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Mitsubishi Lancer EVO 4 & 5 Service Repair Workshop Manual

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๐Ÿท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: IV (CN9A) / V (CP9A) Production Years Covered: 1996-1999 Codes Chassis Code Evo4: CN9A Chassis Code Evo5: CP9A ๐Ÿ‘‹ Introduction Market Position Positioning: Iconic rally-bred performance sedan, positioned as a homologation special for WRC competition. Known for its advanced all-wheel-drive system and turbocharged engine. Competitive Analysis Competitors: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth, Peugeot 306 Maxi. Key Features Performance Focus: Designed for maximum performance and handling on diverse terrain, with a focus on rally racing homologation. Awc System: Advanced Symmetrical All-Wheel Drive (ASC) with Active Yaw Control (AYC) on many variants, a key differentiator. Engine Technology: Robust turbocharged 4G63 engine known for its tunability and durability. ๐Ÿ“‹ Manual Details Coverage Areas Primary Regions Of Coverage: Global (with specific market variations noted where applicable) Page Count Estimated Page Count: 1500+ (comprehensive digital document) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) ๐Ÿ“– Manual Coverage Systems Covered Powertrain: Engine overhaul, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger and intercooler systems. Drivetrain: Manual Transmission (5-speed/6-speed on Evo V RS), Automatic Transmission (less common for performance variants), Transfer Case, Front Differential, Rear Differential (Active Yaw Control on applicable models), Drive Shafts, Axles. Suspension And Steering: Front and Rear Suspension (MacPherson Strut, Multi-link), Shock Absorbers, Springs, Bushings, Steering Gearbox, Power Steering System. Brakes: Front and Rear Disc Brakes (Brembo calipers on performance variants), ABS System, Brake Booster, Master Cylinder, Parking Brake. Electrical: Battery, Alternator, Starter Motor, Engine Control Unit (ECU), Ignition System, Lighting System, Instrumentation, Wiring Diagrams, Fuses and Relays, Audio System, Power Windows/Locks (if equipped). Bodywork And Chassis: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Chassis Structure, Corrosion Prevention. HVAC And Comfort: Air Conditioning System, Heater Core, Ventilation System, Radiator Fan Control. Safety Systems: Airbag System (if equipped), Seatbelt Mechanisms. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Diagnostics And Troubleshooting: Fault code interpretation, common problems and their solutions, diagnostic procedures for all major systems, electrical system troubleshooting guides. Engine Repair: Complete engine rebuild procedures, cylinder head service, piston and ring replacement, crankshaft and connecting rod service, camshaft and timing belt/chain replacement. Transmission Repair: Transmission disassembly, inspection, repair, and reassembly. Clutch replacement procedures, flywheel service. Brake System Repair: Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, bleeding procedures, ABS component diagnosis and replacement. Suspension And Steering Repair: Component replacement (shocks, springs, control arms, ball joints), alignment procedures, steering rack repair/replacement. Electrical System Repair: Component testing and replacement (alternator, starter, sensors), wiring harness repair, troubleshooting of electronic modules. Bodywork And Interior Repair: Panel replacement, door and window regulator repair, interior trim panel removal and installation, glass replacement. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic flowcharts. Diagnostic Capability: Advanced diagnostic procedures, including symptom-based troubleshooting and wiring diagrams for electrical systems. Special Tools: Lists required special tools for specific procedures, aiding in professional repairs. ๐Ÿ“Š Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval. Print Quality Quality: High-resolution scans of original factory documents, ensuring clear text and legible diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) โš™๏ธ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve Displacement Cc: 1997 Performance Horsepower Hp Evo4: 276 Torque Lb-Ft Evo4: 275 Horsepower Hp Evo5: 280 Torque Lb-Ft Evo5: 279 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium (95 RON or higher recommended) ๐Ÿ”ง Transmission Standard Transmission Type: 5-speed Manual (Evo IV), 5-speed or 6-speed Manual (Evo V) Optional Transmission Type: 4-speed Automatic (less common and generally not for performance variants) Features Awc Integration: Close integration with the Active Yaw Control (AYC) system for enhanced cornering. Clutch Type: Single dry plate, hydraulically operated ๐Ÿ“ Dimensions Exterior Length Mm Evo4: 4350 Width Mm Evo4: 1770 Height Mm Evo4: 1415 Wheelbase Mm Evo4: 2600 Length Mm Evo5: 4360 Width Mm Evo5: 1770 Height Mm Evo5: 1415 Wheelbase Mm Evo5: 2600 Weights Curb Weight Kg Approx: 1400-1450 (variant dependent) ๐Ÿ›ก๏ธ Safety Features Ratings Crash Test Ratings: N/A (Focus on performance and homologation, safety ratings from this era for specialized vehicles were less standardized than today. JNCAP data may exist.) Active Features Active Safety: ABS (Anti-lock Braking System), AYC (Active Yaw Control - on applicable models). Passive Features Passive Safety: Reinforced chassis structure, driver and passenger airbags (optional or standard depending on market and trim). ๐Ÿ’ก Technology Features Infotainment Audio System: Factory cassette/CD players, often with basic amplifier systems. Aftermarket upgrades are common. Driver Assistance Performance Aids:...
