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Mitsubishi Lancer EVO 4 & EVO 5 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Platform: Mitsubishi E-platform Codes Generation Codes: CP9A (EVO IV), CP9A (EVO V) 👋 Introduction Market Position Positioning: High-performance rally homologation special, iconic JDM icon Competitive Analysis Competitors Evo4: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Competitors Evo5: Subaru Impreza WRX STI (GC8 chassis), Toyota Celica GT-Four Key Features Performance Focus: Designed for rally racing homologation, emphasizing advanced AWD and turbocharged performance Brand Heritage Rally Legacy: Direct descendant of Mitsubishi's successful WRC Lancer Evolution cars 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Coverage: All repairs covered A-Z, all models covered within the specified generations Format File Format: PDF Language Language: English 📖 Manual Coverage Systems Covered Engine: Comprehensive engine overhaul, diagnostics, tuning, lubrication, cooling, fuel injection, emission control systems (e.g., ACD, AYC) Transmission: Manual and Automatic transmission overhaul, diagnostics, clutch, driveline, transfer case, differentials (front, rear, ACD) Suspension Steering: Front and rear suspension components, steering rack, power steering system, wheel alignment specifications Brakes: Brake system diagnostics, hydraulic components, ABS, brake rotor and pad replacement, bleeding procedures Electrical Electronics: Full electrical schematics, wiring diagrams, starter, alternator, battery, lighting, ignition, instrument cluster, ECU diagnostics, SRS (Airbag) system Body Chassis: Body panel repair, interior trim removal/installation, glass replacement, chassis specifications, corrosion protection Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, fluid checks and changes Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation Diagnostics: On-board diagnostics (OBD-II) information, sensor testing, actuator testing, special tool usage Technical Depth Depth Level: Comprehensive (factory-level detail for professional technicians) 📊 Manual Specifications File Format Searchability: Fully searchable text for quick information retrieval Printability: Printable pages for workshop use Layout: Organized into logical sections with clear headings and subheadings ⚙️ Engine Specifications Primary Engine Engine Code Evo4: 4G63T Engine Displacement Evo4: 2.0 Liters (1997cc) Engine Configuration Evo4: Inline-4, DOHC, 16-valve, Turbocharged Performance Horsepower Evo4: 280 PS (276 hp) @ 6,500 rpm (Japanese Domestic Market, Gentlemen's Agreement) Torque Evo4: 350 Nm (258 lb-ft) @ 3,000 rpm Horsepower Evo5: 280 PS (276 hp) @ 6,500 rpm (Japanese Domestic Market, Gentlemen's Agreement) Torque Evo5: 373 Nm (275 lb-ft) @ 3,000 rpm (Increased torque over EVO IV) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel System Evo5: Multi-point Fuel Injection (MPI), larger turbocharger, improved intercooler Engine Code Evo5 Engine Code Evo5: 4G63T (Revised) Engine Displacement Evo5 Engine Displacement Evo5: 2.0 Liters (1997cc) Engine Configuration Evo5 Engine Configuration Evo5: Inline-4, DOHC, 16-valve, Turbocharged 🔧 Transmission Standard Transmission Type Evo4: 5-speed Manual Transmission Type Evo5: 5-speed Manual Optional Transmission Type Evo4 Optional: None (Manual exclusively for performance models) Transmission Type Evo5 Optional: None Features AWD System Evo4: Active Center Differential (ACD), Twin-Plate Clutch LSD (Front), Helical LSD (Rear) AWD System Evo5: Active Center Differential (ACD), Twin-Plate Clutch LSD (Front), Helical LSD (Rear) - enhanced grip and torque distribution 📐 Dimensions Exterior Length Evo4: 4,345 mm (171.1 in) Width Evo4: 1,770 mm (69.7 in) Height Evo4: 1,405 mm (55.3 in) Wheelbase Evo4: 2,600 mm (102.4 in) Length Evo5: 4,350 mm (171.3 in) Width Evo5: 1,770 mm (69.7 in) Height Evo5: 1,405 mm (55.3 in) Wheelbase Evo5: 2,600 mm (102.4 in) Weights Curb Weight Evo4: Approx. 1,400 kg (3,086 lbs) Curb Weight Evo5: Approx. 