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Mitsubishi Evo 4 and 5 Service Manual

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This manual covers the Lancer Evolution IV (CN9A) and Evolution V (CP9A) models, produced between 1996 and 1999. Renowned for their legendary rally heritage and exceptional performance capabilities, these vehicles feature advanced all-wheel-drive systems with Active Yaw Control (AYC), powerful 2.0-liter 4G63 turbocharged engines, and robust chassis designed for dynamic handling. Engineered for enthusiasts and motorsport, the Lancer Evolution series is celebrated for its direct driving experience and track-ready performance, making it a significant entry in the performance sedan segment. This comprehensive factory service manual provides detailed information essential for the maintenance, diagnosis, and repair of your Lancer Evolution IV or V. It encompasses a wide range of systems, including the powertrain, drivetrain with its unique AYC system, suspension, brakes, and electrical components. Within its over 900 pages, you will find step-by-step procedures for routine maintenance, in-depth troubleshooting guides, component testing, and factory specifications. This resource is designed to assist owners and professional technicians in preserving the optimal performance and longevity of these iconic vehicles. 🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V Generation Generation Name: CN9A (Evo IV) / CP9A (Evo V) Codes Chassis Codes: CN9A (Evo IV), CP9A (Evo V) Engine Codes: 4G63 (Evo IV), 4G63 (Evo V) 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale. Key Features Performance Focus: Legendary rally heritage, advanced all-wheel-drive system (AYC), powerful turbocharged engine, high handling capabilities. Target Audience: Enthusiasts, motorsport participants, mechanics specializing in performance vehicles. 📋 Manual Details Coverage Areas Service Manual Coverage: Comprehensive repair, maintenance, diagnosis, and specifications for Mitsubishi Lancer Evolution IV and V. Page Count Estimated Page Count: 900+ Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger system. Drivetrain: Manual transmission (type TY856WB), transfer case, front differential, rear differential (Active Yaw Control - AYC). Suspension Steering: Front suspension (McPherson strut), rear suspension (Multi-link), power steering system, wheel alignment specifications. Brakes: Front brakes (Brembo 4-piston calipers), rear brakes (Brembo 2-piston calipers), ABS system, parking brake. Electrical Electronics: Engine control unit (ECU), body control module (BCM), lighting, wipers, horn, power windows, audio system, diagnostic connectors (OBD-I/OBD-II). Body Chassis: Body construction, interior trim, exterior panels, doors, hood, trunk, glass, chassis components, corrosion protection. Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad replacement. Diagnostics: Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams, component testing procedures. Repair Rebuild: Engine disassembly and reassembly, transmission overhaul, clutch replacement, suspension component replacement, brake system repair, turbocharger rebuild. Special Procedures: AYC system calibration, timing belt replacement, fuel injector cleaning and replacement, ECU reprogramming. Technical Depth Depth: Complete technical information for factory-level repairs and diagnostics, suitable for professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Clarity: High-resolution scans with clear diagrams, text, and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Likely text-searchable PDF, allowing quick access to specific information. ⚙️ Engine Specifications Primary Engine Engine Family: 4G63 Engine Type: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Displacement: 2.0 Liters (1997cc) Performance Horsepower Evo4: 276 PS (272 hp) @ 6250 RPM (Japanese Spec, often under-reported) Torque Evo4: 350 Nm (258 lb-ft) @ 3000 RPM (Japanese Spec) Horsepower Evo5: 276 PS (272 hp) @ 6250 RPM (Japanese Spec, increased for GSR/RS-Sprint models) Torque Evo5: 373 Nm (275 lb-ft) @ 3000 RPM (GSR) / 357 Nm (263 lb-ft) (RS) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection. Fuel Type: Unleaded Premium (95 RON / 91 AKI recommended) Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant) Lubrication System Oil Capacity: Approx. 4.5 Liters (4.8 US Quarts) with filter change Recommended Oil Viscosity: 10W-30 or 10W-40 (check manual for specific conditions) 🔧 Transmission Standard Transmission Type: 5-speed Manual (TY856WB) Optional Transmission Options: N/A (Manual transmission was standard across all Evo IV/V models) Features AWD System: Full-time All-Wheel Drive with Active Yaw Control (AYC) for Evo IV, and AYC Type R for Evo V. Helical front LSD, viscous coupling center diff. Transfer Case Fluid: API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation) Rear Differential Fluid: API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation, especially for AYC) 📐 Dimensions Exterior Length: Approx. 4,350 mm (171.3 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,405 mm (55.3 in) Wheelbase: Approx. 2,625 mm (103.3 in) Weights Curb Weight: Approx. 1,360 kg (2,998 lb) - Varies by model (GSR/RS) Gross Vehicle Weight Rating: Varies by specific model and...
