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Mitsubishi Lancer Evo 6 1999-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Production Years Covered: 1999-2001 Codes Chassis Code: CP9A 👋 Introduction Market Position Segment: Homologation Special / Performance Rally-Bred Sedan Reputation: Iconic status in rallying (WRC) and enthusiast circles for its performance, handling, and raw driving experience. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione. Key Features Performance: Advanced all-wheel-drive system, powerful turbocharged engine, sophisticated active differentials (AYC). Design: Aggressive styling, functional aerodynamics, lightweight construction. 📋 Manual Details Coverage Areas Regions Covered: Global (primarily targeting markets where the Evo 6 was officially sold or imported) Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 4G63T (2.0L DOHC MIVEC Turbocharged) - including diagnostics, overhaul, tuning, and emissions control Transmission: 5-speed Manual (W5M51) and optional 6-speed Manual (Getrag 6-speed found in RS models), including clutch, gearbox overhaul, and drivetrain components Suspension: Front MacPherson strut with anti-roll bar, Rear multi-link independent suspension with anti-roll bar; includes damper, spring, bushing, and alignment specifications Brakes: Front and Rear ventilated disc brakes, ABS (Anti-lock Braking System) and AYC (Active Yaw Control) system diagnostics and repair Steering: Power-assisted rack and pinion, steering components, and related hydraulic systems Electrical: Full wiring diagrams, ECU (Engine Control Unit) and TCU (Transmission Control Unit) information, lighting, ignition system, charging system, starting system, instrumentation, and accessories Body And Chassis: Exterior panels, interior trim, doors, windows, bumpers, body repair, rust prevention, and structural integrity Cooling System: Radiator, fan, thermostat, water pump, and coolant specifications Fuel System: Fuel pump, injectors, fuel filter, fuel tank, and fuel pressure regulation Exhaust System: Manifold, catalytic converter, muffler, and pipework specifications HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, tune-ups, and inspections Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, error code interpretation Repair And Overhaul: Step-by-step procedures for complete engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, and bodywork Diagnostics: Detailed procedures for using diagnostic tools, reading sensor data, and identifying fault sources Specifications And Tolerances: Precise measurements, clearances, torque specifications, and material requirements for all components Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval Printability: Printable pages for workshop use Print Quality Quality: High-resolution scans for clear diagrams and text Binding Type Type: N/A (Digital PDF format) Paper Type Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: Inline-4, DOHC, 16-valve, turbocharged, intercooled Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Valve Train: MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system Performance Horsepower Ps Eu: 276 PS (272 bhp; 203 kW) @ 6500 rpm (JDM/European Spec) Torque Nm Eu: 373 Nm (275 lb-ft) @ 3000 rpm (JDM/European Spec) Turbocharger: Mitsubishi TD05H-16G (or similar variant depending on specific market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch fuel injectors Fuel Type: Premium Unleaded (95 RON or higher recommended) Engine Management ECU Type: ECU controlled ignition and fuel systems, specific model ECU part numbers can be found within the manual. 🔧 Transmission Standard Type: 5-speed Manual Transmission (W5M51) Optional Type: 6-speed Manual Transmission (Getrag - typically on RS models) Features All Wheel Drive System: Full-time All-Wheel Drive with Active Yaw Control (AYC) and viscous coupling center differential. Differentials: Front Helical Limited-Slip Differential (LSD), Rear Helical Limited-Slip Differential (LSD) on some models, AYC controlled rear differential. 📐 Dimensions Exterior Length: 4350 mm (171.3 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2635 mm (103.7 in) Track Width Front: 1515 mm (59.6 in) Track Width Rear: 1505 mm (59.3 in) Weights Curb Weight Kg: Approx. 1360-1400 kg (2998-3086 lbs), varies by trim and specification. Gross Weight Limit Kg: Refer to vehicle VIN plate or manual for exact GVWR. Interior Seating Capacity: 5 Cargo Trunk Volume Liters: Approx. 430 liters (15.2 cu ft) - figures may vary. 🛡️ Safety Features Ratings Crash Test Data: Specific official crash test ratings for this era may vary by region. Consult the manual for any chassis or safety structure reinforcement details. Active Features ABS: Standard Anti-lock Braking System (ABS) Ayc: Standard Active Yaw Control (AYC) system for enhanced cornering stability. AWD: Advanced electronically controlled All-Wheel Drive system. Passive Features Airbags: Driver and front passenger airbags standard. Seatbelts: 3-point inertia-reel seatbelts with pre-tensioners for front occupants. Body Construction: Reinforced body structure for impact absorption. 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM stereo with cassette player and CD player (optional), typically 4-6 speakers. Aftermarket head unit compatibility is common. Climate Control: Manual or...
