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Mitsubishi Lancer Evolution 6 2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Model Code: CP9A Year: 2000 Codes Chassis Code: CP9A Engine Code: 4G63T 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution VI (Evo VI) was a legendary homologation special, renowned for its rally-bred performance and technological advancements in the late 1990s and early 2000s compact sports sedan segment. Segment: High-performance compact sports sedan Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale (historically), and later, cars like the BMW M3 and Audi RS4 in terms of performance envelope, albeit in different segments. Key Features Performance Focus: Iconic 4G63T engine, advanced all-wheel-drive systems (AYC/Super AYC), aggressive aerodynamics, performance-oriented suspension and braking. Rally Heritage: Directly derived from Mitsubishi's WRC (World Rally Championship) program, embodying the spirit and engineering prowess of its rally counterparts. Manual Purpose Target Audience: Professional mechanics, experienced DIY enthusiasts, and owners seeking to meticulously maintain or restore their Mitsubishi Lancer Evolution VI. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive factory service and repair procedures for all systems of the Mitsubishi Lancer Evolution VI (2000 model year). Page Count Estimated Page Count: Approx. 1500-2000 pages (typical for comprehensive factory service manuals of this era). Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (likely PDF, but potentially physical reproduction) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair, tuning, performance modifications, lubrication systems, cooling systems, fuel systems, emission control systems. Engine Electrical: Ignition system, starting system, charging system, ECU control, sensors, actuators, wiring diagrams, diagnostic procedures. Transmission: Manual transmission (Getrag 5-speed), clutch system, transfer case, driveshafts, differential service, troubleshooting, repair. Drivetrain: All-Wheel Drive (AYC - Active Center Differential), Super AYC (Active Yaw Control), propeller shafts, CV joints, wheel hubs. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, alignment specifications, troubleshooting. Brakes: Brake system components (calipers, rotors, pads, lines, master cylinder, ABS), hydraulic circuits, bleeding procedures, parking brake, troubleshooting. Steering: Power steering system, steering rack, tie rods, steering column, hydraulic fluid specifications, troubleshooting. Body: Body panel removal and installation, interior trim, exterior trim, doors, hood, trunk, glass, weatherstripping, chassis structure, corrosion prevention. Electrical System: Lighting system (headlights, taillights, interior), power windows, power mirrors, central locking, horn, wipers, washers, fuse box locations, relay functions, wiring diagrams. Climate Control: Air conditioning system, heater core, blower motor, HVAC controls, refrigerant type, charging procedures, troubleshooting. Fuel System: Fuel pump, fuel injectors, fuel pressure regulator, fuel lines, fuel tank, emissions controls (EVAP). Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, belt inspection and replacement. Repair: Engine overhaul, transmission rebuild, clutch replacement, brake caliper overhaul, suspension component replacement, radiator replacement, alternator replacement, starter motor replacement. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, code reading and interpretation (OBD-II or equivalent for the era), electrical system diagnostics. Installation: Component installation and removal procedures for all major systems, including aftermarket parts where applicable for performance. Disassembly Assembly: Detailed step-by-step instructions for taking apart and putting back together all vehicle components and systems. Technical Depth Depth: Extremely high. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed torque specifications and specialized tool requirements. Diagnostic Capability: Detailed diagnostic procedures for electronic control units (ECUs), sensors, actuators, and mechanical systems. Includes wiring diagrams for tracing electrical faults. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Image Resolution: High-resolution images, diagrams, and schematics for clarity. Diagrams Illustrations: Detailed exploded views, line drawings, and schematics. Binding Type Physical Binding: N/A (Digital format) Paper Type Physical Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Engine Code: 4G63T Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Performance Horsepower Ps: 280 PS (approx. 276 bhp) at 6,500 rpm (JDM/European spec; may vary slightly by region) Torque Kgf M: 34.2 kgf·m (approx. 247 lb-ft) at 3,000 rpm (JDM/European spec; may vary slightly by region) Redline: Approx. 7,000 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Unleaded gasoline, minimum 95 RON (required for optimal performance) Turbocharger: Mitsubishi TD05H-16G (common for Evo VI, though variations exist for RS models) Intercooler: Air-to-air front-mounted intercooler (FMIC) 🔧 Transmission Standard Type: 5-speed manual transmission Manufacturer: Getrag (often the renowned 5-speed 'Dog-leg' gearbox for certain performance variants) Optional Type: N/A (Evo VI was exclusively manual transmission) Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (AYC) and Super AYC on GSR models. Clutch: Hydraulically operated, multi-plate clutch Gear Ratios: Specific ratios detailed in the manual, optimized for performance driving. Transmission Fluid Spec: Refer to manual for specific Mitsubishi or API GL-4/GL-5 specification (e.g., DiaQueen Super...
