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Mitsubishi Lancer Evolution 4 1996-1998 Repair Service

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Model Nickname: Evo IV Body Style: 4-door Sedan Generation Generation: Fourth Generation (CN9A/CP9A) Codes Chassis Code Range: CN9A, CP9A Engine Code Primary: 4G63 👋 Introduction Market Position Market Segment: Performance Sedan / Rally Homologation Special Target Audience: Enthusiasts, performance drivers, tuners, professional mechanics, and owners seeking detailed repair and maintenance information. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth (during its relevant period). Key Features Vehicle Usp: Advanced Active Yaw Control (AYC), potent 4G63T engine, sophisticated all-wheel-drive system, rally-bred performance and handling. Manual Value Proposition: Provides the definitive technical documentation for diagnosing, maintaining, and repairing the Evo IV, essential for preserving its performance and value. 📋 Manual Details Coverage Areas Supported Years: 1996, 1997, 1998 Market Coverage: Primarily JDM (Japanese Domestic Market), but applicable to global variants with specification notes. Page Count Estimated Page Count: Comprehensive (Specific count not provided, but typical for factory service manuals is 1000+ pages). Manual Type Manual Type: Factory Service Manual (FSM) / Repair Manual Language Language: English (Likely translated from Japanese original) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (4G63 DOHC Turbo), fuel injection, ignition system, lubrication, cooling, emissions control, engine management (ECU). Drivetrain Systems: Clutch, manual transmission (5-speed), transfer case, front differential, rear differential (Active Yaw Control - AYC). Suspension Steering: Front MacPherson struts, rear multi-link suspension, power steering system, steering linkage. Braking Systems: Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics. Electrical Systems: Charging system (alternator, battery), starting system, lighting, instrumentation, wiring diagrams, fuses, relays, body control modules. Body Chassis: Body construction, exterior trim, interior trim, doors, windows, seats, climate control (HVAC). Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement. Diagnostic Procedures: Troubleshooting charts, DTC (Diagnostic Trouble Code) lookup and interpretation, component testing, sensor diagnostics. Repair Procedures: Engine component overhaul, transmission rebuild, suspension component replacement, brake system servicing, electrical component repair, body panel repair. Adjustment Procedures: Wheel alignment, clutch adjustment, handbrake adjustment, idle speed adjustment. Technical Depth Depth Of Information: Comprehensive. Covers from basic maintenance to in-depth mechanical and electrical diagnostics and repair, suitable for professional mechanics and advanced enthusiasts. Diagnostic Tools: Includes specifications for special tools required for specific procedures and diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, enabling quick access to information. Print Quality Image Clarity: Typically high quality for diagrams and illustrations when sourced from official manuals. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Ps Jdm: 280 PS (206 kW) at 6,500 rpm (Factory stated; often underestimated) Torque Nm Jdm: 35.0 kgf·m (343 N·m) at 5,000 rpm (Factory stated; often underestimated) Redline: 7,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Injection Turbocharger: Mitsubishi TD05HR-16G (twin-scroll) Intercooler: Air-to-air front-mounted Recommended Fuel: 95 RON (Research Octane Number) unleaded gasoline 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Gear Ratios Approx: 1st: 3.142, 2nd: 2.105, 3rd: 1.428, 4th: 1.034, 5th: 0.766, Reverse: 2.800 Optional Optional Transmission: N/A (Manual only for Evo IV) Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Yaw Control (AYC) AWD System Details: Viscous coupling center differential, electronic torque split, AYC controlled rear differential. Transmission Fluid Type: API GL-4 / GL-5, SAE 75W-90 (Manual Transmission); API GL-5, SAE 80W-90 (Transfer Case/Differentials) - Refer to manual for specific Mitsubishiofficial specifications. 📐 Dimensions Exterior Length: 4,350 mm Width: 1,770 mm Height: 1,415 mm Wheelbase: 2,600 mm Track Front: 1,515 mm Track Rear: 1,505 mm Weights Curb Weight: Approx. 1,360 kg Gross Vehicle Weight: Approx. 1,635 kg Towing Capacity: Not specified/recommended. 🛡️ Safety Features Ratings Jncsa Crash Test: While specific ratings for the 1996-1998 models are not as widely published as modern vehicles, Mitsubishi employed advanced chassis design and structural reinforcements typical of performance vehicles of the era. Active Features Active Safety Systems: ABS (Anti-lock Braking System), AYC (Active Yaw Control) for enhanced cornering stability and traction. Traction Control: Included as part of AYC and AWD system functionality. Passive Features Airbags: Driver and front passenger airbags standard. Seat Belts: 3-point ELR seatbelts with pre-tensioners. Chassis Reinforcement: Reinforced chassis for increased rigidity and crashworthiness. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player with optional CD player. Basic speaker setup. Instrumentation: Comprehensive driver's information display, including boost gauge, oil pressure, and oil temperature gauges (on some variants). Driver Assistance Driver Assistance Features: ABS, AYC. Connectivity Connectivity Options: None from factory; aftermarket solutions are common for modern connectivity. 🔧 Maintenance Service Intervals...
