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1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual - 2.2GB

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$133.00
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$133.00
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The Mitsubishi Lancer Evolution, often referred to as the Lancer EVO, is a celebrated performance sedan renowned for its rally-bred engineering and exceptional handling capabilities. Spanning production years from 1996 to 2007, this iconic vehicle, particularly chassis codes CP9A (Evo IV-VI) and CT9A (Evo VII-IX), is powered by the robust 4G63 and 4G63T 2.0L DOHC turbocharged engines. Its design is a testament to commitment to performance, featuring advanced All-Wheel Drive systems with Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC, contributing to its legendary grip and dynamic prowess. The Lancer Evolution has consistently been recognized for its outstanding performance metrics and its frequent appearance on prestigious automotive lists, underscoring its status as a benchmark in the sports sedan segment. This comprehensive workshop service repair manual provides extensive coverage for the Mitsubishi Lancer Evolution models from 1996 through 2007, encompassing generations IV through IX. With over 4600 pages of detailed information, this manual is an indispensable resource for owners, technicians, and mechanics. It covers all major systems, including powertrain, chassis, electrical, and bodywork, detailing everything from scheduled maintenance and routine service to complex engine and transmission overhauls. Essential procedures for diagnostics, component replacement, and installation are clearly outlined, supported by technical specifications, wiring diagrams, and troubleshooting guidance, ensuring the Lancer Evolution can be maintained and repaired to optimal performance standards. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Common Name: Lancer EVO Product Name: 1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual Codes Chassis Codes Covered: CP9A (Evo IV-VI), CT9A (Evo VII-IX) Engine Codes Covered: 4G63, 4G63T (2.0L DOHC Turbocharged) 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution (Evo) is a high-performance sports sedan that defined the affordable performance car segment and became a rally homologation special icon. Known for its advanced All-Wheel Drive (AWD) system, potent turbocharged engine, and exceptional handling, the Evo attracted enthusiasts worldwide seeking track-day capability and aggressive styling. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Audi S3, Volkswagen Golf R (later generations), BMW M3 (higher price bracket) Key Features Performance Focus: All-Wheel Drive, turbocharged engine, advanced suspension, robust braking system, lightweight construction Rally Heritage: Developed for Group A rally homologation, leading to its aggressive styling and performance-oriented engineering. Technical Innovation: Active Yaw Control (AYC), Super AYC, ACD (Active Center Differential) across different generations, showcasing Mitsubishi's focus on dynamic handling. 📋 Manual Details Coverage Areas Model Generations Covered: Evolution IV (1996-1997), Evolution V (1998-1999), Evolution VI (1999-2001), Evolution VII (2001-2003), Evolution VIII (2003-2005), Evolution IX (2005-2007) Included Manuals: 1996-2001 Mitsubishi Lancer Evolution IV, V, VI Workshop Service Repair Manual; 2001-2007 Mitsubishi Lancer Evolution VII, VIII, IX Workshop Service Repair Manual Page Count Total Pages Estimated: 4600+ Manual Type Type: Comprehensive Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine electrical, fuel system, ignition system, lubrication system, cooling system, exhaust system, turbocharger system, intercooler system, transmission (manual & automatic), clutch, drivetrain (transfer case, differentials), drive shafts, axles Chassis: Suspension (front & rear), steering system, braking system (ABS included), wheels, tires, chassis and frame Electrical: Body electrical systems, lighting, instruments, interior electronics, exterior electronics, engine control unit (ECU), power distribution, wiring diagrams, diagnostics, multiplex communication systems (CAN bus for later models) Bodywork: Exterior body panels, interior trim, doors, windows, locks, seats, HVAC system, body repair, corrosion protection Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, belt replacement Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component repair, electrical component troubleshooting and replacement, body panel repair Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), specific system diagnostic procedures, use of diagnostic tools Installation: Component replacement procedures, installation guidelines for factory options and accessories Technical Depth Depth: Comprehensive: From basic maintenance and adjustments to complete engine and transmission rebuilds, detailed electrical schematics, and bodywork procedures. Includes torque specifications, clearances, and diagnostic parameters. 📊 Manual Specifications File Format Format: PDF Searchable: Yes Printable: Yes Ipad Ready: Yes Print Quality Quality: High-resolution scans, clear text and diagrams Binding Type Binding: Digital Download (Not Applicable) Paper Type Paper Type: Digital Download (Not Applicable) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged and Intercooled Engine Code: 4G63/4G63T Displacement: 2.0 Liters (1997 cc) Performance Horsepower Range: Approximately 271 hp to 291 hp (depending on generation and market) Torque Range: Approximately 274 lb-ft to 300 lb-ft (depending on generation and market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Turbocharger: Mitsubishi TD05, TD06, or similar variable geometry turbochargers (depending on generation) Technical Specs Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 to 9.0:1 (depending on generation) 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag/Mitsubishi), 6-speed Manual (later generations) Optional Transmission Type: 4-speed Automatic (available on some standard Lancer models, less common/desirable on...
