Mitsubishi Lancer Evolution 6 1999-2001 Workshop Service Repair Manual
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đˇď¸ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo VI) Production Years Covered By Manual: 1999, 2000, 2001 Generation Generation Code: CP9A Codes Chassis Code: CP9A đ Introduction Market Position Positioning: Iconic rally homologation special, performance benchmark in its era Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Performance Features: Aggressive aerodynamic styling, advanced AWD system with AYC/S-AYC, powerful turbocharged engine, rally-bred chassis Target Audience: Performance car enthusiasts, motorsport fans, owners seeking in-depth maintenance and repair knowledge đ Manual Details Coverage Areas Manual Coverage: Comprehensive workshop service and repair Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download đ Manual Coverage Systems Covered Engine: 4G63T DOHC, turbocharged, intercooled engine overhaul, diagnostics, tuning Transmission: 5-speed manual (F5M42-2) and optional 6-speed manual (Newer models) service, repair, and diagnostics Drivetrain: All-Wheel Drive (AWD) system, Active Yaw Control (AYC) and Super AYC (S-AYC) diagnostics and calibration, front/rear differentials, driveshafts Suspension: Front MacPherson strut, rear multi-link suspension, shock absorbers, springs, bushings, alignment procedures Brakes: Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS system, brake fluid, hydraulic lines, rotor and pad replacement Steering: Power assisted rack and pinion, steering column, tie rods, calibration of power steering system Electrical System: Complete wiring diagrams, battery, alternator, starter, lighting system, ignition system, engine control unit (ECU) and sensors, body control module (BCM), diagnostics Fuel System: Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, fuel system diagnostics Cooling System: Radiator, fan, thermostat, water pump, coolant specifications, bleeding procedures Exhaust System: Exhaust manifold, catalytic converter, mufflers, oxygen sensors Body And Interior: Body panel removal and installation, interior trim, seats, door mechanisms, HVAC system (Heating, Ventilation, Air Conditioning) Body Control Module: BCM functions, door locks, power windows, interior lighting Safety Systems: Airbag system, seat belt pre-tensioners, ABS, AYC/S-AYC control module diagnostics Procedures Included Maintenance Procedures: Scheduled maintenance, oil and filter changes, fluid checks and top-offs, spark plug replacement, belt inspection and replacement Repair Procedures: Engine rebuild, transmission overhaul, clutch replacement, brake caliper rebuilding, suspension component replacement, turbocharger service, AYC pump replacement Diagnostics And Troubleshooting: Detailed diagnostic flowcharts, error code explanations, symptom-based troubleshooting guides, electrical circuit testing Special Tools: Identification and usage of required special tools for specific procedures Calibration: AYC/S-AYC calibration, wheel speed sensor calibration, idle air control (IAC) valve learning Technical Depth Depth: Full workshop level detail, suitable for professional technicians and advanced DIY enthusiasts Detail Level: Includes torque specifications, clearances, diagnostic trouble codes (DTCs), wiring diagrams, and step-by-step repair instructions đ Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear text and diagrams for easy printing Binding Type Binding Type: Digital Download (N/A for printed) Paper Type Paper Type: Digital Download (N/A for printed) âď¸ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: Inline 4-cylinder, DOHC, 16 valves Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower: 276 bhp (206 kW) at 6500 rpm (Japanese/European spec, often underestimated) Torque: 350 Nm (258 lb-ft) at 3000 rpm (Japanese/European spec) Fuel System Fuel Delivery: Multi-point fuel injection (MPI), Electronic Fuel Injection (EFI) Turbocharger: Mitsubishi TD05HR-16G6-10.5T twin-scroll turbocharger, intercooled Fuel Type: Unleaded gasoline (Octane rating 95 RON or higher recommended) đ§ Transmission Standard Type: 5-speed manual (F5M42-2) Optional Type: 6-speed manual (Specific models/regions, e.g., Tommi Makinen Edition) Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC) Clutch Type: Hydraulically operated, single dry plate đ Dimensions Exterior Length: 4350 mm (171.3 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2600 mm (102.4 in) Front Track: 1515 mm (59.6 in) Rear Track: 1505 mm (59.3 in) Weights Curb Weight: 1400-1450 kg (3086-3197 lbs) depending on trim and specification Gross Vehicle Weight Rating: Approx. 1800 kg (3968 lbs) Cargo Trunk Volume: Approx. 260 Liters (9.2 cu ft) đĄď¸ Safety Features Ratings Jncsa Crash Safety: Achieved 4-star ratings in Japanese NCAP tests for its era Active Features Active Safety: Anti-lock Braking System (ABS), Active Yaw Control (AYC) / Super Active Yaw Control (S-AYC), limited-slip differentials Passive Features Passive Safety: Driver and front passenger airbags, front and rear seatbelts with pre-tensioners, reinforced chassis structure, side impact bars đĄ Technology Features Infotainment Audio System: Factory fitted AM/FM stereo with CD player and cassette deck (optional) Display: Basic LCD display for radio and clock Driver Assistance Performance Aids: Active Yaw Control (AYC) / Super Active Yaw Control (S-AYC) for enhanced cornering stability and grip Connectivity Connectivity Features: None (basic analog systems typical for the era) đ§ Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, under normal use. Shorter intervals recommended for spirited driving. Timing Belt Replacement: Every 60,000 miles...
