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Mitsubishi Evo 4 1996-1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Model Code: CN9A Year: 1996-1998 Codes Chassis Code: CN9A Engine Code Primary: 4G63T 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Target Demographic: Enthusiasts, Rally Fans, Performance Car Buyers Competitive Analysis Key Competitors Era: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth Key Features Performance Focus: Emphasizes performance tuning, advanced drivetrain, and rally-derived technology. Documentation Value: Provides critical technical information for maintaining and repairing the highly specialized Evo IV. 📋 Manual Details Coverage Areas Language: English Manual Type: Service Repair Manual Format Detail: PDF Intended Audience: Professional Technicians and Enthusiast DIYers Page Count Estimated Pages: 1000+ 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain Chassis: Suspension, Steering, Brakes Electrical: Wiring Diagrams, ECU, Lighting, Instrumentation Body: Body Exterior, Interior Trim, HVAC Diagnostics: Troubleshooting Guides, DTCs, Component Testing Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements Repair: Engine Rebuilds, Transmission Overhauls, Component Replacement Diagnostics: Fault Finding, Symptom Analysis, Electrical Troubleshooting Disassembly Assembly: Step-by-step instructions for major component removal and installation Technical Depth Depth: Comprehensive; covers routine maintenance to complete engine and transmission rebuilds. Diagnostic Tools: Details on using diagnostic scan tools and multimeter procedures. Torque Specifications: Detailed torque values for all critical fasteners. Clearances Tolerances: Engine component clearances and assembly tolerances provided. 📊 Manual Specifications File Format Type: Digital PDF Searchability: Searchable text for quick information retrieval Printability: Printable pages for convenient workshop use Print Quality Resolution: High-resolution scans of original factory manuals Binding Type Physical Format Equivalent: Not applicable (digital format) Paper Type Physical Format Equivalent: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged Engine Code: 4G63T (Evo IV specific variant) Displacement: 1997 cc Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Ignition Performance Horsepower Ps Jdm: 280 PS @ 6,500 rpm Torque Kgf M Jdm: 35.0 kgf·m @ 3,000 rpm Turbocharger: Mitsubishi TD05HR-16G (Roller Bearing) Intercooler: Air-to-Air Front Mount 🔧 Transmission Standard Transmission Type: 5-Speed Manual Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Features Clutch Type: Hydraulic Single Plate Ayc System: Active Yaw Control (AYC) with hydraulic torque vectoring to the rear wheels. 📐 Dimensions Exterior Length: 4350 mm Width: 1770 mm Height: 1415 mm Wheelbase: 2600 mm Front Track: 1505 mm Rear Track: 1490 mm Weights Curb Weight Kg: 1360 kg Gross Weight Kg: 1535 kg 🛡️ Safety Features Ratings Ancap Rating: Not officially rated or tested by ANCAP during its production period. NHTSA Rating: Not officially rated or tested by NHTSA during its production period. Active Features ABS: Anti-lock Braking System (ABS) Ayc: Active Yaw Control (AYC) Awc: Active Center Differential (ACD) Passive Features Airbags: Driver and Passenger Front Airbags Seatbelts: 3-point ELR seatbelts with pre-tensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM Stereo Cassette Player with optional CD Player Speakers: 6 Speaker System Driver Assistance Ayc: Active Yaw Control (AYC) is a key handling technology. Acd: Active Center Differential (ACD) automatically distributes torque between front and rear axles. Instrumentation Gauge Cluster: Includes boost gauge, oil pressure, oil temperature, and voltmeter. 🔧 Maintenance Service Intervals Oil Change Interval Km: 5,000 - 10,000 km (depending on driving conditions) Spark Plug Replacement Km: 40,000 - 60,000 km Timing Belt Replacement Km: 100,000 km Fluid Specifications Engine Oil Type: API SG, SF or ACEA A2/A3; SAE 10W-30, 10W-40, 5W-40 (depending on climate) Engine Oil Capacity Liters: 4.5 liters (with filter) Transmission Fluid Type: API GL-4 or GL-5; SAE 75W-90 Differential Fluid Type: API GL-5; SAE 75W-90 Coolant Type: Ethylene Glycol based antifreeze/coolant, Mitsubishi Genuine Brake Fluid Type: DOT 3 or DOT 4 Known Issues Engine Component: Connecting Rod Failures (often due to detonation or excessive stress) Turbocharger: Bearing wear on TD05HR turbocharger, especially if oil maintenance is neglected. Ayc System: Potential for leaks or malfunction in the AYC pump and hydraulic lines. Clutch: Wear and tear on the clutch assembly, particularly with spirited driving. Rust: Common rust points in wheel arches, sills, and around the rear spoiler mounting. 📚 Vehicle History Brand Heritage Motorsport Roots: Built on the foundation of Mitsubishi's rallying success, particularly in the World Rally Championship (WRC). Model Evolution Generation: Fourth generation of the Lancer Evolution Key Advancements: Introduction of Active Yaw Control (AYC) and Active Center Differential (ACD) for enhanced handling and traction. Production Production Years: August 1996 – August 1997 Production Volume Approx: 6,000 units (estimated) Manufacturing Location: Japan 🏆 Awards & Recognition Recognitions Rally Performance: The road-going Evo IV is a direct homologation for WRC regulations, demonstrating significant motorsport pedigree. Enthusiast Acclaim: Consistently ranked among the best affordable performance cars of its era by automotive journalists and enthusiasts. Ratings Handling Dynamics: Praised for its exceptional grip, agility, and balanced chassis, largely due to its AWD system...
