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1997-1999 Mitsubishi Lancer Evolution IV/Evolution V/Evolution VI (EVO 4/EVO 5/EVO 6) Service Repair Factory Manual (1997 1998 1999)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V / VI Generation: CE9A (Evo IV), CP9A (Evo V/VI) Production Years Covered By Manual: 1997, 1998, 1999 Chassis Codes: CE9A (Evo IV), CP9A (Evo V, Evo VI) 👋 Introduction Market Position Market Segment: High-performance rally homologation special, targeting enthusiasts and motorsport competitors. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four. Key Features Model Significance: Represents the pinnacle of Mitsubishi's Lancer Evolution lineage during the late 1990s, renowned for its advanced all-wheel-drive systems, powerful turbocharged engines, and rally-bred performance. 📋 Manual Details Coverage Areas Systems Covered: General Information, Engine, Engine Lubrication, Fuel System, Engine Cooling, Intake and Exhaust, Engine Electrical System, Engine and Emission Control, Clutch, Manual Transmission, Front Axle, Rear Axle, Power Plant Mount, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System, Body, Exterior, Chassis Electrical System, Electrical Wiring Diagrams Page Count Estimated Page Count: Highly comprehensive; actual page count not specified, but typical for factory service manuals covering multiple variants and years is in the range of 1500-2500+ pages. Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF File Format File Quality: PDF format allows for zooming and clear viewing of diagrams and text. Searchable text is a common feature in high-quality PDFs, enhancing usability. Binding Type Binding Type: Digital Download (PDF) - No physical binding. Paper Type Paper Type: Not applicable (Digital format). 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed coverage of 4G63 engine (including variants for Evo IV, V, VI), including cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection, ignition system, turbocharger, intercooler, emission control systems. Drivetrain Transmission And Axles: Comprehensive coverage of the 5-speed manual transmission (W5M33), transfer case, Active Yaw Control (AYC) system (Evo IV/V), Super Active Yaw Control (SAYC) system (Evo VI), front and rear differentials, driveshafts, hubs, and wheel bearings. Suspension And Steering Suspension And Steering Systems: Detailed procedures for front and rear suspension components (struts, springs, control arms, anti-roll bars), power steering system, steering gearbox, and alignment specifications. Brakes Brake System: In-depth coverage of hydraulic brake systems, including ABS, front and rear disc brake components (calipers, rotors, pads), brake lines, master cylinder, and parking brake system. Electrical Chassis And Engine Electrical: Extensive electrical system diagrams, troubleshooting guides for engine control units (ECU), lighting systems, instrument cluster, power windows, central locking, audio systems, and other chassis electrical components. Procedures Included Repair And Rebuild: Step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilding, body panel repair, and electrical component diagnosis and replacement. Maintenance And Tune-Up: Detailed schedules and procedures for routine maintenance such as oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, and comprehensive tune-up procedures. Diagnostics And Troubleshooting: Extensive diagnostic flowcharts, trouble codes (DTCs) with explanations and diagnostic procedures, and troubleshooting guides for common drivability and electrical issues. Technical Depth Diagnostic Capabilities: Advanced diagnostics, including ECU data analysis (if compatible with diagnostic tools of the era), sensor testing, and circuit testing using multimeters and oscilloscopes. ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (various configurations) Performance Horsepower Range: Approximately 280 PS (276 hp) to 320 PS (316 hp) depending on specific model and market regulations (official figures often capped due to Japanese 'Gentlemen's Agreement'). Actual output often higher. Torque Range: Approximately 350 Nm (258 lb-ft) to 390 Nm (288 lb-ft) depending on specific model. Engine Layout Engine Configuration: Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve Displacement Engine Displacement: 1998 cc (2.0 Liters) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), sequential multi-point fuel injection 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Optional Optional Transmission: Not applicable for these high-performance variants; manual transmission was standard. Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super AYC (SAYC) for enhanced cornering stability and traction. 📐 Dimensions Exterior Wheelbase: Evo IV: 2620 mm (103.1 in), Evo V/VI: 2625 mm (103.3 in) Length: Evo IV: 4350 mm (171.3 in), Evo V/VI: 4365 mm (171.9 in) Width: Evo IV: 1770 mm (69.7 in), Evo V/VI: 1770 mm (69.7 in) Height: Evo IV: 1415 mm (55.7 in), Evo V/VI: 1415 mm (55.7 in) Weights Curb Weight: Approximately 1400-1470 kg (3086-3241 lbs) depending on model and specifications. Wheel Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) Tire Size Standard: Evo IV: 205/50R16, Evo V/VI: 225/45R17 🛡️ Safety Features Ratings Crash Test Information: Official crash test ratings for this era may vary by region. The focus was primarily on structural integrity and driver protection within the context of its performance capabilities. Active Features Braking Safety: Anti-lock Braking System (ABS) standard on all models. Ventilated front and rear disc brakes. Passive Features Occupant Protection: Driver and front passenger airbags, reinforced chassis structure, body-side reinforcements. 💡...
