Mitsubishi Lancer Evolution IV/Evolution V/Evolution VI (EVO 4/EVO 5/EVO 6) Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V / VI Model Nickname: Evo 4 / Evo 5 / Evo 6 Vehicle Platform: Mitsubishi Lancer (CJ/CK/CM) Generation Generation Code: CN/CP Series Generation Years: 1996-2001 Codes Chassis Codes: CN9A (Evo IV), CP9A (Evo V & VI) 👋 Introduction Market Position Target Audience: Enthusiasts, DIY mechanics, professional technicians working on Lancer Evolution IV, V, and VI models. Competitive Analysis Manual Value Proposition: Provides in-depth technical knowledge for servicing and repairing these high-performance vehicles, empowering owners and saving on professional labor costs. Key Features Download Advantage: Instant download format saves time and postage costs. Diagram Quality: High-quality diagrams and instructions ensure clarity in repair procedures. 📋 Manual Details Coverage Areas Covered Models: Mitsubishi Lancer Evolution IV, Mitsubishi Lancer Evolution V, Mitsubishi Lancer Evolution VI Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001 Page Count Estimated Page Count: Extensive (exact number not provided, but described as highly comprehensive) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine, Engine Lubrication, Fuel System, Engine Cooling, Intake and Exhaust, Engine Electrical, Engine and Emission Control Drivetrain Systems: Clutch, Manual Transmission, Front Axle, Rear Axle, Power Plant Mount Suspension Steering Brakes: Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering Body Electrical: Body, Exterior, Chassis Electrical, Electrical Wiring Procedures Included General Procedures: General information, disassembly, assembly, inspection, adjustment, replacement Engine Procedures: Engine overhaul, cylinder head service, piston and connecting rod service, crankshaft and bearing service, timing belt replacement, fuel injector service, cooling system flush, exhaust system repair Transmission Procedures: Manual transmission overhaul, clutch replacement, gearbox fluid change, differential service Chassis Procedures: Suspension component replacement (shocks, springs, control arms), brake pad and rotor replacement, brake caliper service, power steering system service, wheel alignment specifications Electrical Procedures: Wiring diagrams, component testing, diagnosis of electrical faults, starter motor replacement, alternator testing, sensor troubleshooting Technical Depth Depth Of Coverage: Comprehensive; suitable for detailed DIY repairs and professional diagnostics Diagnostic Capabilities: Includes diagnostic procedures, troubleshooting guides, and fault code explanations for various systems Rebuild Instructions: Detailed instructions for engine and transmission rebuilds 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: All pages are printable for easy workshop use Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Compatibility Operating Systems: Compatible with all versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (various iterations) Performance Engine Displacement: 2.0 Liters (1997 cc) Engine Type: Inline 4-cylinder, DOHC, 16-valve, Turbocharged, Intercooled Horsepower Evo Iv: Approx. 280 PS (276 hp) @ 6,500 rpm (JDM Spec) Torque Evo Iv: Approx. 35.0 kg·m (343 N·m; 253 lb·ft) @ 3,000 rpm (JDM Spec) Horsepower Evo V: Approx. 280 PS (276 hp) @ 6,500 rpm (JDM Spec); some export markets may have slightly different figures. Torque Evo V: Approx. 37.5 kg·m (368 N·m; 272 lb·ft) @ 3,000 rpm (JDM Spec) Horsepower Evo Vi: Approx. 280 PS (276 hp) @ 6,500 rpm (JDM Spec); RS models often had higher output or specific tuning. Torque Evo Vi: Approx. 40.0 kg·m (392 N·m; 290 lb·ft) @ 3,000 rpm (JDM Spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Turbocharger Fuel Type: Unleaded gasoline, premium octane recommended 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission: N/A (All Evo IV-VI models were exclusively manual transmission) Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) 📐 Dimensions Exterior Wheelbase: Approx. 2,600 mm (102.4 in) Length: Approx. 4,350 - 4,380 mm (171.3 - 172.4 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 - 1,420 mm (55.7 - 55.9 in) Weights Curb Weight: Approx. 1,350 - 1,400 kg (2,976 - 3,086 lb), varies by model and trim 🛡️ Safety Features Ratings Crash Test Data: Specific official crash test ratings from major agencies (NHTSA, Euro NCAP) for these specific JDM-focused models from the late 1990s are limited or not readily available in a comparable format. However, the chassis was designed for rally homologation. Active Features Active Safety Features: Advanced AWD system (ACD/AYC), Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD) Passive Features Passive Safety Features: Reinforced chassis structure, front airbags (driver and passenger), three-point seatbelts. 💡 Technology Features Infotainment Infotainment Features: Basic audio systems with radio and CD player were typical for the era. Advanced infotainment systems were not a focus for these performance-oriented models. Driver Assistance Driver Assistance Systems: The primary driver assistance technology was the sophisticated AWD system (ACD/AYC) designed for optimal traction and cornering. Connectivity Connectivity Features: Limited to basic radio reception and power outlets; no modern Bluetooth or USB connectivity from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 -...
Enthusiasts, DIY mechanics, professional technicians working on Lancer Evolution IV, V, and VI models.
Competitive Analysis
Manual Value Proposition:
Provides in-depth technical knowledge for servicing and repairing these high-performance vehicles, empowering owners and saving on professional labor costs.
