Mitsubishi Evo 4 1996-1998 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV (Evo 4) Chassis Code: CN9A Codes Engine Code: 4G63T Manual Part Number Lookup: Likely corresponds to official Mitsubishi factory documentation for the CN9A platform. 👋 Introduction Market Position Vehicle Segment: Compact performance sedan (rally homologation special). Usp Key Selling Point: All-wheel drive, turbocharged 4G63T engine, advanced AYC system, racing pedigree. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four. Key Features Model Significance: Marked a significant evolution with a wider body, improved suspension geometry, and the introduction of the AYC system. 📋 Manual Details Coverage Areas Covered Model Years: 1996, 1997, 1998 Primary Markets: Japan (JDM), but covers mechanicals applicable globally. Page Count Estimated Pages: Hundreds (as stated, typical factory manuals are extensive, often 1000+ pages when printed). Manual Type Type: Factory Service Repair Manual Language Language: English (assumed from product description context, though original factory may be Japanese. This PDF is likely a translated or professionally compiled English version). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, assembly, and testing of the 4G63T engine, including cylinder head, block, pistons, crankshaft, camshafts, timing belt, oil pump, and cooling system. Engine Management And Ignition: ECU operation, sensor diagnostics (MAP, TPS, O2, knock), fuel injection system, ignition timing, emissions control systems. Transmission Drivetrain: Manual transmission (Getrag 5-speed for Evo IV), clutch system, transfer case, driveshafts, differentials (front, rear, AYC - Active Yaw Control). Suspension And Steering: Front and rear suspension components, shock absorbers, springs, control arms, steering gearbox, power steering system. Brakes: Brake system operation, hydraulic lines, calipers, master cylinder, ABS (Anti-lock Braking System) components, parking brake. Electrical System: Wiring diagrams for all circuits, starter, alternator, battery, lighting, gauges, power windows, mirrors, central locking. Body And Interior: Body panel removal and installation, door mechanisms, seat adjustments, dashboard trim, HVAC system. Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and tensioning. Troubleshooting: Diagnostic flowcharts and symptom-based guides for common and uncommon problems across all vehicle systems. Repair And Rebuild: Step-by-step instructions for component removal, repair, and reinstallation, including engine rebuilds, transmission overhauls, and suspension component replacement. Diagnostics: Detailed explanations of diagnostic trouble codes (DTCs), sensor data interpretation, and use of specialized diagnostic tools (if applicable to the era). Specifications And Tolerances: Precise torque values, clearance measurements, and critical tolerances for all mechanical components. Technical Depth Depth Of Information: Comprehensive. Covers everything from basic fluid services to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Target Audience: Professional mechanics, experienced DIY enthusiasts, and motorsport technicians. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if a properly OCR'd PDF. Print Quality Printability: Designed to be printable. Users can print specific sections or the entire manual. Binding Type Binding For Printed Copy: N/A (Digital PDF, but implies users can bind printed versions). Paper Type Recommended Paper For Printing: N/A (Digital PDF, but typical manuals would be printed on durable, matte paper). ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Engine Code: 4G63T Displacement: 1997 cc (2.0 L) Performance Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Horsepower Ps: 280 PS (approx. 276 hp) at 6,500 rpm (JDM spec) Torque Kgm: 35.0 kgm (approx. 253 lb-ft) at 3,000 rpm (JDM spec) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI - Multi-Point Injection) Fuel Type: Unleaded premium gasoline (RON 98 recommended) Turbocharger: Mitsubishi TD05HR-16G (twin-scroll) with intercooler 🔧 Transmission Standard Transmission Type: 5-speed manual Gearbox Model: Getrag Type G-5M-P (shared with some Evos) Optional Optional Transmission: None (Manual transmission was standard across all Evo IV models) Features Drivetrain Layout: All-Wheel Drive (AWD) Active Yaw Control: Standard (AYC - Active Yaw Control) with torque vectoring to the rear wheels. Transfer Case: Mechanical front and rear differentials, with AYC integration at the rear. 📐 Dimensions Exterior Length: 4,340 mm (170.9 in) Width: 1,770 mm (69.7 in) Height: 1,415 mm (55.7 in) Wheelbase: 2,600 mm (102.4 in) Track Width Front: 1,515 mm (59.6 in) Track Width Rear: 1,505 mm (59.3 in) Weights Curb Weight: 1,410 kg (3,108 lbs) approx. Gross Weight: N/A (Not typically specified in this detail for performance models) 🛡️ Safety Features Ratings Crash Test Ratings: Not typically rated by modern global agencies like NHTSA or Euro NCAP for this era/market. JDM safety standards applied. Active Features Active Features List: AYC (Active Yaw Control), ABS (Anti-lock Braking System), high-performance braking system. Passive Features Passive Features List: Driver and passenger airbags, reinforced chassis, 3-point seatbelts with pretensioners. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player and cassette tape (typical JDM specification). Driver Assistance Driver Assistance List: AYC (Active Yaw Control), ABS (Anti-lock Braking System). Connectivity Connectivity Options: Limited. Primarily basic...