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Mitsubishi Lancer Evolution 6 2000 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Model Code:
CP9A
Year:
2000
Codes
Chassis Code:
CP9A
Engine Code:
4G63T
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution VI (Evo VI) was a legendary homologation special, renowned for its rally-bred performance and technological advancements in the late 1990s and early 2000s compact sports sedan segment.
Segment:
High-performance compact sports sedan
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale (historically), and later, cars like the BMW M3 and Audi RS4 in terms of performance envelope, albeit in different segments.
Key Features
Performance Focus:
Iconic 4G63T engine, advanced all-wheel-drive systems (AYC/Super AYC), aggressive aerodynamics, performance-oriented suspension and braking.
Rally Heritage:
Directly derived from Mitsubishi's WRC (World Rally Championship) program, embodying the spirit and engineering prowess of its rally counterparts.
Manual Purpose
Target Audience:
Professional mechanics, experienced DIY enthusiasts, and owners seeking to meticulously maintain or restore their Mitsubishi Lancer Evolution VI.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive factory service and repair procedures for all systems of the Mitsubishi Lancer Evolution VI (2000 model year).
Page Count
Estimated Page Count:
Approx. 1500-2000 pages (typical for comprehensive factory service manuals of this era).
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, but potentially physical reproduction)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, tuning, performance modifications, lubrication systems, cooling systems, fuel systems, emission control systems.
Engine Electrical:
Ignition system, starting system, charging system, ECU control, sensors, actuators, wiring diagrams, diagnostic procedures.
Transmission:
Manual transmission (Getrag 5-speed), clutch system, transfer case, driveshafts, differential service, troubleshooting, repair.
Drivetrain:
All-Wheel Drive (AYC - Active Center Differential), Super AYC (Active Yaw Control), propeller shafts, CV joints, wheel hubs.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, alignment specifications, troubleshooting.
Brakes:
Brake system components (calipers, rotors, pads, lines, master cylinder, ABS), hydraulic circuits, bleeding procedures, parking brake, troubleshooting.
Steering:
Power steering system, steering rack, tie rods, steering column, hydraulic fluid specifications, troubleshooting.
Body:
Body panel removal and installation, interior trim, exterior trim, doors, hood, trunk, glass, weatherstripping, chassis structure, corrosion prevention.
Electrical System:
Lighting system (headlights, taillights, interior), power windows, power mirrors, central locking, horn, wipers, washers, fuse box locations, relay functions, wiring diagrams.
Climate Control:
Air conditioning system, heater core, blower motor, HVAC controls, refrigerant type, charging procedures, troubleshooting.
Fuel System:
Fuel pump, fuel injectors, fuel pressure regulator, fuel lines, fuel tank, emissions controls (EVAP).
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, belt inspection and replacement.
Repair:
Engine overhaul, transmission rebuild, clutch replacement, brake caliper overhaul, suspension component replacement, radiator replacement, alternator replacement, starter motor replacement.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, code reading and interpretation (OBD-II or equivalent for the era), electrical system diagnostics.
Installation:
Component installation and removal procedures for all major systems, including aftermarket parts where applicable for performance.
Disassembly Assembly:
Detailed step-by-step instructions for taking apart and putting back together all vehicle components and systems.
Technical Depth
Depth:
Extremely high. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed torque specifications and specialized tool requirements.
Diagnostic Capability:
Detailed diagnostic procedures for electronic control units (ECUs), sensors, actuators, and mechanical systems. Includes wiring diagrams for tracing electrical faults.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Likely searchable text within the PDF for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics for clarity.
Diagrams Illustrations:
Detailed exploded views, line drawings, and schematics.
Binding Type
Physical Binding:
N/A (Digital format)
Paper Type
Physical Paper:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63T
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Ps:
280 PS (approx. 276 bhp) at 6,500 rpm (JDM/European spec; may vary slightly by region)
Torque Kgf M:
34.2 kgf·m (approx. 247 lb-ft) at 3,000 rpm (JDM/European spec; may vary slightly by region)
Redline:
Approx. 7,000 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded gasoline, minimum 95 RON (required for optimal performance)
Turbocharger:
Mitsubishi TD05H-16G (common for Evo VI, though variations exist for RS models)
Intercooler:
Air-to-air front-mounted intercooler (FMIC)
🔧 Transmission
Standard
Type:
5-speed manual transmission
Manufacturer:
Getrag (often the renowned 5-speed 'Dog-leg' gearbox for certain performance variants)
Optional
Type:
N/A (Evo VI was exclusively manual transmission)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (AYC) and Super AYC on GSR models.
Clutch:
Hydraulically operated, multi-plate clutch
Gear Ratios:
Specific ratios detailed in the manual, optimized for performance driving.