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1997-1999 Mitsubishi Lancer Evolution IV/Evolution V/Evolution VI (EVO 4/EVO 5/EVO 6) Service Repair Factory Manual (1997 1998 1999)
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV / V / VI
Generation:
CE9A (Evo IV), CP9A (Evo V/VI)
Production Years Covered By Manual:
1997, 1998, 1999
Chassis Codes:
CE9A (Evo IV), CP9A (Evo V, Evo VI)
👋 Introduction
Market Position
Market Segment:
High-performance rally homologation special, targeting enthusiasts and motorsport competitors.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Key Features
Model Significance:
Represents the pinnacle of Mitsubishi's Lancer Evolution lineage during the late 1990s, renowned for its advanced all-wheel-drive systems, powerful turbocharged engines, and rally-bred performance.
📋 Manual Details
Coverage Areas
Systems Covered:
General Information, Engine, Engine Lubrication, Fuel System, Engine Cooling, Intake and Exhaust, Engine Electrical System, Engine and Emission Control, Clutch, Manual Transmission, Front Axle, Rear Axle, Power Plant Mount, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System, Body, Exterior, Chassis Electrical System, Electrical Wiring Diagrams
Page Count
Estimated Page Count:
Highly comprehensive; actual page count not specified, but typical for factory service manuals covering multiple variants and years is in the range of 1500-2500+ pages.
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
File Format
File Quality:
PDF format allows for zooming and clear viewing of diagrams and text. Searchable text is a common feature in high-quality PDFs, enhancing usability.
Binding Type
Binding Type:
Digital Download (PDF) - No physical binding.
Paper Type
Paper Type:
Not applicable (Digital format).
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed coverage of 4G63 engine (including variants for Evo IV, V, VI), including cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection, ignition system, turbocharger, intercooler, emission control systems.
Drivetrain
Transmission And Axles:
Comprehensive coverage of the 5-speed manual transmission (W5M33), transfer case, Active Yaw Control (AYC) system (Evo IV/V), Super Active Yaw Control (SAYC) system (Evo VI), front and rear differentials, driveshafts, hubs, and wheel bearings.
Suspension And Steering
Suspension And Steering Systems:
Detailed procedures for front and rear suspension components (struts, springs, control arms, anti-roll bars), power steering system, steering gearbox, and alignment specifications.
Brakes
Brake System:
In-depth coverage of hydraulic brake systems, including ABS, front and rear disc brake components (calipers, rotors, pads), brake lines, master cylinder, and parking brake system.
Electrical
Chassis And Engine Electrical:
Extensive electrical system diagrams, troubleshooting guides for engine control units (ECU), lighting systems, instrument cluster, power windows, central locking, audio systems, and other chassis electrical components.
Procedures Included
Repair And Rebuild:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilding, body panel repair, and electrical component diagnosis and replacement.
Maintenance And Tune-Up:
Detailed schedules and procedures for routine maintenance such as oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, and comprehensive tune-up procedures.
Diagnostics And Troubleshooting:
Extensive diagnostic flowcharts, trouble codes (DTCs) with explanations and diagnostic procedures, and troubleshooting guides for common drivability and electrical issues.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including ECU data analysis (if compatible with diagnostic tools of the era), sensor testing, and circuit testing using multimeters and oscilloscopes.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (various configurations)
Performance
Horsepower Range:
Approximately 280 PS (276 hp) to 320 PS (316 hp) depending on specific model and market regulations (official figures often capped due to Japanese 'Gentlemen's Agreement'). Actual output often higher.
