Mitsubishi Evo 4 1996-1998 Workshop Repair Service Manual
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV (Evo 4) Generation: Fourth Generation Production Years: 1996-1998 Codes Chassis Code: CN9A ๐ Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special Reputation: Legendary, iconic status in rally racing and performance tuning communities Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione Key Features Driving Dynamics: Exceptional handling, grip, and driver feedback thanks to AWD and advanced chassis design Engine Technology: Robust turbocharged inline-4 with advanced intercooling and engine management Rally Heritage: Directly derived from Mitsubishi's WRC program, offering a pure, unfiltered driving experience ๐ Manual Details Coverage Areas Regions Covered: Global (primarily Japanese Domestic Market, but applicable to worldwide variants) Vehicle Variants: All models and engines for Lancer Evolution IV Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download ๐ Manual Coverage Systems Covered Powertrain: Engine, transmission, clutch, cooling system, exhaust system, fuel system, ignition system, lubrication system Drivetrain: All-Wheel Drive (AYC - Active Yaw Control), front differential, rear differential, driveshafts, transfer case Chassis: Suspension (front and rear), steering system, brakes (front and rear), wheels, tires Electrical: Battery, charging system, starting system, lighting, instrumentation, audio system, power accessories, wiring diagrams, ECU, sensors Body: Body structure, interior trim, exterior trim, doors, windows, seats, airbags Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections Repair: Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical system diagnosis and repair, body panel repair Troubleshooting: Diagnostic procedures, fault codes, common issues and solutions Diagnostics: Component testing, sensor readings, electrical circuit diagnosis Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, detailed electrical schematics ๐ Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically) Print Quality Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Engine Code: 4G63T (MIVEC variant not yet introduced) Configuration: Turbocharged and Intercooled Inline-4 DOHC 16-valve Displacement: 1997 cc (2.0 Liters) Performance Horsepower: 280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese domestic market 'gentleman's agreement' limit) Torque: 352 Nm (259 lb-ft) at 3,000 rpm Fuel System Induction: Electronic Fuel Injection (EFI) with Twin-Scroll Turbocharger Fuel Type: Unleaded Gasoline (Premium Recommended) Cooling System Type: Water-cooled Lubrication System Type: Forced lubrication with wet sump ๐ง Transmission Standard Type: 5-speed Manual Transmission Optional Type: N/A (Manual exclusively for Evo 4) Features Drivetrain: All-Wheel Drive (Full-time) Ayc: Active Yaw Control (AYC) for enhanced cornering stability Differentials: Front Helical LSD, Rear Viscous LSD with AYC control ๐ Dimensions Exterior Length: 4,350 mm (171.3 in) Width: 1,770 mm (69.7 in) Height: 1,415 mm (55.7 in) Wheelbase: 2,600 mm (102.4 in) Track Width Front: 1,515 mm (59.6 in) Track Width Rear: 1,505 mm (59.3 in) Weights Curb Weight: 1,450 kg (3,197 lb) Gross Weight: 1,725 kg (3,803 lb) Cargo Trunk Volume: Approx. 357 liters (12.6 cu ft) ๐ก๏ธ Safety Features Ratings Crash Test Ratings: Not independently rated by agencies like NHTSA or Euro NCAP for this era, but built to high performance standards. Active Features ABS: Standard Anti-lock Braking System Ayc: Active Yaw Control contributes to stability under hard cornering Passive Features Airbags: Driver and Passenger Airbags (standard) Seatbelts: Three-point front and rear seatbelts Body Structure: Reinforced safety cell construction ๐ก Technology Features Infotainment System: Basic factory radio/cassette player with optional CD player. Limited by era. Speakers: Typically 4-6 speakers Driver Assistance System Focus: Performance enhancement and stability control through AYC and AWD, not modern electronic aids. Connectivity Features: N/A (Pre-modern connectivity era) ๐ง Maintenance Service Intervals Oil Change: Every 5,000-7,500 km (3,000-5,000 miles) or 6 months Air Filter Replacement: Every 15,000-30,000 km (9,000-18,000 miles) Spark Plug Replacement: Every 30,000-50,000 km (18,000-30,000 miles), depending on type Timing Belt Replacement: Every 90,000-100,000 km (56,000-62,000 miles) or 7 years Fluid Specifications Engine Oil: API SG/SH or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature) Coolant: Mitsubishi Dia Queen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with anti-corrosion additives) Transmission Fluid: GL-4 SAE 75W-85 or 75W-90 (specific Mitsubishi specification may apply) Transfer Case Fluid: GL-4 SAE 75W-85 or 75W-90 (specific Mitsubishi specification may apply) Differential Fluid: GL-5 SAE 80W-90 (or specific Mitsubishi specification) Brake Fluid: DOT 3 or DOT 4 Known Issues Engine: Cracked cylinder head (under extreme heat/abuse), turbocharger wear, piston ring wear with high mileage Drivetrain: AYC pump failure, differential wear (especially rear if abused), gearbox synchro wear Chassis: Rust in common areas (wheel arches, sills), worn suspension bushings, brake component wear Electrical: Sensor failures (e.g., crank angle sensor), wiring harness degradation over time ๐ Vehicle History Brand Heritage Rally Success: Mitsubishi has a long and illustrious history in World Rally Championship (WRC), winning multiple manufacturer and...
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical system diagnosis and repair, body panel repair
Troubleshooting:
Diagnostic procedures, fault codes, common issues and solutions