1,400 kg (3,086 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Primarily Japanese market, safety standards evolved) Active Features Active Safety Features: ACD (Active Center Differential), AYC (Active Yaw Control - later models/optional), ABS (Anti-lock Braking System), Performance braking systems (e.g., Brembo on some trims) Passive Features Passive Safety Features: SRS Airbags (Driver and Passenger), Reinforced chassis, Sport seats with enhanced bolstering 💡 Technology Features Infotainment Infotainment System: Basic factory radio with cassette player/CD player (depending on trim/market). Focus on performance over luxury tech. Driver Assistance Driver Assistance Features: Limited by modern standards; primary assistance provided by ACD and AYC for traction and handling. Connectivity Connectivity Options: Basic; typically no advanced connectivity features like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 km (4,500 miles) or 6 months, more frequent under hard driving conditions. Spark Plug Replacement: Refer to manual, typically around 30,000-50,000 km (18,000-30,000 miles) depending on plug type. Fluid Specifications Engine Oil Spec: API SG/SH or ACEA A2-96 equivalent, SAE 10W-30 or 10W-40 recommended. Check manual for specific viscosity based on climate. Coolant Spec: Ethylene glycol-based coolant, 50/50 mix with distilled water. Transmission Oil Spec: Refer to manual for specific manual transmission fluid (MTF) and ACD/rear diff oil specifications. Typically GL-4 for manual gearbox, specialized fluids for ACD/diffs. Known Issues Common Issues: Timing belt failure (if not maintained), turbocharger wear, clutch wear, rust in certain climates, AYC pump failure (if equipped), potential for ringland failure...
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Mitsubishi Lancer EVO 4 & EVO 5 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Platform:
Mitsubishi E-platform
Codes
Generation Codes:
CP9A (EVO IV), CP9A (EVO V)
👋 Introduction
Market Position
Positioning:
High-performance rally homologation special, iconic JDM icon
Competitive Analysis
Competitors Evo4:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale
Competitors Evo5:
Subaru Impreza WRX STI (GC8 chassis), Toyota Celica GT-Four
Key Features
Performance Focus:
Designed for rally racing homologation, emphasizing advanced AWD and turbocharged performance
Brand Heritage
Rally Legacy:
Direct descendant of Mitsubishi's successful WRC Lancer Evolution cars
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Coverage:
All repairs covered A-Z, all models covered within the specified generations
Format
File Format:
PDF
Language
Language:
English
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine overhaul, diagnostics, tuning, lubrication, cooling, fuel injection, emission control systems (e.g., ACD, AYC)
Transmission:
Manual and Automatic transmission overhaul, diagnostics, clutch, driveline, transfer case, differentials (front, rear, ACD)
Suspension Steering:
Front and rear suspension components, steering rack, power steering system, wheel alignment specifications
Brakes:
Brake system diagnostics, hydraulic components, ABS, brake rotor and pad replacement, bleeding procedures
Electrical Electronics:
Full electrical schematics, wiring diagrams, starter, alternator, battery, lighting, ignition, instrument cluster, ECU diagnostics, SRS (Airbag) system
Body Chassis:
Body panel repair, interior trim removal/installation, glass replacement, chassis specifications, corrosion protection
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, fluid checks and changes
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides
Repair Rebuild:
Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation
Diagnostics:
On-board diagnostics (OBD-II) information, sensor testing, actuator testing, special tool usage
Technical Depth
Depth Level:
Comprehensive (factory-level detail for professional technicians)
📊 Manual Specifications
File Format
Searchability:
Fully searchable text for quick information retrieval
Printability:
Printable pages for workshop use
Layout:
Organized into logical sections with clear headings and subheadings
⚙️ Engine Specifications
Primary Engine
Engine Code Evo4:
4G63T
Engine Displacement Evo4:
2.0 Liters (1997cc)
Engine Configuration Evo4:
Inline-4, DOHC, 16-valve, Turbocharged
Performance
Horsepower Evo4:
280 PS (276 hp) @ 6,500 rpm (Japanese Domestic Market, Gentlemen's Agreement)
Torque Evo4:
350 Nm (258 lb-ft) @ 3,000 rpm
Horsepower Evo5:
280 PS (276 hp) @ 6,500 rpm (Japanese Domestic Market, Gentlemen's Agreement)
Torque Evo5:
373 Nm (275 lb-ft) @ 3,000 rpm (Increased torque over EVO IV)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel System Evo5:
Multi-point Fuel Injection (MPI), larger turbocharger, improved intercooler
Engine Code Evo5
Engine Code Evo5:
4G63T (Revised)
Engine Displacement Evo5
Engine Displacement Evo5:
2.0 Liters (1997cc)
Engine Configuration Evo5
Engine Configuration Evo5:
Inline-4, DOHC, 16-valve, Turbocharged
🔧 Transmission
Standard
Transmission Type Evo4:
5-speed Manual
Transmission Type Evo5:
5-speed Manual
Optional
Transmission Type Evo4 Optional:
None (Manual exclusively for performance models)
Transmission Type Evo5 Optional:
None
Features
AWD System Evo4:
Active Center Differential (ACD), Twin-Plate Clutch LSD (Front), Helical LSD (Rear)
AWD System Evo5:
Active Center Differential (ACD), Twin-Plate Clutch LSD (Front), Helical LSD (Rear) - enhanced grip and torque distribution
📐 Dimensions
Exterior
Length Evo4:
4,345 mm (171.1 in)
Width Evo4:
1,770 mm (69.7 in)
Height Evo4:
1,405 mm (55.3 in)
Wheelbase Evo4:
2,600 mm (102.4 in)
Length Evo5:
4,350 mm (171.3 in)
Width Evo5:
1,770 mm (69.7 in)
Height Evo5:
1,405 mm (55.3 in)
Wheelbase Evo5:
2,600 mm (102.4 in)
Weights
Curb Weight Evo4:
Approx. 1,400 kg (3,086 lbs)
Curb Weight Evo5:
Approx. 1,400 kg (3,086 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Primarily Japanese market, safety standards evolved)
Active Features
Active Safety Features:
ACD (Active Center Differential), AYC (Active Yaw Control - later models/optional), ABS (Anti-lock Braking System), Performance braking systems (e.g., Brembo on some trims)
Passive Features
Passive Safety Features:
SRS Airbags (Driver and Passenger), Reinforced chassis, Sport seats with enhanced bolstering
💡 Technology Features
Infotainment
Infotainment System:
Basic factory radio with cassette player/CD player (depending on trim/market). Focus on performance over luxury tech.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primary assistance provided by ACD and AYC for traction and handling.
Connectivity
Connectivity Options:
Basic; typically no advanced connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 km (4,500 miles) or 6 months, more frequent under hard driving conditions.
Spark Plug Replacement:
Refer to manual, typically around 30,000-50,000 km (18,000-30,000 miles) depending on plug type.
Fluid Specifications
Engine Oil Spec:
API SG/SH or ACEA A2-96 equivalent, SAE 10W-30 or 10W-40 recommended. Check manual for specific viscosity based on climate.
Coolant Spec:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Transmission Oil Spec:
Refer to manual for specific manual transmission fluid (MTF) and ACD/rear diff oil specifications. Typically GL-4 for manual gearbox, specialized fluids for ACD/diffs.
Known Issues
Common Issues:
Timing belt failure (if not maintained), turbocharger wear, clutch wear, rust in certain climates, AYC pump failure (if equipped), potential for ringland failure on heavily modified engines.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi Motors, with a strong lineage in rallying and performance vehicles.
Model Evolution
Evo4 Introduction:
Launched in August 1996, featuring a significantly revised chassis, larger intercooler, and improved ACD.
Evo5 Introduction:
Launched in January 1998, with a wider track, revised front bumper for better cooling, larger spoiler, and upgraded engine internals for increased torque.
Production
Production Period Evo4:
August 1996 – August 1998
Production Period Evo5:
January 1998 – January 1999
🏆 Awards & Recognition
Recognitions
Rally Success:
Basis for highly successful Mitsubishi Lancer WRC cars.
Motorsport Icon:
Widely regarded as one of the most iconic and capable performance cars of its era.
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