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Mitsubishi Lancer EVO 4 & 5 Service Repair Workshop Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Generation:
IV (CN9A) / V (CP9A)
Production Years Covered:
1996-1999
Codes
Chassis Code Evo4:
CN9A
Chassis Code Evo5:
CP9A
๐Ÿ‘‹ Introduction
Market Position
Positioning:
Iconic rally-bred performance sedan, positioned as a homologation special for WRC competition. Known for its advanced all-wheel-drive system and turbocharged engine.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth, Peugeot 306 Maxi.
Key Features
Performance Focus:
Designed for maximum performance and handling on diverse terrain, with a focus on rally racing homologation.
Awc System:
Advanced Symmetrical All-Wheel Drive (ASC) with Active Yaw Control (AYC) on many variants, a key differentiator.
Engine Technology:
Robust turbocharged 4G63 engine known for its tunability and durability.
๐Ÿ“‹ Manual Details
Coverage Areas
Primary Regions Of Coverage:
Global (with specific market variations noted where applicable)
Page Count
Estimated Page Count:
1500+ (comprehensive digital document)
Manual Type
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
๐Ÿ“– Manual Coverage
Systems Covered
Powertrain:
Engine overhaul, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger and intercooler systems.
Drivetrain:
Manual Transmission (5-speed/6-speed on Evo V RS), Automatic Transmission (less common for performance variants), Transfer Case, Front Differential, Rear Differential (Active Yaw Control on applicable models), Drive Shafts, Axles.
Suspension And Steering:
Front and Rear Suspension (MacPherson Strut, Multi-link), Shock Absorbers, Springs, Bushings, Steering Gearbox, Power Steering System.
Brakes:
Front and Rear Disc Brakes (Brembo calipers on performance variants), ABS System, Brake Booster, Master Cylinder, Parking Brake.
Electrical:
Battery, Alternator, Starter Motor, Engine Control Unit (ECU), Ignition System, Lighting System, Instrumentation, Wiring Diagrams, Fuses and Relays, Audio System, Power Windows/Locks (if equipped).
Bodywork And Chassis:
Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Chassis Structure, Corrosion Prevention.
HVAC And Comfort:
Air Conditioning System, Heater Core, Ventilation System, Radiator Fan Control.
Safety Systems:
Airbag System (if equipped), Seatbelt Mechanisms.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Diagnostics And Troubleshooting:
Fault code interpretation, common problems and their solutions, diagnostic procedures for all major systems, electrical system troubleshooting guides.
Engine Repair:
Complete engine rebuild procedures, cylinder head service, piston and ring replacement, crankshaft and connecting rod service, camshaft and timing belt/chain replacement.
Transmission Repair:
Transmission disassembly, inspection, repair, and reassembly. Clutch replacement procedures, flywheel service.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, bleeding procedures, ABS component diagnosis and replacement.
Suspension And Steering Repair:
Component replacement (shocks, springs, control arms, ball joints), alignment procedures, steering rack repair/replacement.
Electrical System Repair:
Component testing and replacement (alternator, starter, sensors), wiring harness repair, troubleshooting of electronic modules.
Bodywork And Interior Repair:
Panel replacement, door and window regulator repair, interior trim panel removal and installation, glass replacement.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic flowcharts.
Diagnostic Capability:
Advanced diagnostic procedures, including symptom-based troubleshooting and wiring diagrams for electrical systems.
Special Tools:
Lists required special tools for specific procedures, aiding in professional repairs.
๐Ÿ“Š Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick information retrieval.
