Mitsubishi Lancer Evolution 6 EVO 6 Complete Workshop Service Repair Manual 1999 2000 2001
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo VI) Generation: Evo VI Product Name: Mitsubishi Lancer Evolution 6 EVO 6 Complete Workshop Service Repair Manual 1999 2000 2001 Codes Chassis Codes: CP9A Engine Codes: 4G63T 👋 Introduction Market Position Market Position: The Mitsubishi Lancer Evolution VI (Evo VI) occupied a niche in the performance car market as a homologation special for rally racing, appealing to driving enthusiasts seeking ultimate on-road performance and handling. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale Evoluzione. Key Features Rally Homologation: Developed for WRC homologation, inheriting technology and tuning from its rally counterparts. All Wheel Drive: Advanced Super Active Yaw Control (AYC) and Active Center Differential (ACD) for superior traction and cornering. Engine Performance: Renowned 4G63T turbocharged inline-four engine known for its robustness and tuning potential. 📋 Manual Details Coverage Areas Language: English Format: Downloadable PDF Manual Type: Workshop Service Repair Manual Page Count Page Count: Extensive (specific count not provided, but described as 'Complete') 📖 Manual Coverage Systems Covered Engine System: Full diagnosis, overhaul, tuning, and component repair for the 4G63T engine. Drivetrain System: Manual and automatic transmissions, transfer cases, front and rear differentials, driveshafts, and CV joints. Suspension System: Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, and wheel alignment. Braking System: Front and rear brake systems, including ABS, caliper service, rotor replacement, brake fluid flush, and parking brake. Steering System: Power steering system, steering rack, tie rod ends, and steering column. Electrical System: Complete electrical schematics, wiring diagrams, ECU functions, sensors, actuators, lighting, and battery/charging system. Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, and fuel tank service. Cooling System: Radiator, water pump, thermostat, cooling fans, and coolant specifications. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and exhaust pipe service. Body And Chassis: Body panel repair, door mechanisms, interior trim, glass replacement, and chassis structure. Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements, spark plug service, and fluid checks. Troubleshooting: Detailed diagnostic procedures for common and complex issues, fault code interpretation, and problem isolation. Repair: Step-by-step instructions for component removal, installation, and rebuilding for all major vehicle systems. Diagnostics: On-board diagnostics (OBD-II) procedures, sensor testing, and ECU flash/update information. Calibration: Wheel alignment specifications and procedures, steering angle sensor calibration. Overhaul: Complete engine and transmission overhaul procedures with torque specifications and assembly sequences. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to full engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text-based PDF. Print Quality Print Quality: High-resolution, suitable for printing all diagrams and text. Binding Type Binding Type: Digital Download (N/A for physical binding) Paper Type Paper Type: Digital Download (N/A for physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63T, 2.0L Inline-4, DOHC, 16-valve, Turbocharged Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Performance Horsepower: Approx. 276-280 PS (203-206 kW; 272-276 hp) (JDM/European spec, often understated) Torque: Approx. 343-370 Nm (253-273 lb-ft) Redline: Approximately 7,500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential multi-port injection Fuel Type: Unleaded gasoline (premium, 95+ RON recommended) Turbocharger Turbocharger Model: Mitsubishi TD05HR-16G (often upgraded in aftermarket) Intercooler: Front-mounted air-to-air intercooler 🔧 Transmission Standard Transmission Type: 5-speed manual (Getrag) Optional Transmission Type: Rarely, some markets might have had a 4-speed automatic (less performance-oriented) Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC) Clutch: Hydraulically operated, single-plate dry clutch 📐 Dimensions Exterior Length: Approx. 4,350 mm (171.3 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,405 mm (55.3 in) Wheelbase: Approx. 2,600 mm (102.4 in) Ground Clearance: Approx. 135 mm (5.3 in) (can vary) Weights Curb Weight: Approx. 1,440 kg (3,175 lbs) Gross Vehicle Weight Rating: Not typically specified for performance models in this era. Cargo Trunk Capacity: Limited, typical for compact sport sedans. 🛡️ Safety Features Ratings Crash Test Ratings: No official NHTSA/Euro NCAP ratings for this specific JDM homologation model, but built to robust rally standards. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Active Yaw Control (AYC) and Active Center Differential (ACD) for enhanced traction and stability. Passive Features Airbags: Driver and front passenger airbags Seat Belts: Three-point inertia-reel seat belts with pre-tensioners Body Structure: Reinforced chassis and body for rally-era safety and rigidity. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM stereo with CD player or cassette. Often aftermarket head units are installed. Driver Assistance Advanced Aids: ACD (Active Center Differential) and AYC (Active Yaw Control) are the primary advanced drivetrain technologies. Connectivity Connectivity Features: Limited to basic audio inputs; no integrated Bluetooth or USB connectivity in stock form. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 - 10,000 km (4,500 -...