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Mitsubishi Lancer Evo 6 1999-2001 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI (Evo 6)
Production Years Covered:
1999-2001
Codes
Chassis Code:
CP9A
👋 Introduction
Market Position
Segment:
Homologation Special / Performance Rally-Bred Sedan
Reputation:
Iconic status in rallying (WRC) and enthusiast circles for its performance, handling, and raw driving experience.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione.
Key Features
Performance:
Advanced all-wheel-drive system, powerful turbocharged engine, sophisticated active differentials (AYC).
Design:
Aggressive styling, functional aerodynamics, lightweight construction.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily targeting markets where the Evo 6 was officially sold or imported)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
4G63T (2.0L DOHC MIVEC Turbocharged) - including diagnostics, overhaul, tuning, and emissions control
Transmission:
5-speed Manual (W5M51) and optional 6-speed Manual (Getrag 6-speed found in RS models), including clutch, gearbox overhaul, and drivetrain components
Suspension:
Front MacPherson strut with anti-roll bar, Rear multi-link independent suspension with anti-roll bar; includes damper, spring, bushing, and alignment specifications
Brakes:
Front and Rear ventilated disc brakes, ABS (Anti-lock Braking System) and AYC (Active Yaw Control) system diagnostics and repair
Steering:
Power-assisted rack and pinion, steering components, and related hydraulic systems
Electrical:
Full wiring diagrams, ECU (Engine Control Unit) and TCU (Transmission Control Unit) information, lighting, ignition system, charging system, starting system, instrumentation, and accessories
Body And Chassis:
Exterior panels, interior trim, doors, windows, bumpers, body repair, rust prevention, and structural integrity
Cooling System:
Radiator, fan, thermostat, water pump, and coolant specifications
Fuel System:
Fuel pump, injectors, fuel filter, fuel tank, and fuel pressure regulation
Exhaust System:
Manifold, catalytic converter, muffler, and pipework specifications
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, tune-ups, and inspections
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, error code interpretation
Repair And Overhaul:
Step-by-step procedures for complete engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, and bodywork
Diagnostics:
Detailed procedures for using diagnostic tools, reading sensor data, and identifying fault sources
Specifications And Tolerances:
Precise measurements, clearances, torque specifications, and material requirements for all components
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval
Printability:
Printable pages for workshop use
Print Quality
Quality:
High-resolution scans for clear diagrams and text
Binding Type
Type:
N/A (Digital PDF format)
Paper Type
Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
Inline-4, DOHC, 16-valve, turbocharged, intercooled
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Valve Train:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system
Performance
Horsepower Ps Eu:
276 PS (272 bhp; 203 kW) @ 6500 rpm (JDM/European Spec)
Torque Nm Eu:
373 Nm (275 lb-ft) @ 3000 rpm (JDM/European Spec)
Turbocharger:
Mitsubishi TD05H-16G (or similar variant depending on specific market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch fuel injectors
Fuel Type:
Premium Unleaded (95 RON or higher recommended)
Engine Management
ECU Type:
ECU controlled ignition and fuel systems, specific model ECU part numbers can be found within the manual.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (W5M51)
Optional
Type:
6-speed Manual Transmission (Getrag - typically on RS models)
Features
All Wheel Drive System:
Full-time All-Wheel Drive with Active Yaw Control (AYC) and viscous coupling center differential.
Differentials:
Front Helical Limited-Slip Differential (LSD), Rear Helical Limited-Slip Differential (LSD) on some models, AYC controlled rear differential.
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2635 mm (103.7 in)
Track Width Front:
1515 mm (59.6 in)
Track Width Rear:
1505 mm (59.3 in)
Weights
Curb Weight Kg:
Approx. 1360-1400 kg (2998-3086 lbs), varies by trim and specification.
Gross Weight Limit Kg:
Refer to vehicle VIN plate or manual for exact GVWR.
