Mitsubishi Evo 4 1996-1998 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Common Name: Evo 4 Chassis Code: CN9A Production Years Covered: 1996-1998 Codes Engine Code Primary: 4G63 👋 Introduction Market Position Market Segment: Performance Compact Sedan / Rally Homologation Special Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale. Key Features Performance Focus: Engineered for rally racing, emphasizing power, handling, and all-wheel-drive traction. Technology: Introduction of Active Yaw Control (AYC) for enhanced cornering stability. Design: Aggressive styling, large rear spoiler, functional aerodynamic aids. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Coverage Scope: Complete Official Full Factory Service Repair Manual Page Count Estimated Page Count: Hundreds of pages (Exact number not specified, implying comprehensive) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostic, repair, and overhaul procedures for the 4G63 engine, including turbocharger, cooling, lubrication, and fuel systems. Transmission: Service and repair information for the F5M33 5-speed manual transmission, including clutch, gearbox, and drivetrain components. Drivetrain: Covers front and rear differentials, driveshafts, transfer cases, and the Active Yaw Control (AYC) system. Suspension: Front MacPherson strut and multi-link rear suspension, including alignment specifications, shock absorbers, springs, and bushings. Brakes: Front and rear disc brakes, including ABS system, brake fluid specifications, caliper overhaul, and pad replacement procedures. Steering: Power steering system diagnosis and repair, including pump, rack, and fluid specifications. Electrical: Wiring diagrams, ECU pinouts, starter, alternator, ignition system, lighting, and accessory circuits. Body And Chassis: Body panel removal/installation, interior trim, glass replacement, structural components, and chassis repair. Heating And Air Conditioning: AC system diagnosis, refrigerant types, component replacement, and heater core service. Safety Systems: Airbag system (SRS) diagnosis and repair, seatbelt mechanisms. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, belt inspections. Diagnostics: Troubleshooting charts for common problems, fault code interpretation, component testing procedures. Repair: Step-by-step instructions for component removal, installation, and overhaul across all major vehicle systems. Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, engine timing settings. Alignment: Detailed suspension alignment parameters (camber, caster, toe) for optimal handling. Rebuilds: Comprehensive instructions for engine, transmission, and differential rebuilds. Technical Depth Depth: Factory-level technical depth covering everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (standard for well-digitized manuals). Print Quality Printability: Designed to be printable, allowing users to create a physical copy. Binding Type Binding Type: N/A (Digital Download - user dependent) Paper Type Paper Type: N/A (Digital Download - user dependent) ⚙️ Engine Specifications Primary Engine Engine Type: 2.0L Inline 4-cylinder DOHC 16-valve turbocharged Engine Code: 4G63 (Revised for Evo IV) Performance Horsepower Ps: 280 PS (276 hp) - Officially rated due to the 'gentleman's agreement' among Japanese manufacturers. Torque Nm: 352 Nm (260 lb-ft) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Point Injection Fuel Type: Unleaded Premium Gasoline (95 RON or higher recommended) Engine Management ECU: Engine Control Unit (ECU) with ignition timing and fuel mapping adjustments. Cooling System Cooling Type: Water-cooled, pressurized system Lubrication System Oil Capacity Liters: 4.5 liters (with filter change) Oil Type Recommendation: API SG or SH, SAE 10W-30 or 10W-40 (Synthetic recommended for high-performance use) 🔧 Transmission Standard Type: 5-speed Manual Transmission (F5M33) Optional Type: None (All Evo IV models featured a manual transmission) Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Gear Ratios 1St: 3.071 Gear Ratios 2Nd: 1.777 Gear Ratios 3Rd: 1.307 Gear Ratios 4Th: 1.000 Gear Ratios 5Th: 0.742 Final Drive Ratio: 4.529 Transmission Fluid Fluid Type Recommendation: API GL-3 or GL-4, SAE 75W-90 (Manual Transmission Fluid) Capacity Liters: 2.7 liters (Manual Transmission) 📐 Dimensions Exterior Length Mm: 4350 Width Mm: 1770 Height Mm: 1415 Wheelbase Mm: 2600 Front Track Mm: 1505 Rear Track Mm: 1505 Weights Curb Weight Kg: 1400 - 1450 kg (depending on specification) Gross Vehicle Weight Rating Kg: Approx. 1800 kg Towing Capacity Kg: Not Recommended/Specified Wheels And Tires Wheel Size: 17 inches Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) Tire Size Front: 225/45R17 Tire Size Rear: 225/45R17 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Not officially tested by NHTSA in the US market during its production years as it was primarily a Japanese Domestic Market (JDM) vehicle. Active Features Traction Control: Yes (AYC - Active Yaw Control) Anti Lock Brakes: Yes (ABS) Electronic Brakeforce Distribution: Integrated with ABS system. Passive Features Airbags: Driver and Passenger Airbags (standard on most trims) Seatbelts: Three-point inertia-reel seatbelts with pretensioners Crumple Zones: Designed with front and rear crumple zones for energy absorption. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player (often optional) and cassette tape player. Speaker configuration typically 4-6 speakers. Display: Basic...
Detailed suspension alignment parameters (camber, caster, toe) for optimal handling.
Rebuilds:
Comprehensive instructions for engine, transmission, and differential rebuilds.
