Mitsubishi Evo 4 & 5 1996-1999 Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV & V Model Code Evo4: CN9A Model Code Evo5: CP9A Codes Engine Codes: 4G63 (2.0L Turbocharged I4) 👋 Introduction Market Position Category: Performance Rally Homologation Special / Sports Sedan Segment: Compact Performance Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four. Key Features Drivetrain: Advanced All-Wheel Drive (AWD) with Active Yaw Control (AYC) on some variants. Engine Technology: Legendary 4G63 2.0L DOHC turbocharged engine with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some later models. Chassis Dynamics: MacPherson strut front suspension, multi-link rear suspension, robust chassis design optimized for rally performance. Aerodynamics: Aggressive body kits, large rear spoilers, functional hood vents for improved downforce and cooling. 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999 Markets: Global (primarily Japan domestic market) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharger system, transmission (manual & automatic options), drivetrain (transfer case, differentials). Chassis: Suspension (front & rear), steering system, braking system (ABS included), wheels and tires. Electrical: Wiring diagrams, lighting, instruments, audio system, power windows, power locks, climate control, engine control unit (ECU), body control module (BCM). Body: Body exterior (panels, bumpers, glass), interior trim, seats, safety systems (airbags). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues. Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, electrical component repair, body panel repair and replacement. Diagnostics: Detailed diagnostic flowcharts, specifications for sensor readings, ECU pinouts, testing procedures for electronic components. Technical Depth Depth: Comprehensive: Covers basic to advanced repair and diagnostic procedures. Includes disassembly, reassembly, specifications, tolerances, and torque values for all major components. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution scans suitable for detailed viewing of diagrams and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged Displacement: 1997 cc (2.0 Liters) Bore X Stroke Evo4: 85.0 mm x 88.0 mm Bore X Stroke Evo5: 85.0 mm x 88.0 mm Compression Ratio Evo4: 8.8:1 Compression Ratio Evo5: 8.8:1 Performance Horsepower Evo4: 276 hp (206 kW) @ 6250 rpm (JDM spec - often underestimated) Torque Evo4: 343 Nm (253 lb-ft) @ 3000 rpm (JDM spec - often underestimated) Horsepower Evo5: 276 hp (206 kW) @ 6250 rpm (JDM spec - often underestimated) Torque Evo5: 377 Nm (278 lb-ft) @ 3000 rpm (JDM spec - often underestimated) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC) Fuel Type: Unleaded Premium (95 RON or higher recommended) Turbocharger: Mitsubishi TD05H-16G (Evo IV) / TD05HRA-15G (Evo V) Intercooler: Front-mounted air-to-air intercooler 🔧 Transmission Standard Type Evo4: 5-speed Manual (Type R/RS models often featured 6-speed manual) Type Evo5: 5-speed Manual (RS/GSR models) Optional Type: 4-speed Automatic (less common for performance variants) Features Clutch: Single dry plate, hydraulically operated diaphragm spring clutch AWD System: Full-time 4WD with viscous coupling center differential (AYC system on GSR models). Differential Rear: Mechanical Limited-Slip Differential (LSD) (Helical LSD on RS models, Viscous LSD on GSR). 📐 Dimensions Exterior Length Evo4: 4350 mm (171.3 in) Width Evo4: 1770 mm (69.7 in) Height Evo4: 1415 mm (55.7 in) Wheelbase Evo4: 2600 mm (102.4 in) Length Evo5: 4360 mm (171.7 in) Width Evo5: 1770 mm (69.7 in) Height Evo5: 1415 mm (55.7 in) Wheelbase Evo5: 2600 mm (102.4 in) Weights Curb Weight Evo4 Gsr: 1450 kg (3197 lbs) Curb Weight Evo4 Rs: 1400 kg (3086 lbs) Curb Weight Evo5 Gsr: 1450 kg (3197 lbs) Curb Weight Evo5 Rs: 1400 kg (3086 lbs) Cargo Cargo Volume: Not prominently advertised, sedan configuration. 🛡️ Safety Features Ratings Crash Test Ratings: Not independently tested by major agencies like NHTSA/Euro NCAP during its original production era. Active Features ABS: Standard on GSR, optional on RS. Advanced ABS system. Ayc: Active Yaw Control (AYC) system on GSR models, electronically controlling torque distribution to rear wheels. Passive Features Airbags: Driver and passenger airbags standard on GSR, optional/absent on RS. Seatbelts: Pretensioner and force-limiting seatbelts. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo cassette player with optional CD player, 4-6 speakers. Driver Assistance Traction Control: Not typically equipped with electronic traction control; relies on AWD and AYC for grip. Connectivity Bluetooth: Not available on factory systems. ECU Tuning: ECU is highly programmable for performance tuning, a common modification. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km (3,000 -...
Suspension (front & rear), steering system, braking system (ABS included), wheels and tires.
Electrical:
Wiring diagrams, lighting, instruments, audio system, power windows, power locks, climate control, engine control unit (ECU), body control module (BCM).
Body:
Body exterior (panels, bumpers, glass), interior trim, seats, safety systems (airbags).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, electrical component repair, body panel repair and replacement.