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1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual - 2.2GB1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual - 2.2GB1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual - 2.2GB1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual - 2.2GB
The Mitsubishi Lancer Evolution, often referred to as the Lancer EVO, is a celebrated performance sedan renowned for its rally-bred engineering and exceptional handling capabilities. Spanning production years from 1996 to 2007, this iconic vehicle, particularly chassis codes CP9A (Evo IV-VI) and CT9A (Evo VII-IX), is powered by the robust 4G63 and 4G63T 2.0L DOHC turbocharged engines. Its design is a testament to commitment to performance, featuring advanced All-Wheel Drive systems with Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC, contributing to its legendary grip and dynamic prowess. The Lancer Evolution has consistently been recognized for its outstanding performance metrics and its frequent appearance on prestigious automotive lists, underscoring its status as a benchmark in the sports sedan segment. This comprehensive workshop service repair manual provides extensive coverage for the Mitsubishi Lancer Evolution models from 1996 through 2007, encompassing generations IV through IX. With over 4600 pages of detailed information, this manual is an indispensable resource for owners, technicians, and mechanics. It covers all major systems, including powertrain, chassis, electrical, and bodywork, detailing everything from scheduled maintenance and routine service to complex engine and transmission overhauls. Essential procedures for diagnostics, component replacement, and installation are clearly outlined, supported by technical specifications, wiring diagrams, and troubleshooting guidance, ensuring the Lancer Evolution can be maintained and repaired to optimal performance standards.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Common Name:
Lancer EVO
Product Name:
1996-2008 Mitsubishi Lancer Evolution (Lancer EVO) Workshop Repair Service Manual
Codes
Chassis Codes Covered:
CP9A (Evo IV-VI), CT9A (Evo VII-IX)
Engine Codes Covered:
4G63, 4G63T (2.0L DOHC Turbocharged)
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution (Evo) is a high-performance sports sedan that defined the affordable performance car segment and became a rally homologation special icon. Known for its advanced All-Wheel Drive (AWD) system, potent turbocharged engine, and exceptional handling, the Evo attracted enthusiasts worldwide seeking track-day capability and aggressive styling.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Focus RS, Audi S3, Volkswagen Golf R (later generations), BMW M3 (higher price bracket)
Key Features
Performance Focus:
All-Wheel Drive, turbocharged engine, advanced suspension, robust braking system, lightweight construction
Rally Heritage:
Developed for Group A rally homologation, leading to its aggressive styling and performance-oriented engineering.
Technical Innovation:
Active Yaw Control (AYC), Super AYC, ACD (Active Center Differential) across different generations, showcasing Mitsubishi's focus on dynamic handling.
📋 Manual Details
Coverage Areas
Model Generations Covered:
Evolution IV (1996-1997), Evolution V (1998-1999), Evolution VI (1999-2001), Evolution VII (2001-2003), Evolution VIII (2003-2005), Evolution IX (2005-2007)
Included Manuals:
1996-2001 Mitsubishi Lancer Evolution IV, V, VI Workshop Service Repair Manual; 2001-2007 Mitsubishi Lancer Evolution VII, VIII, IX Workshop Service Repair Manual
Page Count
Total Pages Estimated:
4600+
Manual Type
Type:
Comprehensive Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel system, ignition system, lubrication system, cooling system, exhaust system, turbocharger system, intercooler system, transmission (manual & automatic), clutch, drivetrain (transfer case, differentials), drive shafts, axles
Chassis:
Suspension (front & rear), steering system, braking system (ABS included), wheels, tires, chassis and frame
Electrical:
Body electrical systems, lighting, instruments, interior electronics, exterior electronics, engine control unit (ECU), power distribution, wiring diagrams, diagnostics, multiplex communication systems (CAN bus for later models)
Bodywork:
Exterior body panels, interior trim, doors, windows, locks, seats, HVAC system, body repair, corrosion protection
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, belt replacement
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component repair, electrical component troubleshooting and replacement, body panel repair
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs), specific system diagnostic procedures, use of diagnostic tools
Installation:
Component replacement procedures, installation guidelines for factory options and accessories
Technical Depth
Depth:
Comprehensive: From basic maintenance and adjustments to complete engine and transmission rebuilds, detailed electrical schematics, and bodywork procedures. Includes torque specifications, clearances, and diagnostic parameters.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes
Printable:
Yes
Ipad Ready:
Yes
Print Quality
Quality:
High-resolution scans, clear text and diagrams
Binding Type
Binding:
Digital Download (Not Applicable)
Paper Type
Paper Type:
Digital Download (Not Applicable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged and Intercooled
Engine Code:
4G63/4G63T
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Range:
Approximately 271 hp to 291 hp (depending on generation and market)
Torque Range:
Approximately 274 lb-ft to 300 lb-ft (depending on generation and market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Turbocharger:
Mitsubishi TD05, TD06, or similar variable geometry turbochargers (depending on generation)
Technical Specs
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1 to 9.0:1 (depending on generation)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag/Mitsubishi), 6-speed Manual (later generations)
Optional
Transmission Type:
4-speed Automatic (available on some standard Lancer models, less common/desirable on performance Evos)
Features
AWD System:
Full-time All-Wheel Drive with Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC
Transfer Case:
Mechanical front differential, mechanical rear differential, electronically controlled center differential (ACD)
📐 Dimensions
Exterior
Length Overall:
Approx. 4,350 - 4,490 mm (171.3 - 176.8 inches)
Width Overall:
Approx. 1,770 - 1,810 mm (69.7 - 71.3 inches)
Height Overall:
Approx. 1,430 - 1,450 mm (56.3 - 57.1 inches)
Wheelbase:
Approx. 2,600 - 2,625 mm (102.4 - 103.3 inches)
Weights
Curb Weight:
Approx. 1,450 - 1,500 kg (3,197 - 3,307 lbs)
Gross Vehicle Weight Rating:
Varies by model and market
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency (e.g., IIHS, NHTSA). Later models generally performed better due to updated safety standards.