Likely corresponds to official Mitsubishi factory documentation for the CN9A platform.
👋 Introduction
Market Position
Vehicle Segment:
Compact performance sedan (rally homologation special).
Usp Key Selling Point:
All-wheel drive, turbocharged 4G63T engine, advanced AYC system, racing pedigree.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Key Features
Model Significance:
Marked a significant evolution with a wider body, improved suspension geometry, and the introduction of the AYC system.
📋 Manual Details
Coverage Areas
Covered Model Years:
1996, 1997, 1998
Primary Markets:
Japan (JDM), but covers mechanicals applicable globally.
Page Count
Estimated Pages:
Hundreds (as stated, typical factory manuals are extensive, often 1000+ pages when printed).
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (assumed from product description context, though original factory may be Japanese. This PDF is likely a translated or professionally compiled English version).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, assembly, and testing of the 4G63T engine, including cylinder head, block, pistons, crankshaft, camshafts, timing belt, oil pump, and cooling system.
Wiring diagrams for all circuits, starter, alternator, battery, lighting, gauges, power windows, mirrors, central locking.
Body And Interior:
Body panel removal and installation, door mechanisms, seat adjustments, dashboard trim, HVAC system.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and tensioning.
Troubleshooting:
Diagnostic flowcharts and symptom-based guides for common and uncommon problems across all vehicle systems.
Repair And Rebuild:
Step-by-step instructions for component removal, repair, and reinstallation, including engine rebuilds, transmission overhauls, and suspension component replacement.
Diagnostics:
Detailed explanations of diagnostic trouble codes (DTCs), sensor data interpretation, and use of specialized diagnostic tools (if applicable to the era).
Specifications And Tolerances:
Precise torque values, clearance measurements, and critical tolerances for all mechanical components.
Technical Depth
Depth Of Information:
Comprehensive. Covers everything from basic fluid services to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.
Target Audience:
Professional mechanics, experienced DIY enthusiasts, and motorsport technicians.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if a properly OCR'd PDF.
Print Quality
Printability:
Designed to be printable. Users can print specific sections or the entire manual.
Binding Type
Binding For Printed Copy:
N/A (Digital PDF, but implies users can bind printed versions).
Paper Type
Recommended Paper For Printing:
N/A (Digital PDF, but typical manuals would be printed on durable, matte paper).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63T
Displacement:
1997 cc (2.0 L)
Performance
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Horsepower Ps:
280 PS (approx. 276 hp) at 6,500 rpm (JDM spec)
Torque Kgm:
35.0 kgm (approx. 253 lb-ft) at 3,000 rpm (JDM spec)
Limited. Primarily basic power accessories and speaker connections.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe use).
Transmission Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Transfer Case Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Rear Differential Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 5 years.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific grade based on climate).
Transmission Fluid:
GL-4 SAE 75W-90 (manual transmission)
Transfer Case Fluid:
GL-4 SAE 75W-90
Rear Differential Fluid:
GL-5 SAE 80W-90 (for standard differential), specific LSD or AYC fluid may be required by manual.
Coolant:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Known Issues
Common Problems:
Eccentric cam/pulley wear, turbocharger seal failure (leading to oil burning), clutch wear, AYC pump failure, cracked exhaust manifold, piston ring land failure (due to detonation/abuse).
Critical Maintenance Points:
Strict adherence to timing belt replacement schedule, regular oil changes with quality oil, avoiding detonation, proper AYC fluid maintenance.
📚 Vehicle History
Brand Heritage
Motorsport Link:
Mitsubishi's extensive rallying heritage, particularly in the World Rally Championship (WRC).
Model Evolution
Predecessor:
Mitsubishi Lancer Evolution III (Evo 3)
Successor:
Mitsubishi Lancer Evolution V (Evo 5)
Evolutionary Step:
Significant chassis rigidity improvements, wider track, revised suspension geometry, and introduction of AYC.
Production
Production Years:
August 1996 – January 1998
Production Volume:
Approximately 6,000 units produced.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Accolades:
Basis for Mitsubishi's successful Group A rally cars, though Evo 4 was not directly homologated for WRC Group A as its predecessors/successors were. It served as a transition model.
Ratings
Performance Reviews:
Universally praised for its handling, grip, and turbocharged performance in contemporary automotive journalism.
Certifications
Homologation Status:
Not directly homologated for WRC Group A (Evo III and V were). Designed as a road-going version of rally technology.