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Mitsubishi Lancer EVO 6 Service Repair Workshop Manual

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๐Ÿท๏ธ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo VI) Common Name: Evo VI Generation Generation Identifier: CP9A Codes Chassis Code: CP9A ๐Ÿ‘‹ Introduction Market Position Positioning: The Mitsubishi Lancer Evolution VI represented the pinnacle of rally-bred performance for its era, offering a potent blend of power, handling, and advanced technology aimed at serious enthusiasts and competitive drivers. Competitive Analysis Competitors: Competed directly with iconic performance sedans such as the Subaru Impreza WRX STI, Ford Escort RS Cosworth, and Lancia Delta Integrale. Key Features Performance Focus: Renowned for its aggressive styling, potent turbocharged engine, sophisticated all-wheel-drive system with Active Yaw Control (AYC), and exceptional handling capabilities. Rally Heritage: Directly influenced by Mitsubishi's WRC success, featuring homologation specials like the Tommi Mรคkinen Edition. Manual Value Value Proposition: This manual provides the essential, factory-accurate information required to maintain, diagnose, and repair the Lancer Evolution VI, ensuring optimal performance and longevity for this highly specialized vehicle. ๐Ÿ“‹ Manual Details Coverage Areas Models Covered: All Lancer Evolution VI models (e.g., GSR, RS, Tommi Mรคkinen Edition) Regions Covered: Primarily Japan Domestic Market (JDM) specifications, with applicable global variations noted where relevant Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) ๐Ÿ“– Manual Coverage Systems Covered Engine: 4G63T (2.0L DOHC MIVEC Turbocharged inline-4) Engine Management: ECU diagnostics, sensor testing, fuel injection control, ignition timing Transmission: 5-speed manual (Type RZ) and 5-speed manual (Type RS) options Transfer Case: Active Transfer (AYC - Active Yaw Control) system Differentials: Front and Rear Limited Slip Differentials (LSD) Suspension: MacPherson strut front, multi-link rear, adjustable dampers (RS models), AYC integration Brakes: Front Brembo 4-piston calipers, rear 2-piston calipers, ABS system Steering: Hydraulic power steering, steering rack and column Electrical: Full vehicle wiring diagrams, battery, alternator, starter, lighting, instrumentation, ECU pinouts Bodywork: Exterior panels, interior trim, doors, windows, chassis repair HVAC: Air conditioning, heating, ventilation system components and repair Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator Cooling System: Radiator, water pump, thermostat, coolant passages Exhaust System: Exhaust manifold, catalytic converter, muffler Wheels Tires: Wheel specifications, tire fitment, alignment procedures Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement Troubleshooting: Diagnostic flowcharts for common and uncommon issues, fault code interpretation Repair: Component removal and installation, adjustments, rebuilds (e.g., engine, transmission, turbocharger) Diagnostics: Step-by-step diagnostic procedures for all major systems, electrical testing methods Engine Rebuild: Complete engine overhaul instructions, torque specifications, assembly procedures Transmission Overhaul: Gearbox disassembly, inspection, reassembly, clutch service Turbocharger Service: Turbocharger inspection, rebuild, and replacement procedures Suspension Alignment: Wheel alignment specifications and adjustment procedures Brake System Service: Brake pad replacement, caliper service, bleeding procedures, ABS component testing Electrical Diagnostics: Wiring diagram interpretation, component testing with multimeters and oscilloscopes Body Repair: Dent removal, panel replacement, rust repair techniques Technical Depth Depth: Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and troubleshooting. ๐Ÿ“Š Manual Specifications File Format Searchability: Fully searchable PDF text Printability: Printable, allowing for hard copy reference Quality: High-resolution scans of original factory documentation Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) โš™๏ธ Engine Specifications Primary Engine Engine Code: 4G63T Configuration: 2.0L (1997cc) DOHC MIVEC Turbocharged Inline-4 Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Cylinder Head: DOHC 16-valve with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system Turbocharger: Mitsubishi TD05HR-16G or similar twin-scroll turbocharger with intercooler Performance Horsepower: Approx. 276 hp (206 kW) @ 6500 rpm (JDM Spec, often underestimated) Torque: Approx. 275 lb-ft (373 Nm) @ 3000 rpm (JDM Spec) Fuel System Injection: Multi-point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (95-98 RON) Fuel Pump: High-flow electric fuel pump ๐Ÿ”ง Transmission Standard Type: 5-speed Manual Gear Ratios: Specific ratios for RZ and RS models available in manual Optional Transmission Options: None (Manual transmission was standard across all Evo VI variants) Features Driver Selectable Modes: N/A (No driver selectable modes for transmission) Clutch: Hydraulically actuated single-plate or twin-plate clutch (RZ models) ๐Ÿ“ Dimensions Exterior Length: Approx. 4,350 mm (171.3 in) Width: Approx. 1,770 mm (69.7 in) Height: Approx. 1,415 mm (55.7 in) Wheelbase: Approx. 2,600 mm (102.4 in) Track Width Front: Approx. 1,470 mm (57.9 in) Track Width Rear: Approx. 1,465 mm (57.7 in) Weights Curb Weight: Approx. 1,240 - 1,300 kg (2,734 - 2,866 lbs) depending on trim Gross Vehicle Weight: Refer to vehicle placard or manual Cargo Trunk Volume: Approx. 0.275 mยณ (9.7 cu ft) ๐Ÿ›ก๏ธ Safety Features Ratings Crash Test Results: N/A (Modern crash testing standards were less prevalent at time of release for such vehicles; focus on inherent design safety) Active Features Braking System: ABS (Anti-lock Braking System) with EBD (Electronic Brakeforce Distribution) Traction Control: AYC (Active Yaw Control) system and ACD (Active Center Differential) Stability Control: N/A...