Torque Range:
Approximately 350 Nm (258 lb-ft) to 390 Nm (288 lb-ft) depending on specific model.
Engine Layout
Engine Configuration:
Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve
Displacement
Engine Displacement:
1998 cc (2.0 Liters)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), sequential multi-point fuel injection
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Optional
Optional Transmission:
Not applicable for these high-performance variants; manual transmission was standard.
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) or Super AYC (SAYC) for enhanced cornering stability and traction.
📐 Dimensions
Exterior
Wheelbase:
Evo IV: 2620 mm (103.1 in), Evo V/VI: 2625 mm (103.3 in)
Length:
Evo IV: 4350 mm (171.3 in), Evo V/VI: 4365 mm (171.9 in)
Width:
Evo IV: 1770 mm (69.7 in), Evo V/VI: 1770 mm (69.7 in)
Height:
Evo IV: 1415 mm (55.7 in), Evo V/VI: 1415 mm (55.7 in)
Weights
Curb Weight:
Approximately 1400-1470 kg (3086-3241 lbs) depending on model and specifications.
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Tire Size Standard:
Evo IV: 205/50R16, Evo V/VI: 225/45R17
🛡️ Safety Features
Ratings
Crash Test Information:
Official crash test ratings for this era may vary by region. The focus was primarily on structural integrity and driver protection within the context of its performance capabilities.
Active Features
Braking Safety:
Anti-lock Braking System (ABS) standard on all models. Ventilated front and rear disc brakes.
Passive Features
Occupant Protection:
Driver and front passenger airbags, reinforced chassis structure, body-side reinforcements.
💡 Technology Features
Infotainment
Audio System:
Factory radio/cassette player or CD player with basic speaker system. Aftermarket upgrades common.
Driver Assistance
Advanced Handling Systems:
Iconic Active Yaw Control (AYC) and Super AYC (SAYC) systems, which actively manage torque distribution to the rear wheels to improve cornering ability.
Traction Control:
All-wheel-drive system with center differential and electronically controlled viscous coupling. Traction control systems may vary by market and specific model year.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under severe driving conditions. Use of high-quality synthetic oil is recommended.
Timing Belt:
Every 80,000 km (50,000 miles) or 4 years. Critical component to inspect and replace to avoid catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG or higher, viscosity 10W-30 or 10W-40 (synthetic recommended for performance).
Coolant:
Mitsubishi Diaqueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze with distilled water (50/50 mix).
Transmission Fluid:
Mitsubishi Diaqueen LSD Gear Oil (for AYC/SAYC equipped models) or equivalent API GL-4/GL-5 gear oil.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Engine Component Wear:
Worn valve stem seals leading to oil consumption, turbocharger wear due to heat cycling and lubrication issues, piston ring wear, potential head gasket failure under extreme heat/stress.
Drivetrain Wear:
AYC/SAYC hydraulic system leaks or pump failures, differential wear, clutch wear due to aggressive driving. Synchro wear in manual transmissions.
Chassis And Body:
Rust and corrosion, particularly on underbody components and wheel arches. Suspension bushing wear, leading to imprecise handling.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Directly derived from Mitsubishi's successful World Rally Championship (WRC) Lancer, homologated for Group A rallying.
Model Evolution
Evolution Iv Features:
Introduced Active Yaw Control (AYC) system for improved handling dynamics. Revised aerodynamics and chassis.
Evolution V Features:
Wider body, larger wheels and tires (17-inch), updated suspension geometry, improved engine cooling, more robust clutch, and revised aerodynamics. Tuned for tarmac rallying.
Evolution Vi Features:
Further refinements including a more robust engine (oil cooler, different pistons), revised AYC (SAYC), improved cooling, and updated styling. Introduced the Tommi Mäkinen Edition (TME) variant.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution platform achieved significant success in the World Rally Championship, with numerous driver and manufacturer titles during the 1990s and early 2000s, directly contributing to the road car's legendary status.
Performance Acclaim:
Consistently lauded by automotive journalists and enthusiasts for its exhilarating performance, precise handling, and advanced technology, often outperforming more expensive sports cars.
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