Print Quality
Quality:
High-resolution scans of original factory documents, ensuring clear text and legible diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
โš™๏ธ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve
Displacement Cc:
1997
Performance
Horsepower Hp Evo4:
276
Torque Lb-Ft Evo4:
275
Horsepower Hp Evo5:
280
Torque Lb-Ft Evo5:
279
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Premium (95 RON or higher recommended)
๐Ÿ”ง Transmission
Standard
Transmission Type:
5-speed Manual (Evo IV), 5-speed or 6-speed Manual (Evo V)
Optional
Transmission Type:
4-speed Automatic (less common and generally not for performance variants)
Features
Awc Integration:
Close integration with the Active Yaw Control (AYC) system for enhanced cornering.
Clutch Type:
Single dry plate, hydraulically operated
๐Ÿ“ Dimensions
Exterior
Length Mm Evo4:
4350
Width Mm Evo4:
1770
Height Mm Evo4:
1415
Wheelbase Mm Evo4:
2600
Length Mm Evo5:
4360
Width Mm Evo5:
1770
Height Mm Evo5:
1415
Wheelbase Mm Evo5:
2600
Weights
Curb Weight Kg Approx:
1400-1450 (variant dependent)
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Ratings:
N/A (Focus on performance and homologation, safety ratings from this era for specialized vehicles were less standardized than today. JNCAP data may exist.)
Active Features
Active Safety:
ABS (Anti-lock Braking System), AYC (Active Yaw Control - on applicable models).
Passive Features
Passive Safety:
Reinforced chassis structure, driver and passenger airbags (optional or standard depending on market and trim).
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Factory cassette/CD players, often with basic amplifier systems. Aftermarket upgrades are common.
Driver Assistance
Performance Aids:
Active Yaw Control (AYC) is a key technological feature, actively distributing torque between the rear wheels for improved cornering grip. Driver adjustable modes for AYC/AWD (e.g., Tarmac, Gravel, Snow) may exist on some versions.
Connectivity
Connectivity Features:
Limited by era; primarily focused on vehicle performance rather than external connectivity. No Bluetooth or USB typically from the factory.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval Km:
5,000-7,500 km (depending on driving conditions, more frequently for spirited driving)
Timing Belt Replacement Km:
100,000 km or 5 years (critical replacement interval for the 4G63 engine)
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, ACEA A3/B3 or equivalent. Viscosity typically 10W-30 or 10W-40 (synthetic recommended).
Engine Oil Capacity Liters:
4.5 (without filter), 4.8 (with filter)
Coolant Type:
Ethylene Glycol based antifreeze (Mitsubishi Super Long Life Coolant or equivalent)
Transmission Fluid Type Manual:
API GL-4 or GL-5, SAE 75W-90 (Hypoid gear oil)
Differential Fluid Type Rear:
API GL-5, SAE 75W-90 (or specific AYC fluid if applicable, check manual)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
Generally robust 4G63 engine, but prone to head gasket failure if overheated or poorly maintained. Timing belt integrity is paramount.
Ayc System:
AYC pump and solenoids can fail over time, leading to warning lights and loss of active yaw control function. Fluid needs regular checking/changing.
Turbocharger:
Turbocharger can suffer from oil starvation if the engine is run hard and then shut off immediately without a cool-down period. Regular oil changes and proper maintenance are key.
Rust And Corrosion:
As with many cars of this era, particularly those used in challenging climates, rust can be an issue in wheel arches, sills, and suspension mounting points.
๐Ÿ“š Vehicle History
Brand Heritage
Motorsport Roots:
Mitsubishi's extensive rally heritage, particularly from the World Rally Championship (WRC), heavily influenced the development of the Lancer Evolution series.
Model Evolution
Evo4 Introduction:
Introduced a new chassis and significant aerodynamic improvements. The AYC system was a major technological advancement for this generation.
Evo5 Enhancements:
Featured a slightly larger turbocharger, larger intercooler, revised ECU, stiffer suspension, and bodywork tweaks for improved aerodynamics and cooling. Introduced the 6-speed manual option on the RS model.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Limited Editions:
Evolution V RS ('Rally Sport') model was a more stripped-down, performance-oriented version often used for motorsport homologation.
๐Ÿ† Awards & Recognition
Recognitions
Rally Success:
The Lancer Evolution platform achieved significant success in the World Rally Championship, contributing to its legendary status and performance credibility.
Automotive Press:
Consistently lauded by automotive journalists for its exceptional handling, powertrain, and rally-bred performance capabilities.
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