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Mitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service ManualMitsubishi Evo 4 and 5 Service Manual
This manual covers the Lancer Evolution IV (CN9A) and Evolution V (CP9A) models, produced between 1996 and 1999. Renowned for their legendary rally heritage and exceptional performance capabilities, these vehicles feature advanced all-wheel-drive systems with Active Yaw Control (AYC), powerful 2.0-liter 4G63 turbocharged engines, and robust chassis designed for dynamic handling. Engineered for enthusiasts and motorsport, the Lancer Evolution series is celebrated for its direct driving experience and track-ready performance, making it a significant entry in the performance sedan segment. This comprehensive factory service manual provides detailed information essential for the maintenance, diagnosis, and repair of your Lancer Evolution IV or V. It encompasses a wide range of systems, including the powertrain, drivetrain with its unique AYC system, suspension, brakes, and electrical components. Within its over 900 pages, you will find step-by-step procedures for routine maintenance, in-depth troubleshooting guides, component testing, and factory specifications. This resource is designed to assist owners and professional technicians in preserving the optimal performance and longevity of these iconic vehicles.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV / V
Generation
Generation Name:
CN9A (Evo IV) / CP9A (Evo V)
Codes
Chassis Codes:
CN9A (Evo IV), CP9A (Evo V)
Engine Codes:
4G63 (Evo IV), 4G63 (Evo V)
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally Homologation Special
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.
Key Features
Performance Focus:
Legendary rally heritage, advanced all-wheel-drive system (AYC), powerful turbocharged engine, high handling capabilities.
Target Audience:
Enthusiasts, motorsport participants, mechanics specializing in performance vehicles.
📋 Manual Details
Coverage Areas
Service Manual Coverage:
Comprehensive repair, maintenance, diagnosis, and specifications for Mitsubishi Lancer Evolution IV and V.
Page Count
Estimated Page Count:
900+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger system.
Drivetrain:
Manual transmission (type TY856WB), transfer case, front differential, rear differential (Active Yaw Control - AYC).
Suspension Steering:
Front suspension (McPherson strut), rear suspension (Multi-link), power steering system, wheel alignment specifications.
Brakes:
Front brakes (Brembo 4-piston calipers), rear brakes (Brembo 2-piston calipers), ABS system, parking brake.
Electrical Electronics:
Engine control unit (ECU), body control module (BCM), lighting, wipers, horn, power windows, audio system, diagnostic connectors (OBD-I/OBD-II).
Body Chassis:
Body construction, interior trim, exterior panels, doors, hood, trunk, glass, chassis components, corrosion protection.
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad replacement.
Diagnostics:
Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams, component testing procedures.
Repair Rebuild:
Engine disassembly and reassembly, transmission overhaul, clutch replacement, suspension component replacement, brake system repair, turbocharger rebuild.
Special Procedures:
AYC system calibration, timing belt replacement, fuel injector cleaning and replacement, ECU reprogramming.
Technical Depth
Depth:
Complete technical information for factory-level repairs and diagnostics, suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Clarity:
High-resolution scans with clear diagrams, text, and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Search:
Likely text-searchable PDF, allowing quick access to specific information.
