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Mitsubishi Lancer Evolution 6 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Year: 1999 Codes Chassis Code: CP9A Engine Code: 4G63 👋 Introduction Market Position Classification: Homologation Special / Rally-bred Performance Sedan Target Audience: Performance enthusiasts, Rally fans, DIY mechanics Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Engine Performance: Iconic 4G63 engine with robust tuning potential Drivetrain Technology: Advanced AWD system with Active Yaw Control (AYC) for superior handling Braking System: High-performance Brembo braking package Rally Heritage: Direct lineage from WRC championship-winning vehicles 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Component Repair, Overhaul Page Count Estimated Page Count: 1500+ Manual Type Type: Workshop Manual / Service Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 4G63 MIVEC Turbocharged (2.0L) Transmission: 5-speed Manual (GETRAG) Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Suspension: Front: MacPherson Strut, Rear: Multi-link Brakes: Front: Brembo 4-piston calipers, Rear: Brembo 2-piston calipers Electrical: Engine Control Unit (ECU), Lighting, Instrumentation, Power Accessories, Audio System Bodywork: Exterior Panels, Interior Trim, Chassis Structure Cooling System: Radiator, Fans, Hoses, Thermostat, Water Pump Fuel System: Fuel Pump, Injectors, Fuel Filter, Fuel Pressure Regulator Exhaust System: Manifold, Downpipe, Catalytic Converter, Muffler Steering: Power Steering System, Steering Column HVAC: Heating, Ventilation, Air Conditioning (HVAC) System Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement Diagnostics: Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation, Sensor Testing Repair: Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement Installation: Component Installation (e.g., turbocharger, intercooler), Body Panel Replacement Disassembly Assembly: Detailed step-by-step guides for all major components Technical Depth Depth: Comprehensive, from basic checks to complete engine and transmission rebuilds Diagnostic Tools: Specific tool requirements and diagnostic procedures Torque Specs: Detailed torque specifications for all critical fasteners Wiring Diagrams: Includes electrical schematics for all systems 📊 Manual Specifications File Format Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution for clear diagrams and photos Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline-4, DOHC, 16-valve, turbocharged with intercooler Displacement: 1997 cc (2.0 Liters) Performance Horsepower Ps: 280 PS (DIN) @ 6500 rpm Torque Nm: 373 Nm (275 lb-ft) @ 3000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection Fuel Type: Unleaded Gasoline (95 RON recommended) Engine Management ECU Type: Engine Control Unit (ECU) with MIVEC control Cooling System Coolant Capacity L: Approx. 7.5 Liters Lubrication Oil Capacity L: Approx. 4.5 Liters (with filter) Oil Type: API SG, ACEA A3 or higher recommended (e.g., 10W-30, 10W-40) 🔧 Transmission Standard Transmission Type: 5-Speed Manual (GETRAG F5M51) Optional Optional Transmission: None Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Center Differential: Mechanical Limited Slip Center Differential Rear Differential: Active Yaw Control (AYC) equipped LSD Fluid Capacity L Transmission Oil Capacity: Approx. 2.7 Liters Fluid Specifications Transmission Oil Type: GL-4 or GL-5, API rating, viscosity 75W-90 recommended 📐 Dimensions Exterior Length Mm: 4350 mm Width Mm: 1770 mm Height Mm: 1415 mm Wheelbase Mm: 2600 mm Track Front Mm: 1500 mm Track Rear Mm: 1495 mm Weights Curb Weight Kg: 1400 kg Wheels Tires Wheel Size: 17 inches Bolt Pattern: 5x114.3 mm Tire Size Front: 225/45R17 Tire Size Rear: 225/45R17 🛡️ Safety Features Ratings NHTSA Rating: Not extensively tested under modern NHTSA protocols for this era Active Features ABS: Standard Anti-lock Braking System (ABS) Ayc: Active Yaw Control (AYC) for enhanced stability and cornering Passive Features Airbags: Driver and Passenger Front Airbags Seatbelts: 3-point front seatbelts with pre-tensioners Chassis Construction: Reinforced body structure for rigidity and crashworthiness 💡 Technology Features Infotainment Audio System: Factory AM/FM Stereo with CD Player and Speakers Instrumentation: Comprehensive gauge cluster including Boost Gauge, Oil Pressure, Oil Temperature, Water Temperature Driver Assistance Traction Control: Integrated with AYC and AWD systems Connectivity Bluetooth: Not available in stock configuration 🔧 Maintenance Service Intervals Oil Change Interval Km: Every 7,500 km or 6 months, whichever comes first (under normal use) Air Filter Replacement Km: Every 15,000 km or 12 months Spark Plug Replacement Km: Every 30,000-45,000 km (depending on plug type) Timing Belt Replacement Km: Every 90,000 km or 5 years (critical component) Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 Coolant Type: Mitsubishi Super Long Life Coolant (or equivalent) Known Issues Common Wear Items: Clutch wear, turbocharger longevity (depending on maintenance and driving style), AYC pump failure Engine Issues: Head gasket failure can occur under extreme heat or detonation; rod bearing failure at high mileage or with aggressive tuning without proper support. Maintenance Tips Performance Driving: Regularly check and maintain the cooling and lubrication systems; ensure proper warm-up and cool-down cycles for the turbocharger. 📚 Vehicle History Brand...