Active Features
AWD System:
Mitsubishi's advanced AWD systems (ACD, AYC, Super AYC) significantly enhance active safety and stability.
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Active Traction Control (TCL) often integrated with AWD system
Passive Features
Airbags:
Driver and front passenger airbags (standard), side airbags (optional on some models)
Seatbelts:
3-point front and rear seatbelts with pretensioners
Body Structure:
Reinforced chassis and crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory-installed ETR AM/FM stereo with cassette/CD player. Later models may feature upgraded audio systems with more speakers.
Navigation:
Rare factory option, more commonly aftermarket GPS units are installed.
Driver Assistance
Traction Control System:
Integrated with AWD for enhanced stability and grip.
ABS:
Standard Anti-lock Braking System.
Connectivity
Original Connectivity:
Basic AM/FM radio, CD player. No integrated Bluetooth or smartphone connectivity in original factory configurations.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type. Enthusiast drivers often adhere to shorter intervals.
Spark Plug Replacement:
Around 30,000-60,000 miles, depending on plug type (copper vs. platinum/iridium)
Timing Belt Replacement:
Critical interval, typically every 60,000 miles or 5 years for the 4G63T engine. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
High-performance synthetic oil, typically 10W-40 or 5W-40. Consult manual for specific API service classification.
Coolant Type:
Ethylene glycol-based coolant (e.g., green or pink), typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, often 75W-90 or 80W-90. Specific viscosity may vary by generation and manufacturer recommendation.
Differential Fluid:
GL-5 gear oil, often 75W-90 or 80W-90 for front and rear differentials. Rear differentials with LSDs may require specific friction modifiers.
Transfer Case Fluid:
Typically the same as transmission fluid, GL-4/GL-5.
Known Issues
Engine:
Head gasket failures (especially with aggressive tuning), turbocharger wear, oil consumption, piston ring issues (7-bolt 4G63 engines), valve seat recession.
Transmission:
Synchro wear (especially 2nd and 3rd gears), clutch wear, differential failures in heavily modified vehicles.
Suspension:
Wear of bushings, ball joints, and shock absorbers due to performance driving.
Electrical:
Alternator failures, sensor issues (MAP, MAF, O2), wiring harness degradation.
📚 Vehicle History
Brand Heritage
Brand:
Mitsubishi Motors Corporation
Motorsport Legacy:
Long and successful history in World Rally Championship (WRC), dominating in the 1990s with Tommi Mäkinen.
Model Evolution
Evo I Iii:
Initial generations focused on rally homologation, less common outside Japan.
Evo Iv Vi:
Introduction of more advanced AWD systems (AYC), wider track, and significant engine tuning. The 'VI' saw the introduction of the 'Tommi Mäkinen Edition' with a titanium-turbine turbocharger.
Evo Vii Ix:
Further refinement of AWD systems (ACD, Super AYC), introduction of 6-speed transmissions, increased engine power and torque, and styling updates reflecting the Lancer platform evolution. Evo IX introduced MIVEC variable valve timing.
Production
Production Start Date:
1992 (for Evo I)
Production Period Covered:
1996-2007 (for manuals in this product)
Manufacturing Locations:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Best 10:
Frequently appeared on Car and Driver's '10Best' list during its production run, praised for its performance and value.
Wrc Titles:
Numerous World Rally Championship Manufacturers' and Drivers' titles, cementing its motorsport pedigree.
Ratings
Performance Metrics:
Consistently praised for acceleration, braking, and handling capabilities.
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