Technical Depth
Depth:
Factory-level technical depth covering everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text (standard for well-digitized manuals).
Print Quality
Printability:
Designed to be printable, allowing users to create a physical copy.
Binding Type
Binding Type:
N/A (Digital Download - user dependent)
Paper Type
Paper Type:
N/A (Digital Download - user dependent)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2.0L Inline 4-cylinder DOHC 16-valve turbocharged
Engine Code:
4G63 (Revised for Evo IV)
Performance
Horsepower Ps:
280 PS (276 hp) - Officially rated due to the 'gentleman's agreement' among Japanese manufacturers.
Torque Nm:
352 Nm (260 lb-ft)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Multi-Point Injection
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Engine Management
ECU:
Engine Control Unit (ECU) with ignition timing and fuel mapping adjustments.
Cooling System
Cooling Type:
Water-cooled, pressurized system
Lubrication System
Oil Capacity Liters:
4.5 liters (with filter change)
Oil Type Recommendation:
API SG or SH, SAE 10W-30 or 10W-40 (Synthetic recommended for high-performance use)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (F5M33)
Optional
Type:
None (All Evo IV models featured a manual transmission)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Gear Ratios 1St:
3.071
Gear Ratios 2Nd:
1.777
Gear Ratios 3Rd:
1.307
Gear Ratios 4Th:
1.000
Gear Ratios 5Th:
0.742
Final Drive Ratio:
4.529
Transmission Fluid
Fluid Type Recommendation:
API GL-3 or GL-4, SAE 75W-90 (Manual Transmission Fluid)
Capacity Liters:
2.7 liters (Manual Transmission)
📐 Dimensions
Exterior
Length Mm:
4350
Width Mm:
1770
Height Mm:
1415
Wheelbase Mm:
2600
Front Track Mm:
1505
Rear Track Mm:
1505
Weights
Curb Weight Kg:
1400 - 1450 kg (depending on specification)
Gross Vehicle Weight Rating Kg:
Approx. 1800 kg
Towing Capacity Kg:
Not Recommended/Specified
Wheels And Tires
Wheel Size:
17 inches
Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Tire Size Front:
225/45R17
Tire Size Rear:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Not officially tested by NHTSA in the US market during its production years as it was primarily a Japanese Domestic Market (JDM) vehicle.
Active Features
Traction Control:
Yes (AYC - Active Yaw Control)
Anti Lock Brakes:
Yes (ABS)
Electronic Brakeforce Distribution:
Integrated with ABS system.
Passive Features
Airbags:
Driver and Passenger Airbags (standard on most trims)
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player (often optional) and cassette tape player. Speaker configuration typically 4-6 speakers.
Display:
Basic digital climate control display and analog gauge cluster.
Driver Assistance
Active Yaw Control:
The signature technological feature, actively distributing torque between the rear wheels to enhance cornering performance and stability.
Anti Lock Braking System:
Standard ABS system to prevent wheel lock-up during heavy braking.
Connectivity
Bluetooth:
Not available from the factory.
Usb Ports:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change Km Miles:
Every 5,000-7,500 km (3,000-4,500 miles) or 6 months, whichever comes first (severe duty).
Air Filter Replacement Km Miles:
Every 15,000-20,000 km (9,000-12,000 miles).
Spark Plug Replacement Km Miles:
Every 40,000-60,000 km (24,000-36,000 miles), depending on spark plug type (iridium recommended).
Timing Belt Replacement Km Miles:
Every 90,000-100,000 km (56,000-62,000 miles) or 5 years.
Fluid Specifications
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water (typically green coolant).
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Dexron II or equivalent ATF
Known Issues
Engine Reliability:
Known for robust 4G63 engine, but requires diligent maintenance. Common issues include turbocharger wear, head gasket failures under extreme stress, and oil starvation if not properly maintained.
Ayc System:
The AYC hydraulic pump and solenoids can be prone to failure over time due to age and heat cycles. Fluid leaks can also occur.
Rust:
As with many Japanese performance cars of this era, rust can be a concern, particularly in the wheel arches, sills, and undercarriage, depending on climate and previous care.
Suspension Wear:
Bushings and ball joints can wear out, affecting handling and alignment. Shock absorbers may also lose damping effectiveness.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a long and successful history in rally racing, starting with the Pajero and then transitioning to the Lancer platform for WRC homologation.
Model Evolution
Generation:
Fourth generation of the Lancer Evolution, succeeding the Evo III.
Key Advancements Over Evo Iii:
Introduction of AYC, revised chassis with increased rigidity, improved aerodynamics, and enlarged intercooler.
Production
Manufacturing Location:
Japan
Production Volume:
Significant production numbers, but exact figures for Evo IV are not widely publicized; tens of thousands are estimated.
Market Availability:
Primarily Japan Domestic Market (JDM), with limited imports to other countries.
🏆 Awards & Recognition
Recognitions
Rally Championships:
While the Evo IV itself wasn't a direct WRC homologation for a specific year's championship, it cemented Mitsubishi's reputation built on rally success.
Enthusiast Following:
Highly regarded by automotive enthusiasts and considered a legendary performance car icon.
Ratings
Performance Car Rankings:
Consistently ranked highly in performance driving publications for its handling and acceleration capabilities in its era.