Key Features
Download Advantage:
Instant download format saves time and postage costs.
Diagram Quality:
High-quality diagrams and instructions ensure clarity in repair procedures.
📋 Manual Details
Coverage Areas
Covered Models:
Mitsubishi Lancer Evolution IV, Mitsubishi Lancer Evolution V, Mitsubishi Lancer Evolution VI
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001
Page Count
Estimated Page Count:
Extensive (exact number not provided, but described as highly comprehensive)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine, Engine Lubrication, Fuel System, Engine Cooling, Intake and Exhaust, Engine Electrical, Engine and Emission Control
Drivetrain Systems:
Clutch, Manual Transmission, Front Axle, Rear Axle, Power Plant Mount
Suspension Steering Brakes:
Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering
General information, disassembly, assembly, inspection, adjustment, replacement
Engine Procedures:
Engine overhaul, cylinder head service, piston and connecting rod service, crankshaft and bearing service, timing belt replacement, fuel injector service, cooling system flush, exhaust system repair
Transmission Procedures:
Manual transmission overhaul, clutch replacement, gearbox fluid change, differential service
Chassis Procedures:
Suspension component replacement (shocks, springs, control arms), brake pad and rotor replacement, brake caliper service, power steering system service, wheel alignment specifications
Electrical Procedures:
Wiring diagrams, component testing, diagnosis of electrical faults, starter motor replacement, alternator testing, sensor troubleshooting
Technical Depth
Depth Of Coverage:
Comprehensive; suitable for detailed DIY repairs and professional diagnostics
Diagnostic Capabilities:
Includes diagnostic procedures, troubleshooting guides, and fault code explanations for various systems
Rebuild Instructions:
Detailed instructions for engine and transmission rebuilds
N/A (All Evo IV-VI models were exclusively manual transmission)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2,600 mm (102.4 in)
Length:
Approx. 4,350 - 4,380 mm (171.3 - 172.4 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 - 1,420 mm (55.7 - 55.9 in)
Weights
Curb Weight:
Approx. 1,350 - 1,400 kg (2,976 - 3,086 lb), varies by model and trim
🛡️ Safety Features
Ratings
Crash Test Data:
Specific official crash test ratings from major agencies (NHTSA, Euro NCAP) for these specific JDM-focused models from the late 1990s are limited or not readily available in a comparable format. However, the chassis was designed for rally homologation.
Active Features
Active Safety Features:
Advanced AWD system (ACD/AYC), Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD)
Passive Features
Passive Safety Features:
Reinforced chassis structure, front airbags (driver and passenger), three-point seatbelts.
💡 Technology Features
Infotainment
Infotainment Features:
Basic audio systems with radio and CD player were typical for the era. Advanced infotainment systems were not a focus for these performance-oriented models.
Driver Assistance
Driver Assistance Systems:
The primary driver assistance technology was the sophisticated AWD system (ACD/AYC) designed for optimal traction and cornering.
Connectivity
Connectivity Features:
Limited to basic radio reception and power outlets; no modern Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, depending on driving conditions and oil used. The manual would provide specific intervals.
Timing Belt Replacement:
Recommended every 100,000 km (60,000 miles) or 5 years. This is a critical maintenance item for the 4G63 engine.
Fluid Specifications
Engine Oil Specification:
Refer to manual for specific viscosity grade (e.g., 10W-30, 10W-40) and API classification. High-performance synthetic oil is recommended for boosted engines.
Transmission Fluid Specification:
Refer to manual for specific manual transmission fluid (MTF) grade and type. Gear oil specifications for differentials would also be detailed.
Coolant Specification:
A mixture of deionized water and ethylene glycol-based antifreeze. Manual will specify the correct ratio and type.
Known Issues
Common Wear Items:
Clutch wear, rear differential bushings, fuel pump (especially on modified cars), exhaust manifold cracks (on early models), timing belt tensioner.
Engine Specific Considerations:
The 4G63 is robust but sensitive to oil starvation. Regular maintenance and proper engine warm-up are crucial. Head gasket failure can occur if overheated or abused.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
The Lancer Evolution series is globally renowned for its success in the World Rally Championship (WRC), making it an icon of performance and rally-bred engineering.
Model Evolution
Evolution Iv Features:
Introduced Active Center Differential (ACD) and improved Super AYC (S-AYC) for enhanced traction and handling. Featured a revised front bumper and larger spoiler.
Evolution V Features:
Wider body, larger wheels and tires, revised suspension geometry, improved front brake calipers, and a larger intercooler. Featured a more aggressive front bumper and larger rear spoiler.
Evolution Vi Features:
Further mechanical refinements including a stronger turbocharger, improved intercooler and radiator, revised pistons, and better oil cooling. Introduced the 'Tommi Mäkinen Edition' (TME) with unique styling and performance enhancements.
Production
Production Period:
1996-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Awards:
The Lancer Evolution platform, in general, has a rich history of championship wins in WRC, contributing to the desirability and performance image of models like the Evo IV, V, and VI.
Ratings
Performance Ratings:
Consistently rated as one of the best handling and performing four-wheel-drive performance sedans of its era by automotive journalists and enthusiasts.
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