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Mitsubishi Lancer Evolution 4 1996-1998 Repair Service
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV
Model Nickname:
Evo IV
Body Style:
4-door Sedan
Generation
Generation:
Fourth Generation (CN9A/CP9A)
Codes
Chassis Code Range:
CN9A, CP9A
Engine Code Primary:
4G63
👋 Introduction
Market Position
Market Segment:
Performance Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, performance drivers, tuners, professional mechanics, and owners seeking detailed repair and maintenance information.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth (during its relevant period).
Key Features
Vehicle Usp:
Advanced Active Yaw Control (AYC), potent 4G63T engine, sophisticated all-wheel-drive system, rally-bred performance and handling.
Manual Value Proposition:
Provides the definitive technical documentation for diagnosing, maintaining, and repairing the Evo IV, essential for preserving its performance and value.
📋 Manual Details
Coverage Areas
Supported Years:
1996, 1997, 1998
Market Coverage:
Primarily JDM (Japanese Domestic Market), but applicable to global variants with specification notes.
Page Count
Estimated Page Count:
Comprehensive (Specific count not provided, but typical for factory service manuals is 1000+ pages).
Manual Type
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English (Likely translated from Japanese original)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (4G63 DOHC Turbo), fuel injection, ignition system, lubrication, cooling, emissions control, engine management (ECU).
Drivetrain Systems:
Clutch, manual transmission (5-speed), transfer case, front differential, rear differential (Active Yaw Control - AYC).
Suspension Steering:
Front MacPherson struts, rear multi-link suspension, power steering system, steering linkage.
Braking Systems:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics.
Electrical Systems:
Charging system (alternator, battery), starting system, lighting, instrumentation, wiring diagrams, fuses, relays, body control modules.
Body Chassis:
Body construction, exterior trim, interior trim, doors, windows, seats, climate control (HVAC).
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement.
Diagnostic Procedures:
Troubleshooting charts, DTC (Diagnostic Trouble Code) lookup and interpretation, component testing, sensor diagnostics.
Repair Procedures:
Engine component overhaul, transmission rebuild, suspension component replacement, brake system servicing, electrical component repair, body panel repair.
Adjustment Procedures:
Wheel alignment, clutch adjustment, handbrake adjustment, idle speed adjustment.
Technical Depth
Depth Of Information:
Comprehensive. Covers from basic maintenance to in-depth mechanical and electrical diagnostics and repair, suitable for professional mechanics and advanced enthusiasts.
Diagnostic Tools:
Includes specifications for special tools required for specific procedures and diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, enabling quick access to information.