5-speed manual (F5M42-2) and optional 6-speed manual (Newer models) service, repair, and diagnostics
Drivetrain:
All-Wheel Drive (AWD) system, Active Yaw Control (AYC) and Super AYC (S-AYC) diagnostics and calibration, front/rear differentials, driveshafts
Suspension:
Front MacPherson strut, rear multi-link suspension, shock absorbers, springs, bushings, alignment procedures
Brakes:
Front Brembo 4-piston calipers, rear Brembo 2-piston calipers, ABS system, brake fluid, hydraulic lines, rotor and pad replacement
Steering:
Power assisted rack and pinion, steering column, tie rods, calibration of power steering system
Electrical System:
Complete wiring diagrams, battery, alternator, starter, lighting system, ignition system, engine control unit (ECU) and sensors, body control module (BCM), diagnostics
Unleaded gasoline (Octane rating 95 RON or higher recommended)
đ§ Transmission
Standard
Type:
5-speed manual (F5M42-2)
Optional
Type:
6-speed manual (Specific models/regions, e.g., Tommi Makinen Edition)
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super Active Yaw Control (S-AYC)
Clutch Type:
Hydraulically operated, single dry plate
đ Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Front Track:
1515 mm (59.6 in)
Rear Track:
1505 mm (59.3 in)
Weights
Curb Weight:
1400-1450 kg (3086-3197 lbs) depending on trim and specification
Gross Vehicle Weight Rating:
Approx. 1800 kg (3968 lbs)
Cargo
Trunk Volume:
Approx. 260 Liters (9.2 cu ft)
đĄď¸ Safety Features
Ratings
Jncsa Crash Safety:
Achieved 4-star ratings in Japanese NCAP tests for its era
Active Features
Active Safety:
Anti-lock Braking System (ABS), Active Yaw Control (AYC) / Super Active Yaw Control (S-AYC), limited-slip differentials
Passive Features
Passive Safety:
Driver and front passenger airbags, front and rear seatbelts with pre-tensioners, reinforced chassis structure, side impact bars
đĄ Technology Features
Infotainment
Audio System:
Factory fitted AM/FM stereo with CD player and cassette deck (optional)
Display:
Basic LCD display for radio and clock
Driver Assistance
Performance Aids:
Active Yaw Control (AYC) / Super Active Yaw Control (S-AYC) for enhanced cornering stability and grip
Connectivity
Connectivity Features:
None (basic analog systems typical for the era)
đ§ Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, under normal use. Shorter intervals recommended for spirited driving.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years. Critical for the 4G63T engine; failure can cause catastrophic damage.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (e.g., iridium recommended).
Transmission Fluid Change:
Manual Transmission: Every 30,000 miles (48,000 km) or 2 years. AYC/S-AYC Fluid: Every 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40, API SG/SH or higher. Full synthetic recommended for performance. Capacity: Approx. 4.5 Liters (4.8 US Quarts).
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Capacity: Approx. 7.0 Liters (7.4 US Quarts).
Brake Fluid:
DOT 3 or DOT 4. High-performance DOT 4 recommended for track use.
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90. Capacity: Approx. 2.5 Liters (2.6 US Quarts).
Differential Fluid Front:
API GL-5, SAE 80W-90. Capacity: Approx. 1.2 Liters (1.3 US Quarts).
Differential Fluid Rear:
API GL-5, SAE 80W-90. Capacity: Approx. 1.2 Liters (1.3 US Quarts).
Ayc S Ayc Fluid:
Specific Mitsubishi Electric Fluid (MECO) or equivalent ATF (e.g., Dexron III).
Known Issues
Engine Issues:
Cracked cylinder heads (less common on Evo VI than earlier gens but possible), piston ring land failure from detonation, turbocharger wear, valve stem seal leakage.
Drivetrain Issues:
AYC pump failure, worn driveshaft U-joints, differential pinion seal leaks.
Suspension Issues:
Worn control arm bushings, blown front struts, wheel bearing noise.
Rust on fenders, sills, and rear quarter panels; weak door hinges; aging window seals.
đ Vehicle History
Brand Heritage
Rally Heritage:
Directly derived from Mitsubishi's WRC (World Rally Championship) successes, particularly Tommi Mäkinen's championships
Model Evolution
Evolution Line:
Sixth generation of the Lancer Evolution, building upon the success of previous models
Evo Vi Specifics:
Introduction of Super Active Yaw Control (S-AYC) on some models, revised engine internals for increased durability, larger turbocharger, wider wheels and tires, improved aerodynamics (larger rear spoiler, front bumper)
Production
Production Period:
January 1999 - March 2001
Production Variants:
GSR, RS (lighter, more basic), RS Sprint, Tommi Mäkinen Edition (TME)
đ Awards & Recognition
Recognitions
Rally Championships:
Tommi Mäkinen won the WRC Driver's Championship four consecutive times (1996-1999), with the Lancer Evolution being his primary weapon in the later years, cementing its motorsport legend.
Ratings
Performance Magazine Ratings:
Consistently rated highly by automotive publications for its handling, acceleration, and overall performance capabilities.