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Mitsubishi Lancer Evolution 6 1999 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Year:
1999
Codes
Chassis Code:
CP9A
Engine Code:
4G63
👋 Introduction
Market Position
Classification:
Homologation Special / Rally-bred Performance Sedan
Target Audience:
Performance enthusiasts, Rally fans, DIY mechanics
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Engine Performance:
Iconic 4G63 engine with robust tuning potential
Drivetrain Technology:
Advanced AWD system with Active Yaw Control (AYC) for superior handling
Braking System:
High-performance Brembo braking package
Rally Heritage:
Direct lineage from WRC championship-winning vehicles
📋 Manual Details
Coverage Areas
Primary Coverage:
Factory Service Repair
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Component Repair, Overhaul
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Manual / Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
4G63 MIVEC Turbocharged (2.0L)
Transmission:
5-speed Manual (GETRAG)
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Suspension:
Front: MacPherson Strut, Rear: Multi-link
Brakes:
Front: Brembo 4-piston calipers, Rear: Brembo 2-piston calipers
Electrical:
Engine Control Unit (ECU), Lighting, Instrumentation, Power Accessories, Audio System
Bodywork:
Exterior Panels, Interior Trim, Chassis Structure
Cooling System:
Radiator, Fans, Hoses, Thermostat, Water Pump
Fuel System:
Fuel Pump, Injectors, Fuel Filter, Fuel Pressure Regulator
Exhaust System:
Manifold, Downpipe, Catalytic Converter, Muffler
Steering:
Power Steering System, Steering Column
HVAC:
Heating, Ventilation, Air Conditioning (HVAC) System
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement
Diagnostics:
Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation, Sensor Testing
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement
Installation:
Component Installation (e.g., turbocharger, intercooler), Body Panel Replacement
Disassembly Assembly:
Detailed step-by-step guides for all major components
Technical Depth
Depth:
Comprehensive, from basic checks to complete engine and transmission rebuilds
Diagnostic Tools:
Specific tool requirements and diagnostic procedures
Torque Specs:
Detailed torque specifications for all critical fasteners
Wiring Diagrams:
Includes electrical schematics for all systems
📊 Manual Specifications
File Format
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution for clear diagrams and photos
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged with intercooler
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (DIN) @ 6500 rpm
Torque Nm:
373 Nm (275 lb-ft) @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Engine Management
ECU Type:
Engine Control Unit (ECU) with MIVEC control
Cooling System
Coolant Capacity L:
Approx. 7.5 Liters
Lubrication
Oil Capacity L:
Approx. 4.5 Liters (with filter)
Oil Type:
API SG, ACEA A3 or higher recommended (e.g., 10W-30, 10W-40)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (GETRAG F5M51)
Optional
Optional Transmission:
None
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Center Differential:
Mechanical Limited Slip Center Differential
Rear Differential:
Active Yaw Control (AYC) equipped LSD
Fluid Capacity L
Transmission Oil Capacity:
Approx. 2.7 Liters
Fluid Specifications
Transmission Oil Type:
GL-4 or GL-5, API rating, viscosity 75W-90 recommended
📐 Dimensions
Exterior
Length Mm:
4350 mm
Width Mm:
1770 mm
Height Mm:
1415 mm
Wheelbase Mm:
2600 mm
Track Front Mm:
1500 mm
Track Rear Mm:
1495 mm
Weights
Curb Weight Kg:
1400 kg
Wheels Tires
Wheel Size:
17 inches
Bolt Pattern:
5x114.3 mm
Tire Size Front:
225/45R17
Tire Size Rear:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Rating:
Not extensively tested under modern NHTSA protocols for this era
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) for enhanced stability and cornering
Passive Features
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
3-point front seatbelts with pre-tensioners
Chassis Construction:
Reinforced body structure for rigidity and crashworthiness
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo with CD Player and Speakers
Instrumentation:
Comprehensive gauge cluster including Boost Gauge, Oil Pressure, Oil Temperature, Water Temperature
Driver Assistance
Traction Control:
Integrated with AYC and AWD systems
Connectivity
Bluetooth:
Not available in stock configuration
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Every 7,500 km or 6 months, whichever comes first (under normal use)
Air Filter Replacement Km:
Every 15,000 km or 12 months
Spark Plug Replacement Km:
Every 30,000-45,000 km (depending on plug type)
Timing Belt Replacement Km:
Every 90,000 km or 5 years (critical component)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent)
Known Issues
Common Wear Items:
Clutch wear, turbocharger longevity (depending on maintenance and driving style), AYC pump failure
Engine Issues:
Head gasket failure can occur under extreme heat or detonation; rod bearing failure at high mileage or with aggressive tuning without proper support.
Maintenance Tips
Performance Driving:
Regularly check and maintain the cooling and lubrication systems; ensure proper warm-up and cool-down cycles for the turbocharger.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation, known for rally and performance vehicles
Model Evolution
Evolution Line:
Part of the acclaimed Lancer Evolution series, celebrated for its motorsport success
Evolution Vi Introduction:
Launched in January 1999, as a homologation special for the WRC
Evolution Vi Variants:
RS, GSR, Tommi Mäkinen Edition (TME)
Production
Production Period:
1999-2001
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Rally Championships:
Multiple WRC Manufacturer and Driver Championships (for the Lancer Evolution platform)
Ratings
Car And Driver Ranking:
Frequently featured in '10Best' lists for performance and handling during its production era.
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