Transmission Fluid Spec:
Refer to manual for specific Mitsubishi or API GL-4/GL-5 specification (e.g., DiaQueen Super Multi-Gear Oil)
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,405 mm (55.3 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Track Front:
Approx. 1,510 mm (59.4 in)
Track Rear:
Approx. 1,505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1,400-1,450 kg (3,086-3,197 lbs), depending on trim and options
Gross Weight:
Refer to vehicle compliance plate or manual
Towing Capacity:
Not specified or recommended for this performance vehicle.
🛡️ Safety Features
Ratings
Crash Test Results:
Vehicle safety ratings from this era are not directly comparable to modern standards. Specific regional ratings (e.g., Euro NCAP, NHTSA) may be available but are often limited for JDM homologation specials.
Active Features
Active Features List:
Anti-lock Braking System (ABS), Active Center Differential (AYC), Super AYC (on GSR), performance braking systems (e.g., Brembo optional on some variants).
Passive Features
Passive Features List:
Front airbags, reinforced chassis structure, three-point seat belts with pre-tensioners, impact-absorbing steering column.
Features
Seat Belts:
Front and rear three-point seat belts
💡 Technology Features
Infotainment
Infotainment System:
Basic factory audio system (radio, CD player) typical for the era. Often featured performance-oriented gauge clusters.
Gauges:
Comprehensive dashboard instrumentation including boost gauge, oil pressure gauge, and detailed tachometer/speedometer.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily focused on the advanced AWD and AYC/Super AYC systems for enhanced traction and handling.
Connectivity
Connectivity:
No integrated Bluetooth or advanced connectivity features by today's standards. Analog systems only.
Performance Tech
Ayc System:
Active Yaw Control (AYC) and Super AYC utilize hydraulic actuators and electronic control to manage torque distribution between the rear wheels, significantly improving cornering stability and agility. Detailed calibration and diagnosis are covered in the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under spirited driving conditions. Refer to manual for severe vs. normal service.
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Typically every 40,000-60,000 km (24,000-36,000 miles) depending on type (e.g., iridium recommended).
Timing Belt Replacement:
Crucial! Typically every 80,000-100,000 km (50,000-60,000 miles) or 5-7 years. The 4G63T is an interference engine, so timely replacement is critical to avoid catastrophic engine damage.
Fluid Specifications
Engine Oil Spec:
Refer to manual for recommended viscosity (e.g., 10W-30 or 10W-40 for performance) and API service classification (e.g., SJ/SL). Synthetic oil is highly recommended.
Coolant Spec:
Ethylene glycol based, 50/50 mix with distilled water. Mitsubishi DiaQueen Long Life Coolant recommended.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid. High-temperature racing fluid recommended for performance driving.
Power Steering Fluid Spec:
Refer to manual for specific type (e.g., ATF Dexron II/III or specific Mitsubishi fluid).
Known Issues
Common Wear Items:
Clutch wear, engine mounts, suspension bushings, turbocharger seals (oil leaks), AYC pump issues (though less common on Evo VI compared to later models).
Engine Maintenance:
Strict adherence to timing belt service is paramount. Regular oil changes with quality oil are essential to maintain the longevity of the 4G63T engine, especially if driven hard.
Ayc System Care:
Regular flushing and replacement of AYC fluid is recommended to maintain the performance and longevity of the AYC pump and system.
📚 Vehicle History
Brand Heritage
Brand Heritage Summary:
Mitsubishi Motors has a rich history in motorsport, particularly in rallying, dating back to the 1970s. This heritage directly influenced the development of the Lancer Evolution series.
Model Evolution
Evolution Series Origin:
The Lancer Evolution line was created as a homologation special for Group A rallying, requiring production of a certain number of road-going vehicles to allow competition modifications.
Evo Vi Development:
The Evo VI built upon the successful platform of the Evo IV and V, featuring a larger turbocharger, improved intercooler, revised suspension geometry, and enhanced AYC system, reflecting continuous development based on WRC feedback. Notable variants include the GSR, RS, and the limited-edition Tommi Mäkinen Edition (TME).
Production
Production Years:
1999-2001
Major Markets:
Japan (JDM), Europe, Australia, and other select markets. Not officially sold in North America until later generations.
🏆 Awards & Recognition
Recognitions
Motorsport Awards:
The Lancer Evolution platform, including the Evo VI, was highly successful in the World Rally Championship, earning multiple driver's and manufacturer's titles for Mitsubishi. This racing pedigree is a significant recognition.
Enthusiast Recognition:
Widely regarded by automotive enthusiasts and motorsport publications as one of the most iconic and capable performance cars of its era. Often features on 'best performance car' lists from the late 90s/early 2000s.
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