Mitsubishi Lancer Evolution 6 EVO 6 Complete Workshop Service Repair Manual 1999 2000 2001
Codes
Chassis Codes:
CP9A
Engine Codes:
4G63T
👋 Introduction
Market Position
Market Position:
The Mitsubishi Lancer Evolution VI (Evo VI) occupied a niche in the performance car market as a homologation special for rally racing, appealing to driving enthusiasts seeking ultimate on-road performance and handling.
Detailed diagnostic procedures for common and complex issues, fault code interpretation, and problem isolation.
Repair:
Step-by-step instructions for component removal, installation, and rebuilding for all major vehicle systems.
Diagnostics:
On-board diagnostics (OBD-II) procedures, sensor testing, and ECU flash/update information.
Calibration:
Wheel alignment specifications and procedures, steering angle sensor calibration.
Overhaul:
Complete engine and transmission overhaul procedures with torque specifications and assembly sequences.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to full engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely searchable text-based PDF.
Print Quality
Print Quality:
High-resolution, suitable for printing all diagrams and text.
Electronic Fuel Injection (EFI) with sequential multi-port injection
Fuel Type:
Unleaded gasoline (premium, 95+ RON recommended)
Turbocharger
Turbocharger Model:
Mitsubishi TD05HR-16G (often upgraded in aftermarket)
Intercooler:
Front-mounted air-to-air intercooler
🔧 Transmission
Standard
Transmission Type:
5-speed manual (Getrag)
Optional
Transmission Type:
Rarely, some markets might have had a 4-speed automatic (less performance-oriented)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC)
Clutch:
Hydraulically operated, single-plate dry clutch
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,405 mm (55.3 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Ground Clearance:
Approx. 135 mm (5.3 in) (can vary)
Weights
Curb Weight:
Approx. 1,440 kg (3,175 lbs)
Gross Vehicle Weight Rating:
Not typically specified for performance models in this era.
Cargo
Trunk Capacity:
Limited, typical for compact sport sedans.
🛡️ Safety Features
Ratings
Crash Test Ratings:
No official NHTSA/Euro NCAP ratings for this specific JDM homologation model, but built to robust rally standards.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Active Yaw Control (AYC) and Active Center Differential (ACD) for enhanced traction and stability.
Passive Features
Airbags:
Driver and front passenger airbags
Seat Belts:
Three-point inertia-reel seat belts with pre-tensioners
Body Structure:
Reinforced chassis and body for rally-era safety and rigidity.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with CD player or cassette. Often aftermarket head units are installed.
Driver Assistance
Advanced Aids:
ACD (Active Center Differential) and AYC (Active Yaw Control) are the primary advanced drivetrain technologies.
Connectivity
Connectivity Features:
Limited to basic audio inputs; no integrated Bluetooth or USB connectivity in stock form.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 10,000 km (4,500 - 6,000 miles) or 6 months, depending on driving conditions. Enthusiast driving may warrant more frequent changes.
Timing Belt Replacement:
Approximately 90,000 - 105,000 km (56,000 - 65,000 miles) or 7 years. Crucial due to interference engine design.
Spark Plug Replacement:
Typically every 40,000 - 60,000 km (25,000 - 37,000 miles) depending on plug type.
Fluid Specifications
Engine Oil Type:
API SG, SH, or SJ rated; Viscosity 10W-30 or 10W-40 (synthetic recommended for performance).
Engine Oil Capacity:
Approx. 4.5 - 4.7 liters (4.8 - 5.0 US quarts) with filter change.
Coolant Type:
Ethylene glycol based, 50/50 mix with distilled water. Mitsubishi recommends their Dia-Queen Super Long Life Coolant (SLLC).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 (synthetic recommended).
Differential Fluid Front:
API GL-5, SAE 75W-90.
Differential Fluid Rear:
API GL-5, SAE 75W-90 (some LSDs may require specific friction modifiers).
Power Steering Fluid:
Dexron III or equivalent automatic transmission fluid (ATF).
Known Issues
Engine Bearing Wear:
Rod bearing wear is a common concern at higher mileage or with aggressive tuning, especially on the 4G63T.
Ayc Pump Failure:
The AYC pump can fail over time, affecting yaw control. Regular fluid level checks are important.
Rust And Corrosion:
Common in older Japanese performance cars, particularly around wheel arches, sills, and subframes.
Turbocharger Wear:
The TD05HR turbo is robust but can wear out, leading to decreased boost or failure.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long and successful history in motorsports, particularly in the World Rally Championship (WRC), with the Lancer Evolution line being its most iconic rally-bred street car.
Model Evolution
Evolution Series:
The Evo VI built upon the advancements of its predecessors, refining the aerodynamics, engine, and drivetrain systems, and introducing the iconic Tommi Mäkinen Edition (TME) variant.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
Notable Variants:
Evo VI RS, Evo VI GSR, Evo VI Tommi Mäkinen Edition (TME)
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
The Evo VI, and the Evo lineage in general, achieved legendary status in rallying, securing multiple WRC driver and manufacturer championships.
Ratings
Performance Reviews:
Widely praised by automotive journalists for its exceptional handling, grip, and driver engagement, often cited as one of the greatest rally homologation specials.
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