Mitsubishi Lancer Evo 5 1998 1999 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo 5) Chassis Code: CP9A Generation Generation: Fifth Generation Codes Production Years: 1998-1999 👋 Introduction Market Position Market Segment: High-performance rally homologation special sedan Target Audience: Enthusiasts, tuners, mechanics specializing in rally-bred performance vehicles Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione Key Features Performance Focus: Engineered for high-speed rallying and track performance All Wheel Drive: Advanced Super Active All-Wheel Drive (AYC) system Turbocharged Engine: Powerful turbocharged and intercooled engine designed for responsiveness 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Coverage Scope: Comprehensive repair and overhaul Page Count Page Count: N/A (PDF format, variable depending on digital rendering) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, disassembly, assembly, tuning, diagnostics Engine Electrical: Ignition system, fuel injection system, starting and charging systems, ECU (Engine Control Unit) diagnostics Transmission: Manual transmission (Type-MR), transfer case, differentials (front, center, rear) Suspension: Front and rear suspension systems, struts, springs, bushings, alignment specifications Brakes: Front and rear brake systems, caliper overhaul, ABS (Anti-lock Braking System) diagnostics Steering: Power steering system, steering rack, tie rods, alignment Cooling System: Radiator, water pump, thermostat, coolant hoses, fan assembly Fuel System: Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulator Exhaust System: Exhaust manifold, catalytic converter, muffler, pipes Electrical System: Wiring diagrams, lighting, accessories, battery, fuses, relays Body And Chassis: Body panel removal and installation, chassis components, corrosion protection HVAC System: Heating, Ventilation, and Air Conditioning system components and service Interior Trim: Dashboard, seats, door panels, carpet removal and installation Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based diagnosis Component Overhaul: Detailed steps for rebuilding major components like engines, transmissions, and turbochargers Diagnostic Procedures: Step-by-step guides for identifying and resolving issues using diagnostic tools and methods Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Tightening Torques: Specific torque values for all critical fasteners Special Tools: Identification and usage of specialized tools required for specific procedures Technical Depth Depth: In-depth, suitable for professional technicians and experienced DIY enthusiasts Detail Level: Detailed illustrations, diagrams, specifications, and step-by-step instructions 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable (depending on PDF source quality) Print Quality: Depends on the source PDF; generally printable at home or professional print shops Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (Evo V) Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Displacement: 1997 cc (2.0 Liters) Performance Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Horsepower Ps: 280 PS @ 6500 rpm (JDM specification; actual output often higher) Horsepower Hp: 276 hp @ 6500 rpm (approx. US spec conversion) Torque Nm: 372 Nm @ 3000 rpm (JDM specification) Torque Lb-Ft: 275 lb-ft @ 3000 rpm (approx. US spec conversion) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI) Fuel Type: Premium Unleaded Gasoline (95 RON or higher recommended) Turbocharger: Mitsubishi TD05HR-16G (later spec, often upgraded from earlier models) Intercooler: Large Front-Mount Intercooler (FMIC) 🔧 Transmission Standard Type: 5-speed Manual Transmission (Type-MR) Optional Type: N/A (Manual transmission was standard for Evo V) Features Drivetrain: All-Wheel Drive (AWD) Center Differential: Active Centre Differential (ACD) with mechanical limited-slip differential (LSD) capabilities Rear Differential: Active Yaw Control (AYC) equipped rear differential with LSD Gear Ratios: Specific ratios are detailed in the manual, critical for performance tuning. Clutch Type: Hydraulic, single-plate, dry 📐 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) Track Width Front: 1505 mm (59.3 in) Track Width Rear: 1500 mm (59.1 in) Ground Clearance: 150 mm (5.9 in) Weights Curb Weight: Approx. 1350 kg (2976 lbs) Gross Vehicle Weight Rating: N/A (Specific GVWR not commonly cited for homologation specials) 🛡️ Safety Features Ratings Crash Test Ratings: Not specifically tested by modern agencies like NHTSA or Euro NCAP due to its era and limited production. Focus on active safety for its intended use. Active Features ABS: Standard Anti-lock Braking System (ABS) Ayc: Active Yaw Control (AYC) for enhanced cornering stability and traction Acd: Active Centre Differential (ACD) with selectable modes for varied traction conditions Passive Features Airbags: Driver and front passenger airbags Seatbelts: Three-point inertia-reel seatbelts with pretensioners Chassis Reinforcement: Enhanced chassis rigidity for rally-derived performance 💡 Technology Features Infotainment Audio System: Basic factory AM/FM stereo with cassette player and CD compatibility (depending on market and trim). Likely aftermarket upgrades common. Driver Assistance ABS: Standard ABS system, crucial for high-performance braking. Ayc: Active Yaw Control (AYC) is a key technological feature for torque vectoring and dynamic stability. Connectivity Connectivity Features:...
Manual Transmission Fluid, API GL-4/GL-5, SAE 75W-90. Capacity approx. 2.5 Liters for gearbox, 0.6 Liters for transfer case, 1.0 Liter for rear diff.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF Dexron II or equivalent.
Known Issues
Engine Reliability:
Generally robust 4G63T, but can suffer from ringland failure if consistently run with detonation or pushed beyond its limits without proper tuning/cooling. Turbocharger seals can wear.
Ayc System:
AYC pump and sensors can fail over time, leading to warning lights and loss of functionality. Repair or bypass options exist.
Clutch Wear:
Clutch wear is dependent on driving style; performance clutches can wear faster under aggressive use.
Suspension Bushings:
Rubber bushings in suspension and differentials can degrade over time, affecting handling.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi has a storied history in the World Rally Championship (WRC), with the Lancer Evolution series being a direct result of homologation requirements.
Model Evolution
Evo V Development:
Evo V was a significant step up, featuring wider track, larger wheels, and revised aerodynamics compared to the Evo IV.
Engine Enhancements:
The 4G63T engine received further refinement, including a larger turbocharger and improved intercooler for increased power and responsiveness.
Production
Manufacturing Location:
Japan
Production Volume:
Limited production, highly sought after by enthusiasts and collectors.
Homologation Purpose:
Developed to meet Group A rally regulations for WRC.
🏆 Awards & Recognition
Recognitions
Rally Performance:
Consistently praised for its rally-bred performance and handling capabilities by automotive publications of its era.
Enthusiast Following:
Maintains a strong cult following among car enthusiasts globally for its iconic status and performance.
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