Interior
Seating Capacity:
5
Cargo
Trunk Volume Liters:
Approx. 430 liters (15.2 cu ft) - figures may vary.
🛡️ Safety Features
Ratings
Crash Test Data:
Specific official crash test ratings for this era may vary by region. Consult the manual for any chassis or safety structure reinforcement details.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Standard Active Yaw Control (AYC) system for enhanced cornering stability.
AWD:
Advanced electronically controlled All-Wheel Drive system.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners for front occupants.
Body Construction:
Reinforced body structure for impact absorption.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM stereo with cassette player and CD player (optional), typically 4-6 speakers. Aftermarket head unit compatibility is common.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Driver Assistance
Traction Control:
Integrated within the AWD and AYC systems, not a separate traction control button in the conventional sense.
Connectivity
Bluetooth:
Not available in factory specification for this model year.
Usb:
Not available in factory specification for this model year.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 5,000 km or 6 months, whichever comes first (severe use). Consult manual for specific intervals based on driving conditions.
Air Filter Replacement:
Every 15,000 km or 12 months.
Spark Plug Replacement:
Every 30,000 km (Platinum tipped recommended).
Timing Belt Replacement:
Every 90,000 km or 5 years, whichever comes first. Crucial to follow this interval due to interference engine design.
Fluid Specifications
Engine Oil Type:
API SG, SH, or SJ; ILSAC GF-II or GF-III; Viscosity: 10W-30 or 10W-40 (refer to manual for temperature-specific recommendations).
Engine Oil Capacity Liters:
Approx. 4.5 L (with filter change)
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors).
Transmission Fluid Type 5Mt:
API GL-4 or GL-5; SAE 75W-90 (Manual Transmission fluid, check manual for specific Mitsubishi recommendation).
Transmission Fluid Capacity 5Mt Liters:
Approx. 2.3 L
Transfer Case Fluid Type:
API GL-5; SAE 75W-90 (Gear oil, consult manual for specific Mitsubishi recommendation).
Transfer Case Fluid Capacity Liters:
Approx. 0.7 L
Rear Differential Fluid Type:
API GL-5; SAE 75W-90 (Gear oil, consult manual for specific Mitsubishi recommendation).
Rear Differential Fluid Capacity Liters:
Approx. 1.4 L (standard rear diff), AYC models may differ. Consult manual.
Brake Fluid Type:
DOT 3 or DOT 4 (high-performance synthetic brake fluid recommended).
Power Steering Fluid Type:
ATF (Dexron II/III or equivalent) or specific Mitsubishi power steering fluid.
Known Issues
Engine Reliability:
Generally robust, but prone to issues if maintenance is neglected. Common concerns include head gasket failure (due to high boost), turbocharger wear, and fuel injector clogging.
Ayc System:
AYC pump and sensor failures can occur, leading to warning lights and loss of differential control. Regular fluid changes and system checks are advised.
Rust:
Can be susceptible to rust, particularly in the sills, wheel arches, and floor pans, especially in areas with road salt. Thorough inspections are vital.
Suspension Wear:
Bushings, ball joints, and dampers can wear over time, affecting handling and alignment. Performance-oriented driving can accelerate wear.
Electrical Gremlins:
Older wiring and connectors can develop issues, leading to intermittent problems with various systems.
📚 Vehicle History
Brand Heritage
Rally Success:
Direct lineage from Mitsubishi's highly successful World Rally Championship (WRC) campaigns.
Model Evolution
Previous Generation:
Evolution V (Evo 5)
Next Generation:
Evolution VII (Evo 7)
E6 Updates:
Wider track, improved aerodynamics (larger rear spoiler, front bumper vents), revised suspension geometry, lighter engine components, enhanced AYC system.
Production
Production Period:
1999-2001
Manufacturing Plant:
Mizushima Plant, Kurashiki, Japan
Special Editions:
Tommi Makinen Edition (TME) - a highly sought-after variant with specific mechanical and cosmetic upgrades.
🏆 Awards & Recognition
Recognitions
Rally Titles:
Significant role in Mitsubishi's multiple WRC Manufacturers' and Drivers' Championships.
Enthusiast Awards:
Consistently ranked highly by automotive journalists and enthusiasts for its driving dynamics and performance capabilities.
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