Mitsubishi Evolution IV & V 1996-1999 Factory Service Manual
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V Production Years: 1996-1999 Codes Chassis Codes: CN9A (Evo IV), CP9A (Evo V) ๐ Introduction Market Position Target Audience: Owners and technicians seeking to perform comprehensive maintenance and repairs on Mitsubishi Lancer Evolution IV and V models. Competitive Analysis Manual Authenticity: Actual Genuine Repair Service Factory Manuals, not third-party publications. Key Features Instructional Method: Step-by-step instructions, detailed illustrations, notes, cautions, and warnings. User Friendliness: Designed for ease of use, allowing owners to make informed repair and maintenance decisions. Value Proposition Cost Savings: Potential to save $50-$60 per hour on shop labor costs by performing work independently. ๐ Manual Details Coverage Areas Coverage Scope: Complete Factory Service Repair Manual Page Count Estimated Page Count: Hundreds (Specific number not provided, but indicated as comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF Download ๐ Manual Coverage Systems Covered Engine Service And Repair: Detailed procedures for maintenance, troubleshooting, and repair of the engine. Transmission Service And Repair: Comprehensive coverage for manual and potentially automatic transmission systems. Brake System: In-depth information on brake components, diagnosis, and repair. Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems. Electrical System: Diagnosis and repair of all electrical components and circuits. Suspension And Steering: Procedures for servicing and repairing suspension and steering mechanisms. Cooling System: Maintenance and repair of the engine cooling system. Fuel Injection And Fuel System: Detailed coverage of fuel delivery and injection systems. Emission Control System: Information on emission control components and troubleshooting. HVAC System: Service and repair procedures for the heating, ventilation, and air conditioning system. Engine Control System: Details on ECU diagnostics and control strategies. Chassis And Body: Information on structural components, body panels, and chassis repair. Restraint System: Coverage of airbags and seatbelt systems. Interior Components: Procedures for servicing interior trim and components. Differential And Drive Axles: Detailed coverage of drivetrain components including differentials and axles. Periodic Lubrication: Specific lubrication points and schedules. Procedures Included General Maintenance: Procedures for routine checks, fluid changes, and inspections. Troubleshooting: Advanced diagnostic guides for identifying and resolving common and complex issues. Repair Procedures: Step-by-step repair instructions for virtually all vehicle systems. Rebuilding Procedures: Comprehensive guidance for engine, transmission, and other major component rebuilds. Diagnostics: Detailed diagnostic strategies for all vehicle systems. Technical Depth Depth Of Information: Highly detailed, factory-level technical information for professional technicians and advanced enthusiasts. Coverage Completeness: Covers all styles and variants of the specified models. ๐ Manual Specifications File Format File Format: PDF Print Quality Printability: Printable without restriction; individual pages or entire manual. Binding Type Binding Type: Digital Download (printable) Paper Type Paper Type: Not Applicable (Digital Format) Software Requirements Required Software: Adobe PDF Reader Searchability Search Functionality: Searchable PDF for quick information retrieval. โ๏ธ Engine Specifications Primary Engine Engine Type: 4G63 (DOHC, 16-valve, turbocharged inline-4) Performance Displacement: 2.0 Liters (1997 cc) Horsepower Evo Iv: Approx. 276-280 PS (272-276 hp) at 6,500 rpm (Japanese domestic market 'gentlemen's agreement' limit) Torque Evo Iv: Approx. 350 Nm (258 lb-ft) at 3,000 rpm Horsepower Evo V: Approx. 280 PS (276 hp) at 6,500 rpm (Japanese domestic market 'gentlemen's agreement' limit); some export models may have slightly higher outputs. Torque Evo V: Approx. 373 Nm (275 lb-ft) at 3,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded premium gasoline (Octane rating appropriate for turbocharged engines) Engine Control ECU Type: Engine Control Unit (ECU) with advanced management for turbocharging and engine parameters. ๐ง Transmission Standard Standard Transmission: 5-speed manual transmission Optional Optional Transmission: Not widely offered; primarily manual transmission focused. Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Helical Limited-Slip Front Differential (LSD) on Evo IV; Active Yaw Control (AYC) on Evo IV and an improved AYC system on Evo V. ๐ Dimensions Exterior Length Evo Iv: Approx. 4,350 mm (171.3 in) Width Evo Iv: Approx. 1,770 mm (69.7 in) Height Evo Iv: Approx. 1,415 mm (55.7 in) Wheelbase Evo Iv: Approx. 2,600 mm (102.4 in) Length Evo V: Approx. 4,360 mm (171.7 in) Width Evo V: Approx. 1,770 mm (69.7 in) Height Evo V: Approx. 1,415 mm (55.7 in) Wheelbase Evo V: Approx. 2,600 mm (102.4 in) Weights Curb Weight: Approx. 1,400-1,450 kg (3,086-3,197 lb) depending on specification. ๐ก๏ธ Safety Features Ratings Safety Ratings: Specific crash test ratings for this era may vary by region. Emphasis on chassis rigidity and driver control for active safety. Active Features Active Safety Features: Advanced All-Wheel Drive system (ACD, AYC), powerful braking system, responsive steering. Passive Features Passive Safety Features: Reinforced chassis, airbags (driver and passenger), seatbelt pre-tensioners. ๐ก Technology Features Infotainment Infotainment System: Basic factory audio systems (radio/cassette or CD player) were standard, with options for upgraded sound systems. No advanced infotainment features as understood today. Driver Assistance Driver Assistance Features: Limited by...