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Mitsubishi Evo 4 1996-1998 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV
Model Code:
CN9A
Year:
1996-1998
Codes
Chassis Code:
CN9A
Engine Code Primary:
4G63T
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Target Demographic:
Enthusiasts, Rally Fans, Performance Car Buyers
Competitive Analysis
Key Competitors Era:
Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth
Key Features
Performance Focus:
Emphasizes performance tuning, advanced drivetrain, and rally-derived technology.
Documentation Value:
Provides critical technical information for maintaining and repairing the highly specialized Evo IV.
📋 Manual Details
Coverage Areas
Language:
English
Manual Type:
Service Repair Manual
Format Detail:
PDF
Intended Audience:
Professional Technicians and Enthusiast DIYers
Page Count
Estimated Pages:
1000+
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain
Chassis:
Suspension, Steering, Brakes
Electrical:
Wiring Diagrams, ECU, Lighting, Instrumentation
Body:
Body Exterior, Interior Trim, HVAC
Diagnostics:
Troubleshooting Guides, DTCs, Component Testing
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements
Repair:
Engine Rebuilds, Transmission Overhauls, Component Replacement
Diagnostics:
Fault Finding, Symptom Analysis, Electrical Troubleshooting
Disassembly Assembly:
Step-by-step instructions for major component removal and installation
Technical Depth
Depth:
Comprehensive; covers routine maintenance to complete engine and transmission rebuilds.
Diagnostic Tools:
Details on using diagnostic scan tools and multimeter procedures.
Torque Specifications:
Detailed torque values for all critical fasteners.
Clearances Tolerances:
Engine component clearances and assembly tolerances provided.
📊 Manual Specifications
File Format
Type:
Digital PDF
Searchability:
Searchable text for quick information retrieval
Printability:
Printable pages for convenient workshop use
Print Quality
Resolution:
High-resolution scans of original factory manuals
Binding Type
Physical Format Equivalent:
Not applicable (digital format)
Paper Type
Physical Format Equivalent:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged
Engine Code:
4G63T (Evo IV specific variant)
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Ignition
Performance
Horsepower Ps Jdm:
280 PS @ 6,500 rpm
Torque Kgf M Jdm:
35.0 kgf·m @ 3,000 rpm
Turbocharger:
Mitsubishi TD05HR-16G (Roller Bearing)
Intercooler:
Air-to-Air Front Mount
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Features
Clutch Type:
Hydraulic Single Plate
Ayc System:
Active Yaw Control (AYC) with hydraulic torque vectoring to the rear wheels.
📐 Dimensions
Exterior
Length:
4350 mm
Width:
1770 mm
Height:
1415 mm
Wheelbase:
2600 mm
Front Track:
1505 mm
Rear Track:
1490 mm
Weights
Curb Weight Kg:
1360 kg
Gross Weight Kg:
1535 kg
🛡️ Safety Features
Ratings
Ancap Rating:
Not officially rated or tested by ANCAP during its production period.
NHTSA Rating:
Not officially rated or tested by NHTSA during its production period.
Active Features
ABS:
Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC)
Awc:
Active Center Differential (ACD)
Passive Features
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
3-point ELR seatbelts with pre-tensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo Cassette Player with optional CD Player
Speakers:
6 Speaker System
Driver Assistance
Ayc:
Active Yaw Control (AYC) is a key handling technology.
Acd:
Active Center Differential (ACD) automatically distributes torque between front and rear axles.
Instrumentation
Gauge Cluster:
Includes boost gauge, oil pressure, oil temperature, and voltmeter.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
5,000 - 10,000 km (depending on driving conditions)
Spark Plug Replacement Km:
40,000 - 60,000 km
Timing Belt Replacement Km:
100,000 km
Fluid Specifications
Engine Oil Type:
API SG, SF or ACEA A2/A3; SAE 10W-30, 10W-40, 5W-40 (depending on climate)
Engine Oil Capacity Liters:
4.5 liters (with filter)
Transmission Fluid Type:
API GL-4 or GL-5; SAE 75W-90
Differential Fluid Type:
API GL-5; SAE 75W-90
Coolant Type:
Ethylene Glycol based antifreeze/coolant, Mitsubishi Genuine
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Component:
Connecting Rod Failures (often due to detonation or excessive stress)
Turbocharger:
Bearing wear on TD05HR turbocharger, especially if oil maintenance is neglected.
Ayc System:
Potential for leaks or malfunction in the AYC pump and hydraulic lines.
Clutch:
Wear and tear on the clutch assembly, particularly with spirited driving.
Rust:
Common rust points in wheel arches, sills, and around the rear spoiler mounting.
📚 Vehicle History
Brand Heritage
Motorsport Roots:
Built on the foundation of Mitsubishi's rallying success, particularly in the World Rally Championship (WRC).
Model Evolution
Generation:
Fourth generation of the Lancer Evolution
Key Advancements:
Introduction of Active Yaw Control (AYC) and Active Center Differential (ACD) for enhanced handling and traction.
Production
Production Years:
August 1996 – August 1997
Production Volume Approx:
6,000 units (estimated)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rally Performance:
The road-going Evo IV is a direct homologation for WRC regulations, demonstrating significant motorsport pedigree.
Enthusiast Acclaim:
Consistently ranked among the best affordable performance cars of its era by automotive journalists and enthusiasts.
Ratings
Handling Dynamics:
Praised for its exceptional grip, agility, and balanced chassis, largely due to its AWD system and AYC.
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