Mitsubishi Lancer EVO 6 Complete Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Codes Chassis Code: CP9A Engine Code: 4G63T 👋 Introduction Market Position Market Segment: Performance Rally Homologation Special / Sports Sedan Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four Key Features Rally Heritage: Designed for WRC homologation, renowned for its rallying pedigree and capabilities All Wheel Drive: Advanced Super Active Yaw Control (AYC) and Viscous coupling Limited Slip Center Differential (VLSD) Engine Technology: Iconic 4G63T 2.0L DOHC Turbocharged MIVEC engine Aero Dynamics: Aggressive body kit including front bumper, side skirts, rear bumper, and large rear wing for enhanced downforce 📋 Manual Details Coverage Areas Coverage Continents: Global (Primarily Japan, Europe, Australia) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine Mechanical, Engine Lubrication, Engine Cooling, Fuel & Emission Control Systems, Ignition System, Turbocharging System Transmission: Manual Transmission (5-speed), Transfer Case, Drive Shafts, Differentials (Front, Center, Rear) Brakes: Hydraulic System, Front & Rear Brakes (Disc), ABS System Suspension: Front & Rear Suspension (MacPherson Struts, Multi-link), Steering System Electrical: Electrical System, Battery, Alternator, Starter Motor, Ignition System, Lighting, Instrumentation, Audio System, Power Windows, Mirrors, Central Locking Body And Chassis: Body Construction, Exterior Panels, Interior Trim, Doors, Hood, Trunk, Bumpers, Chassis Components Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Service, Belt Replacement, Fluid Checks and Replacements Repair Overhaul: Engine Rebuild (Top & Bottom End), Transmission Overhaul, Differential Rebuild, Brake System Repair, Suspension Component Replacement, Turbocharger Rebuild Diagnostics Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Guides, Electrical Troubleshooting Diagrams (ETD) Technical Data: Torque Specifications, Clearances, Alignment Procedures, Special Tool Usage Technical Depth Depth Level: Comprehensive (from basic maintenance to full engine and drivetrain rebuilds) 📊 Manual Specifications File Format File Format: PDF Print Quality Scan Quality: High Resolution, Clear Text and Diagrams Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Configuration: Inline-4, DOHC, 16-valve, turbocharged with intercooler Engine Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Performance Horsepower Ps: 276 PS (272 hp) @ 6500 rpm (JDM/European spec) Torque Nm: 373 Nm (275 lb-ft) @ 3000 rpm (JDM/European spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-port Injection Fuel Type: Unleaded Premium Gasoline (95 RON or higher) Turbocharger Turbocharger Model: Mitsubishi TD05H-16G (or similar variant) Boost Pressure: Variable, typically around 1.3 bar (19 psi) with manual boost controller Cylinder Head Cylinder Head Features: MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system on intake camshafts for improved power and response 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (Type R) Optional Optional Transmission: N/A (Manual exclusively for most performance variants) Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) System Center Differential: Viscous Coupling Limited Slip Center Differential (VLSD) Rear Differential: Helical Limited Slip Differential (LSD) 📐 Dimensions Exterior Length: 4350 mm (171.3 in) Width: 1770 mm (69.7 in) Height: 1405 mm (55.3 in) Wheelbase: 2600 mm (102.4 in) Track Front: 1500 mm (59.1 in) Track Rear: 1490 mm (58.7 in) Weights Curb Weight: 1400 kg (3086 lbs) - approximate Gross Vehicle Weight: 1625 kg (3582 lbs) - approximate 🛡️ Safety Features Ratings NHTSA Rating: Not specifically rated by NHTSA for this era of homologation special, but built to rigorous rally safety standards. Active Features Active Safety Systems: AYC (Active Yaw Control), ABS (Anti-lock Braking System) Passive Features Passive Safety Features: Reinforced chassis, driver and passenger airbags, three-point seatbelts with pretensioners, front and rear crumple zones Braking System Front Brakes: Ventilated Discs (4-piston caliper, often Brembo on Ralli Art variants) Rear Brakes: Solid Discs (2-piston caliper) 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD stereo system with multiple speakers. Some models featured premium audio options. Driver Assistance Advanced Systems: AYC (Active Yaw Control) system which electronically controls torque distribution to the rear wheels for improved cornering stability and agility. Connectivity Connectivity Features: Limited by era; primarily focused on vehicle performance and driver engagement. No modern Bluetooth or USB connectivity typically. Instrumentation Gauge Cluster: Comprehensive gauge cluster including speedometer, tachometer, boost gauge, oil pressure, water temperature, and voltmeter. Warning lights for AYC system. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (synthetic oil recommended) Timing Belt Interval: Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5 years Fluid Specifications Engine Oil Type: API SG/SH/SJ or ACEA A2/A3, SAE 10W-30 or 10W-40 (check specific conditions and oil manufacturer recommendations for high-performance use) Coolant Type: Ethylene Glycol based antifreeze, mix 50/50 with deionized water Transmission Fluid Type: GL-4 Hypoid Gear Oil, SAE 75W-90 (for manual transmission) Transfer Case Fluid Type: GL-4...
Reinforced chassis, driver and passenger airbags, three-point seatbelts with pretensioners, front and rear crumple zones
Braking System
Front Brakes:
Ventilated Discs (4-piston caliper, often Brembo on Ralli Art variants)
Rear Brakes:
Solid Discs (2-piston caliper)
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD stereo system with multiple speakers. Some models featured premium audio options.
Driver Assistance
Advanced Systems:
AYC (Active Yaw Control) system which electronically controls torque distribution to the rear wheels for improved cornering stability and agility.
Connectivity
Connectivity Features:
Limited by era; primarily focused on vehicle performance and driver engagement. No modern Bluetooth or USB connectivity typically.
Instrumentation
Gauge Cluster:
Comprehensive gauge cluster including speedometer, tachometer, boost gauge, oil pressure, water temperature, and voltmeter. Warning lights for AYC system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first (synthetic oil recommended)
Timing Belt Interval:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5 years
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or ACEA A2/A3, SAE 10W-30 or 10W-40 (check specific conditions and oil manufacturer recommendations for high-performance use)
Coolant Type:
Ethylene Glycol based antifreeze, mix 50/50 with deionized water
GL-4 Hypoid Gear Oil, SAE 75W-90 (for transfer case)
Differential Fluid Type:
GL-5 Hypoid Gear Oil, SAE 80W-90 or 75W-90 (for front and rear differentials)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Failures:
Cracked cylinder heads (especially early 4G63), turbocharger failure, clutch wear, AYC pump issues, rust in common areas (wheel arches, sills).
Performance Considerations:
Requires meticulous maintenance due to high-performance nature. Regular checks of oil and coolant levels are critical. Upgraded cooling and oil systems are common for heavily modified cars.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation, known for its engineering prowess and motorsport involvement.
Model Evolution
Predecessors:
Lancer Evolution I, II, III
Successors:
Lancer Evolution VII, VIII, IX, X
Production
Production Years:
1999 - 2001
Key Variants:
GSR, RS, Tommi Mäkinen Edition (TME)
Motorsport
Wrc Success:
The Evo VI platform, particularly the Tommi Mäkinen Edition, was dominant in the World Rally Championship, securing manufacturer and driver titles.
🏆 Awards & Recognition
Recognitions
Rally Awards:
Multiple WRC Manufacturer's and Driver's Championship titles with various Evolution models, including significant success attributed to the Evo VI platform.
Ratings
Performance Reviews:
Consistently lauded by automotive press for its exceptional handling, grip, acceleration, and driver involvement, earning it 'legendary' status among enthusiasts.
Certifications
Homologation:
Built as a homologation special to meet the requirements for the World Rally Championship (WRC).