Approx. 280 PS (276 hp) at 6,500 rpm (Japanese domestic market 'gentlemen's agreement' limit); some export models may have slightly higher outputs.
Torque Evo V:
Approx. 373 Nm (275 lb-ft) at 3,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded premium gasoline (Octane rating appropriate for turbocharged engines)
Engine Control
ECU Type:
Engine Control Unit (ECU) with advanced management for turbocharging and engine parameters.
๐ง Transmission
Standard
Standard Transmission:
5-speed manual transmission
Optional
Optional Transmission:
Not widely offered; primarily manual transmission focused.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Helical Limited-Slip Front Differential (LSD) on Evo IV; Active Yaw Control (AYC) on Evo IV and an improved AYC system on Evo V.
๐ Dimensions
Exterior
Length Evo Iv:
Approx. 4,350 mm (171.3 in)
Width Evo Iv:
Approx. 1,770 mm (69.7 in)
Height Evo Iv:
Approx. 1,415 mm (55.7 in)
Wheelbase Evo Iv:
Approx. 2,600 mm (102.4 in)
Length Evo V:
Approx. 4,360 mm (171.7 in)
Width Evo V:
Approx. 1,770 mm (69.7 in)
Height Evo V:
Approx. 1,415 mm (55.7 in)
Wheelbase Evo V:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,400-1,450 kg (3,086-3,197 lb) depending on specification.
๐ก๏ธ Safety Features
Ratings
Safety Ratings:
Specific crash test ratings for this era may vary by region. Emphasis on chassis rigidity and driver control for active safety.
Reinforced chassis, airbags (driver and passenger), seatbelt pre-tensioners.
๐ก Technology Features
Infotainment
Infotainment System:
Basic factory audio systems (radio/cassette or CD player) were standard, with options for upgraded sound systems. No advanced infotainment features as understood today.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Key 'assist' features are the AWD system, ACD, and AYC, focused on performance handling.
Connectivity
Connectivity Features:
None
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 km (3,000-5,000 miles) or 6 months, under performance driving conditions, more frequent changes are recommended.
Timing Belt Replacement:
Refer to manual for specific interval, typically around 80,000-100,000 km (50,000-60,000 miles) for the 4G63 engine.
Fluid Specifications
Engine Oil Specification:
Refer to manual for exact viscosity (e.g., 10W-40 or 5W-40 synthetic often recommended for performance). API SG or higher.
Transmission Fluid Specification:
Refer to manual for specific type (e.g., SAE 75W-90 GL-4/GL-5 synthetic for manual transmission).
Differential Fluid Specification:
Refer to manual for specific type (e.g., SAE 75W-90 synthetic for center and rear differentials).
Coolant Specification:
Ethylene glycol-based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent).
Known Issues
Common Issues:
Turbocharger wear, piston ring issues (especially if heavily modified or neglected), clutch wear, AYC pump failure, minor electrical gremlins.
๐ Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors has a strong heritage in motorsport, particularly rallying, with the Lancer Evolution line being a direct beneficiary and icon of this legacy.
Model Evolution
Evolution Iv Introduction:
Introduced in August 1996, featuring a significantly revised chassis, a new 4G63 engine with twin-scroll turbocharger, and advanced AYC system.
Evolution V Introduction:
Introduced in January 1998, it featured wider track, larger wheels and tires, revised suspension geometry, improved engine internals, and an enhanced AYC system.
Production
Production Location:
Japan
๐ Awards & Recognition
Recognitions
Motorsport Icon:
The Lancer Evolution series is a highly recognized and celebrated platform in rally racing history, making these models desirable among enthusiasts.