⚙️ Engine Specifications
Primary Engine
Engine Family:
4G63
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Displacement:
2.0 Liters (1997cc)
Performance
Horsepower Evo4:
276 PS (272 hp) @ 6250 RPM (Japanese Spec, often under-reported)
Torque Evo4:
350 Nm (258 lb-ft) @ 3000 RPM (Japanese Spec)
Horsepower Evo5:
276 PS (272 hp) @ 6250 RPM (Japanese Spec, increased for GSR/RS-Sprint models)
Torque Evo5:
373 Nm (275 lb-ft) @ 3000 RPM (GSR) / 357 Nm (263 lb-ft) (RS)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection.
Fuel Type:
Unleaded Premium (95 RON / 91 AKI recommended)
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant)
Lubrication System
Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change
Recommended Oil Viscosity:
10W-30 or 10W-40 (check manual for specific conditions)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (TY856WB)
Optional
Transmission Options:
N/A (Manual transmission was standard across all Evo IV/V models)
Features
AWD System:
Full-time All-Wheel Drive with Active Yaw Control (AYC) for Evo IV, and AYC Type R for Evo V. Helical front LSD, viscous coupling center diff.
Transfer Case Fluid:
API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation)
Rear Differential Fluid:
API GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendation, especially for AYC)
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,405 mm (55.3 in)
Wheelbase:
Approx. 2,625 mm (103.3 in)
Weights
Curb Weight:
Approx. 1,360 kg (2,998 lb) - Varies by model (GSR/RS)
Gross Vehicle Weight Rating:
Varies by specific model and market
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not widely tested by modern NHTSA/Euro NCAP standards due to era of production and homologation focus.
Active Features
Driver Assistance:
AYC (Active Yaw Control) for enhanced stability and traction, ABS (Anti-lock Braking System).
Passive Features
Restraints:
Driver and front passenger airbags, three-point seatbelts with pretensioners.
Body Structure:
Reinforced chassis and safety cage designed for rally conditions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette/CD player (market dependent), typically 4-6 speaker system.
Climate Control:
Manual or automatic climate control systems (market dependent).
Driver Assistance
AWD Control:
Advanced AYC system electronically controls torque distribution to rear wheels for superior cornering.
Connectivity
Diagnostics:
On-Board Diagnostics (OBD-I in early models, transitioning to OBD-II), with specific proprietary Mitsubishi diagnostic connectors and protocols.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first (severe use may require more frequent changes).
Air Filter Replacement:
Every 15,000-30,000 km (9,000-18,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Refer to manual, typically around 30,000-60,000 km (18,000-36,000 miles) depending on plug type.
Timing Belt Replacement:
100,000 km (60,000 miles) or 7 years, whichever comes first. Critical item!
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification)
Power Steering Fluid:
Automatic Transmission Fluid (ATF) Dexron II or equivalent (verify with manual)
Known Issues
Common Failures:
Turbocharger failure (oil starvation), AYC pump failure, clutch wear, differential issues, HICAS (if equipped) problems, piston ring wear (higher mileage).
Maintenance Considerations:
Requires diligent adherence to maintenance schedules, especially regarding oil changes and cooling system health, to prevent turbocharger and engine damage.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's extensive history and success in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series.
Model Evolution
Evo Iv Introduction:
Introduced in August 1996. Featured a revised engine, new AYC system, and a significantly redesigned exterior with larger spoilers and aggressive styling.
Evo V Introduction:
Introduced in January 1998. Featured wider bodywork, larger intercooler, improved suspension geometry, larger Brembo brakes, and revised AYC for enhanced performance.
Production
Production Period Evo4:
1996 - 1998
Production Period Evo5:
1998 - 1999
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
Motorsport Achievements:
Multiple WRC Manufacturers' and Drivers' Championships achieved by privateers and factory teams using Lancer Evolution platforms.
Automotive Press:
Consistently praised by automotive journalists for its handling, performance, and rally-bred capabilities.
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