Print Quality
Image Clarity:
Typically high quality for diagrams and illustrations when sourced from official manuals.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Ps Jdm:
280 PS (206 kW) at 6,500 rpm (Factory stated; often underestimated)
Torque Nm Jdm:
35.0 kgf·m (343 N·m) at 5,000 rpm (Factory stated; often underestimated)
Redline:
7,500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Injection
Turbocharger:
Mitsubishi TD05HR-16G (twin-scroll)
Intercooler:
Air-to-air front-mounted
Recommended Fuel:
95 RON (Research Octane Number) unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Gear Ratios Approx:
1st: 3.142, 2nd: 2.105, 3rd: 1.428, 4th: 1.034, 5th: 0.766, Reverse: 2.800
Optional
Optional Transmission:
N/A (Manual only for Evo IV)
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
AWD System Details:
Viscous coupling center differential, electronic torque split, AYC controlled rear differential.
Transmission Fluid Type:
API GL-4 / GL-5, SAE 75W-90 (Manual Transmission); API GL-5, SAE 80W-90 (Transfer Case/Differentials) - Refer to manual for specific Mitsubishiofficial specifications.
📐 Dimensions
Exterior
Length:
4,350 mm
Width:
1,770 mm
Height:
1,415 mm
Wheelbase:
2,600 mm
Track Front:
1,515 mm
Track Rear:
1,505 mm
Weights
Curb Weight:
Approx. 1,360 kg
Gross Vehicle Weight:
Approx. 1,635 kg
Towing Capacity:
Not specified/recommended.
🛡️ Safety Features
Ratings
Jncsa Crash Test:
While specific ratings for the 1996-1998 models are not as widely published as modern vehicles, Mitsubishi employed advanced chassis design and structural reinforcements typical of performance vehicles of the era.
Active Features
Active Safety Systems:
ABS (Anti-lock Braking System), AYC (Active Yaw Control) for enhanced cornering stability and traction.
Traction Control:
Included as part of AYC and AWD system functionality.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
3-point ELR seatbelts with pre-tensioners.
Chassis Reinforcement:
Reinforced chassis for increased rigidity and crashworthiness.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player with optional CD player. Basic speaker setup.
Instrumentation:
Comprehensive driver's information display, including boost gauge, oil pressure, and oil temperature gauges (on some variants).
Driver Assistance
Driver Assistance Features:
ABS, AYC.
Connectivity
Connectivity Options:
None from factory; aftermarket solutions are common for modern connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 6 months, whichever comes first (Recommended for high-performance driving).
Air Filter Replacement:
Every 20,000 km or 1 year.
Spark Plug Replacement:
Every 40,000 km (Platinum-tipped spark plugs).
Timing Belt Replacement:
Every 90,000 km or 5 years.
Fluid Specifications
Engine Oil Capacity:
4.5 Liters (with filter) of 10W-40 or 5W-40 synthetic engine oil (API SG/SH/SJ or ACEA A3/B3).
Coolant Type:
Ethylene glycol based coolant with distilled water (50/50 mix). Mitsubishiprefered coolant or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Clutch wear, AYC pump failure, turbocharger wear, front suspension bushings, engine oil leaks (valve cover gasket, oil pan gasket).
Engine Reliability:
Generally robust 4G63T, but requires diligent maintenance. Turbo failure can occur from oil starvation or lack of warm-up/cool-down periods.
Ayc System:
The AYC pump can be a weak point; regular fluid changes are crucial. Electronic control unit for AYC can also fail.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Directly derived from Mitsubishi's highly successful WRC (World Rally Championship) program. The Evo line is a homologation special.
Model Evolution
Predecessor:
Mitsubishi Lancer Evolution III (Evo III)
Successor:
Mitsubishi Lancer Evolution V (Evo V)
Key Advancements From Evo Iii:
Significantly revised exterior styling, introduction of Active Yaw Control (AYC), enlarged intercooler, revised ECU, introduction of RS and GSR trims.
Production
Production Years:
August 1996 – August 1998
Manufacturing Location:
Mizushima Plant, Kurashiki, Japan
Production Volume Estimate:
Estimated around 10,000 units globally (highly sought after).
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution platform has a legendary motorsport heritage, particularly in WRC, which significantly boosted its desirability and recognition.
Critical Acclaim:
Widely acclaimed by automotive journalists and enthusiasts for its performance, handling, and technological innovation in its era.
Ratings
Performance Benchmark:
Considered a benchmark for performance sedans and AWD sports cars upon its release.
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