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Mitsubishi Lancer Evolution VI Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Common Name: Evo VI Model Code: CP9A Generation Generation Name: Fifth Generation Generation Code: CP9A (JDM) 👋 Introduction Market Position Market Position: Rally-bred homologation special, positioned as a high-performance, all-wheel-drive sports sedan. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale. Key Features Key Features: Aggressive styling, advanced AWD system with ACD and AYC, potent turbocharged engine, robust chassis, rally heritage. Target Audience Target Audience: Enthusiasts, performance drivers, rally fans, owners seeking detailed maintenance and repair information. 📋 Manual Details Coverage Areas Coverage Areas: All Major Systems and Components Page Count Page Count: Estimated 1500-2000 pages (typical for comprehensive factory manuals of this era, exact count not provided in product info) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 4G63T (2.0L DOHC Turbocharged MIVEC) Powertrain Management: ECU Diagnostics, Fuel Injection, Ignition System, Emissions Control Transmission: 5-speed Manual Transmission (Type R/RS spec, Getrag variant likely) Drivetrain: All-Wheel Drive System (ACD - Active Center Differential, AYC - Active Yaw Control), Front/Rear Differentials Suspension: Front MacPherson Struts, Rear Multi-link, Coil Springs, Dampers, Bushings Brakes: Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) Steering: Power Assisted Rack and Pinion Electrical: Battery, Charging System, Starting System, Lighting, Instrumentation, Fuses, Relays, Wiring Diagrams Body: Exterior Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Seats HVAC: Heating, Ventilation, and Air Conditioning Systems Fuel System: Fuel Tank, Fuel Pump, Fuel Lines, Injectors, Fuel Filter Cooling System: Radiator, Water Pump, Thermostat, Cooling Fan Exhaust System: Exhaust Manifold, Catalytic Converter, Muffler Procedures Included Disassembly Reassembly: Complete component-level disassembly and reassembly instructions Inspection Adjustment: Detailed procedures for inspecting components for wear and damage, and adjusting systems for optimal performance Removal Installation: Step-by-step instructions for removing and installing all major assemblies and components Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides Maintenance: Scheduled maintenance procedures, fluid changes, filter replacements Diagnostics: On-board diagnostics (OBD-II) interpretation and system-specific diagnostic procedures Special Tools: Identification and usage of specialized tools required for specific repair procedures Technical Depth Depth: Comprehensive, covering basic to advanced repair and diagnostics, suitable for professional mechanics and experienced DIYers 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable without restriction, high-resolution for clarity of text and diagrams Binding Type Binding Type: Digital Download (PDF format for printing/viewing) Paper Type Paper Type: Not Applicable (Digital) Compatibility Compatibility: All Versions of Windows & Mac Requirements Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: 2.0L Inline-4, DOHC, 16-Valve, Turbocharged with Intercooler Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower: 276 hp @ 6500 rpm (JDM spec, often understated) Torque: 270 lb-ft @ 3000 rpm (JDM spec) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (98 RON / 91+ US octane recommended) Ignition System Ignition Type: Electronic Ignition (Distributorless Ignition System - DIS) Valvetrain Valvetrain: MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft Turbocharger Turbocharger: Mitsubishi TD05H-16G or similar twin-scroll turbocharger 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission: None for Evolution VI Features Gear Ratios: Specific ratios available in the manual, generally close-ratio for performance 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. 1,415 mm (55.7 in) Wheelbase: Approx. 2,600 mm (102.4 in) Weights Curb Weight: Approx. 1,370 kg (3,020 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: Not widely tested by modern agencies, but chassis and safety features reflect period standards. Active Features ABS: Standard, 4-channel ABS Ayc: Standard Active Yaw Control for enhanced cornering stability Acd: Standard Active Center Differential for variable torque distribution Passive Features Airbags: Driver and Front Passenger Airbags (standard on most models) Seatbelts: 3-point seatbelts with pretensioners 💡 Technology Features Infotainment Infotainment System: Basic AM/FM/CD or Cassette player with standard speaker system. Often upgraded by owners. Driver Assistance Driver Assistance: ABS, AYC, ACD are primary driver aids. No electronic stability control (ESC) typical for this generation. Connectivity Connectivity: No integrated Bluetooth or USB connectivity as standard. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe duty, high performance driving recommended) Spark Plug Replacement: Refer to manual, typically 40,000-60,000 km (25,000-37,000 miles) for performance plugs. Timing Belt Replacement: Every 90,000 km (56,000 miles) or 5 years, critical for 4G63T engine. Fluid Specifications Engine Oil: API SN/SP, ACEA A3/B4, Viscosity 10W-40 or 15W-50 recommended for high-performance use. Specific Mitsubishi grades may vary. Coolant: Mitsubishi Super Long Life Coolant (or equivalent OAT-based coolant) Transmission Fluid: Mitsubishi DiaQueen GL-5 75W-90 (for manual transmission) Differential Fluid:...
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Mitsubishi Lancer Evolution VI Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Common Name:
Evo VI
Model Code:
CP9A
Generation
Generation Name:
Fifth Generation
Generation Code:
CP9A (JDM)
👋 Introduction
Market Position
Market Position:
Rally-bred homologation special, positioned as a high-performance, all-wheel-drive sports sedan.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.
Key Features
Key Features:
Aggressive styling, advanced AWD system with ACD and AYC, potent turbocharged engine, robust chassis, rally heritage.
Target Audience
Target Audience:
Enthusiasts, performance drivers, rally fans, owners seeking detailed maintenance and repair information.