Diagnostics:
Detailed diagnostic flowcharts, specifications for sensor readings, ECU pinouts, testing procedures for electronic components.
Technical Depth
Depth:
Comprehensive: Covers basic to advanced repair and diagnostic procedures. Includes disassembly, reassembly, specifications, tolerances, and torque values for all major components.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution scans suitable for detailed viewing of diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke Evo4:
85.0 mm x 88.0 mm
Bore X Stroke Evo5:
85.0 mm x 88.0 mm
Compression Ratio Evo4:
8.8:1
Compression Ratio Evo5:
8.8:1
Performance
Horsepower Evo4:
276 hp (206 kW) @ 6250 rpm (JDM spec - often underestimated)
5-speed Manual (Type R/RS models often featured 6-speed manual)
Type Evo5:
5-speed Manual (RS/GSR models)
Optional
Type:
4-speed Automatic (less common for performance variants)
Features
Clutch:
Single dry plate, hydraulically operated diaphragm spring clutch
AWD System:
Full-time 4WD with viscous coupling center differential (AYC system on GSR models).
Differential Rear:
Mechanical Limited-Slip Differential (LSD) (Helical LSD on RS models, Viscous LSD on GSR).
📐 Dimensions
Exterior
Length Evo4:
4350 mm (171.3 in)
Width Evo4:
1770 mm (69.7 in)
Height Evo4:
1415 mm (55.7 in)
Wheelbase Evo4:
2600 mm (102.4 in)
Length Evo5:
4360 mm (171.7 in)
Width Evo5:
1770 mm (69.7 in)
Height Evo5:
1415 mm (55.7 in)
Wheelbase Evo5:
2600 mm (102.4 in)
Weights
Curb Weight Evo4 Gsr:
1450 kg (3197 lbs)
Curb Weight Evo4 Rs:
1400 kg (3086 lbs)
Curb Weight Evo5 Gsr:
1450 kg (3197 lbs)
Curb Weight Evo5 Rs:
1400 kg (3086 lbs)
Cargo
Cargo Volume:
Not prominently advertised, sedan configuration.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not independently tested by major agencies like NHTSA/Euro NCAP during its original production era.
Active Features
ABS:
Standard on GSR, optional on RS. Advanced ABS system.
Ayc:
Active Yaw Control (AYC) system on GSR models, electronically controlling torque distribution to rear wheels.
Passive Features
Airbags:
Driver and passenger airbags standard on GSR, optional/absent on RS.
Seatbelts:
Pretensioner and force-limiting seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo cassette player with optional CD player, 4-6 speakers.
Driver Assistance
Traction Control:
Not typically equipped with electronic traction control; relies on AWD and AYC for grip.
Connectivity
Bluetooth:
Not available on factory systems.
ECU Tuning:
ECU is highly programmable for performance tuning, a common modification.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, depending on driving conditions.
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles)
Spark Plug Replacement:
Every 40,000 - 60,000 km (24,000 - 36,000 miles), depending on plug type.
Timing Belt Replacement:
Every 100,000 km (60,000 miles) or 5 years.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3, Viscosity 10W-30, 10W-40, or 5W-30 (check manual for specific climate recommendations).
Coolant:
Mitsubishi Genuine Long Life Antifreeze/Coolant (Green) or equivalent ethylene glycol-based coolant.
Transmission Fluid Manual:
API GL-4 or GL-5 Gear Oil, Viscosity 75W-90.
Differential Fluid Rear:
API GL-5 Gear Oil, Viscosity 75W-90 (for mechanical LSD).
Transfer Case Fluid:
API GL-4 Gear Oil, Viscosity 75W-90.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Wear:
Piston ring wear, bearing failures, especially if poorly maintained or driven hard without proper warm-up.
Turbocharger:
Oil leaks, bearing failure, exhaust housing cracks due to high temperatures and stress.
Ayc System:
Failure of the AYC pump or sensors, fluid leaks.
Clutch Wear:
Wear and tear on clutch components due to aggressive driving.
Suspension:
Wear in bushings, ball joints, and shock absorbers due to performance driving and chassis loads.
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi has a long and successful history in the World Rally Championship (WRC), with the Lancer Evolution series being its flagship performance vehicle.
Model Evolution
Evo1 To Evo3:
Evolutions I to III established the Evo's reputation for rally-bred performance and AWD technology.
Evo4 Introduction:
The Evo IV (CN9A), launched in August 1996, featured a completely new chassis, significant engine upgrades, and the introduction of AYC.
Evo5 Introduction:
The Evo V (CP9A), launched in January 1998, was a facelift and enhancement of the Evo IV. It featured wider track, larger front bumper openings, upgraded turbocharger, larger intercooler, Brembo brakes, and a revised AYC system.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Period Evo4:
August 1996 – August 1997
Production Period Evo5:
January 1998 – January 1999
🏆 Awards & Recognition
Recognitions
Rally Pedigree:
Renowned for its direct lineage to WRC-winning vehicles, making it a highly sought-after performance car.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its handling, acceleration, and raw performance.
Certifications
Homologation:
Built to homologate Mitsubishi for Group A and World Rally Championship competition.
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