray
light
Control syste diagra
★1 Oxygen sensor
★2 Air flow sensor
★3 Intake air temperature
sensor
★4 Throttle position
Sensor
★5 Camshaft position
sensor
★6 Crank angle sensor
★7 Barometric pressure
sensor
★8 Engine coolant
temperature sensor
★9 Detonation sensor
• Power supply
• Ignition switch-IG
• Ignition switch-ST
• Vehicle speed sensor
• A/C switch
• A/C load signal
• Power steering fluid
pressure switch
• Alternator F terminal
• Intercooler water spray
switch (Auto)
• Intercooler water spray
switch (Manual)
✩6 Secondary air
control solenoid valve
✩5 Purge control solenoid valve
Canister
Check
valve By-pass valve ★4 Throttle
position Sensor
✩2 Idle
speed control
servo Vacuum
tank
✩3 Fuel pressure control
solenoid valve
Secondary air valve
Air
inlet
★2 Air flow sensor
★7 Barometric pressure sensor ★3 Intake
air temp.
sensor
★1
Oxygen
sensor Fuel pressure
regulator
✩4 Waste gate
solenoid valve
Waste gate
actuator
✩1 Injector
Catalytic converter
Engine
-ECU
From fuel
tank
To
fuel
tank
From
fuel
pump
★5 Camshaft position sensor
★8 Engine coolant temperature
sensor
★9 Detonation sensor
★6 Crank angle sensor
➩➩

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.
Syste configuration diagra
Fuel pressure control
solenoid valve
To fuel tank Injector
Engine
ECU
Air flow sensor
Intake air temp. sensor
Barometric pressure sensor
Throttle position sensor
Ignition switch-ST
Oxygen sensor
Vehicle speed sensor
Crank angle sensor
Detonation sensor
Engine coolant temp. sensor
Camshaft position sensor
Bimetal type limiter
To intake manifold From air cleaner
Speed adjusting screw
Air flow sensor
Barometric pressure sensor
Air intake temp. sensor
Engine coolant temp. sensor
Throttle position sensor
Crank angle sensor
A/C switch
A/C load signal
Vehicle speed sensor
Power steering fluid pressure switch
Alternator F terminal
Ignition switch-IG
Ignition switch-ST
Diagnosis control terminal
Engine
ECU
Idle speed
control servo
(Stepper motor)
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.
Syste configuration diagra
6FU2823
X6046AU
Fuel pressure
regulator From
fuel
pump

ENGINE (4G6) – CONTROL SYSTEM
1-12
3. Ignition ti ing and distribution control
Basically the same control system has been adopted as in the 4G63-DOHC-Turbocharger engine installed in the original
Lancer Evolution-VII.
Syste configuration diagra
4. Other controls
The following controls are basically the same as the control systems adopted in the 4G63-DOHC-Turbocharger engine
installed in the original Lancer Evolution-VII.
• adio fan motor relay control
• Power supply
• Air flow sensor filter reset control
• Fuel pressure control
• Supercharging pressure control
• Secondary air control
• Fuel pump control
• A/C condenser fan relay control
• Alternator control
• Oxygen sensor heater control
• Purge control
Please refer to Emission Control System.
5. Diagnosis syste
The engine ECU has the following functions in order to facilitate system checks.
a. Engine warning light
b. Diagnosis function
c. Service data output
d. Actuator test
Note
Please refer to the maintenance manual for each item.
Engine
ECU
Ignition coil B
Air flow sensor
Barometric pressure sensor
Air intake temp. sensor
Engine coolant temp. sensor
MDP sensor
Crank angle sensor
Camshaft position sensor
Vehicle speed sensor
Ignition switch-ST
Detonator sensor
Ignition coil A
Ignition
switch
Battery
Spark plug
Cylinder No.
X6047AU

ENGINE (4G6) – EMISSION CONTROL SYSTEM 1-13
E ission Control Syste
The following change has been made based on the 4G63-DOHC-Turbocharger engine used in the original Lancer Evolution-
VII.
• The EG system has been discontinued.
E ission Control Syste Diagra
From fuel tank
Check
valve Vacuum tank
Fuel pressure control
solenoid valve
Purge control
solenoid
valve
Fuel pressure
regulator From fuel
pump
Oxygen
sensor To fuel
tank
PCV valve
Injector
Catalytic converter
Air
inlet
Canister