📋 Manual Details
Coverage Areas
Coverage Areas:
All Major Systems and Components
Page Count
Page Count:
Estimated 1500-2000 pages (typical for comprehensive factory manuals of this era, exact count not provided in product info)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
4G63T (2.0L DOHC Turbocharged MIVEC)
Powertrain Management:
ECU Diagnostics, Fuel Injection, Ignition System, Emissions Control
Transmission:
5-speed Manual Transmission (Type R/RS spec, Getrag variant likely)
Drivetrain:
All-Wheel Drive System (ACD - Active Center Differential, AYC - Active Yaw Control), Front/Rear Differentials
Suspension:
Front MacPherson Struts, Rear Multi-link, Coil Springs, Dampers, Bushings
Brakes:
Front Brembo 4-piston calipers, Rear Brembo 2-piston calipers, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Steering:
Power Assisted Rack and Pinion
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, Fuses, Relays, Wiring Diagrams
Body:
Exterior Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Seats
HVAC:
Heating, Ventilation, and Air Conditioning Systems
Fuel System:
Fuel Tank, Fuel Pump, Fuel Lines, Injectors, Fuel Filter
Cooling System:
Radiator, Water Pump, Thermostat, Cooling Fan
Exhaust System:
Exhaust Manifold, Catalytic Converter, Muffler
Procedures Included
Disassembly Reassembly:
Complete component-level disassembly and reassembly instructions
Inspection Adjustment:
Detailed procedures for inspecting components for wear and damage, and adjusting systems for optimal performance
Removal Installation:
Step-by-step instructions for removing and installing all major assemblies and components
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides
Maintenance:
Scheduled maintenance procedures, fluid changes, filter replacements
Diagnostics:
On-board diagnostics (OBD-II) interpretation and system-specific diagnostic procedures
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
Technical Depth
Depth:
Comprehensive, covering basic to advanced repair and diagnostics, suitable for professional mechanics and experienced DIYers
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable without restriction, high-resolution for clarity of text and diagrams
Binding Type
Binding Type:
Digital Download (PDF format for printing/viewing)
Paper Type
Paper Type:
Not Applicable (Digital)
Compatibility
Compatibility:
All Versions of Windows & Mac
Requirements
Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
2.0L Inline-4, DOHC, 16-Valve, Turbocharged with Intercooler
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower:
276 hp @ 6500 rpm (JDM spec, often understated)
Torque:
270 lb-ft @ 3000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (98 RON / 91+ US octane recommended)
Ignition System
Ignition Type:
Electronic Ignition (Distributorless Ignition System - DIS)
Valvetrain
Valvetrain:
MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on intake camshaft
Turbocharger
Turbocharger:
Mitsubishi TD05H-16G or similar twin-scroll turbocharger
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission:
None for Evolution VI
Features
Gear Ratios:
Specific ratios available in the manual, generally close-ratio for performance
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. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,370 kg (3,020 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not widely tested by modern agencies, but chassis and safety features reflect period standards.
Active Features
ABS:
Standard, 4-channel ABS
Ayc:
Standard Active Yaw Control for enhanced cornering stability
Acd:
Standard Active Center Differential for variable torque distribution
Passive Features
Airbags:
Driver and Front Passenger Airbags (standard on most models)
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD or Cassette player with standard speaker system. Often upgraded by owners.
Driver Assistance
Driver Assistance:
ABS, AYC, ACD are primary driver aids. No electronic stability control (ESC) typical for this generation.
Connectivity
Connectivity:
No integrated Bluetooth or USB connectivity as standard. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe duty, high performance driving recommended)
Spark Plug Replacement:
Refer to manual, typically 40,000-60,000 km (25,000-37,000 miles) for performance plugs.
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 5 years, critical for 4G63T engine.
Fluid Specifications
Engine Oil:
API SN/SP, ACEA A3/B4, Viscosity 10W-40 or 15W-50 recommended for high-performance use. Specific Mitsubishi grades may vary.
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent OAT-based coolant)
Transmission Fluid:
Mitsubishi DiaQueen GL-5 75W-90 (for manual transmission)
Differential Fluid:
Mitsubishi DiaQueen GL-5 75W-90 (front and rear, ACD unit may have specific requirements)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine:
Connecting rod failures at high power/RPMs if not built for it, oil starvation due to aggressive driving, exhaust manifold cracking.
Ayc Acd:
Potential failure of the hydraulic pumps and accumulators for AYC/ACD systems, requiring specialized service.
Rust:
Common in areas exposed to road salt, particularly wheel arches, sills, and the underside.
Clutch Wear:
Can wear quickly with aggressive driving, especially clutch-drivable launch control usage.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a strong motorsport pedigree, particularly in the World Rally Championship (WRC).
Model Evolution
Model Evolution:
The Lancer Evolution series was developed to homologate Mitsubishi's rally cars for WRC. The Evo VI (CP9A) built upon the successes of its predecessors, featuring significant mechanical and aerodynamic upgrades.
Evolution Vi Variants:
Standard GSR, RS (Rally Sport - lighter, more basic, often RHD only), RS Sprint (limited edition), Tommi Mäkinen Edition (TME - homologation special for Mäkinen's WRC titles, specific engine/suspension/bodywork tweaks).
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Recognitions:
Consistently praised by automotive journalists for its performance, handling, and rally-inspired capabilities. Often features in 'best affordable sports car' or 'iconic performance car' lists.
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