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Mitsubishi Lancer EVO 6 Service Repair Workshop Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI (Evo VI)
Common Name:
Evo VI
Generation
Generation Identifier:
CP9A
Codes
Chassis Code:
CP9A
๐Ÿ‘‹ Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution VI represented the pinnacle of rally-bred performance for its era, offering a potent blend of power, handling, and advanced technology aimed at serious enthusiasts and competitive drivers.
Competitive Analysis
Competitors:
Competed directly with iconic performance sedans such as the Subaru Impreza WRX STI, Ford Escort RS Cosworth, and Lancia Delta Integrale.
Key Features
Performance Focus:
Renowned for its aggressive styling, potent turbocharged engine, sophisticated all-wheel-drive system with Active Yaw Control (AYC), and exceptional handling capabilities.
Rally Heritage:
Directly influenced by Mitsubishi's WRC success, featuring homologation specials like the Tommi Mรคkinen Edition.
Manual Value
Value Proposition:
This manual provides the essential, factory-accurate information required to maintain, diagnose, and repair the Lancer Evolution VI, ensuring optimal performance and longevity for this highly specialized vehicle.
๐Ÿ“‹ Manual Details
Coverage Areas
Models Covered:
All Lancer Evolution VI models (e.g., GSR, RS, Tommi Mรคkinen Edition)
Regions Covered:
Primarily Japan Domestic Market (JDM) specifications, with applicable global variations noted where relevant
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
๐Ÿ“– Manual Coverage
Systems Covered
Engine:
4G63T (2.0L DOHC MIVEC Turbocharged inline-4)
Engine Management:
ECU diagnostics, sensor testing, fuel injection control, ignition timing
Transmission:
5-speed manual (Type RZ) and 5-speed manual (Type RS) options
Transfer Case:
Active Transfer (AYC - Active Yaw Control) system
Differentials:
Front and Rear Limited Slip Differentials (LSD)
Suspension:
MacPherson strut front, multi-link rear, adjustable dampers (RS models), AYC integration
Brakes:
Front Brembo 4-piston calipers, rear 2-piston calipers, ABS system
Steering:
Hydraulic power steering, steering rack and column
Electrical:
Full vehicle wiring diagrams, battery, alternator, starter, lighting, instrumentation, ECU pinouts
Bodywork:
Exterior panels, interior trim, doors, windows, chassis repair
HVAC:
Air conditioning, heating, ventilation system components and repair
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator
Cooling System:
Radiator, water pump, thermostat, coolant passages
Exhaust System:
Exhaust manifold, catalytic converter, muffler
Wheels Tires:
Wheel specifications, tire fitment, alignment procedures
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement
Troubleshooting:
Diagnostic flowcharts for common and uncommon issues, fault code interpretation
Repair:
Component removal and installation, adjustments, rebuilds (e.g., engine, transmission, turbocharger)
Diagnostics:
Step-by-step diagnostic procedures for all major systems, electrical testing methods
Engine Rebuild:
Complete engine overhaul instructions, torque specifications, assembly procedures
Transmission Overhaul:
Gearbox disassembly, inspection, reassembly, clutch service
Turbocharger Service:
Turbocharger inspection, rebuild, and replacement procedures
Suspension Alignment:
Wheel alignment specifications and adjustment procedures
Brake System Service:
Brake pad replacement, caliper service, bleeding procedures, ABS component testing
Electrical Diagnostics:
Wiring diagram interpretation, component testing with multimeters and oscilloscopes
Body Repair:
Dent removal, panel replacement, rust repair techniques
Technical Depth
Depth:
Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and troubleshooting.
๐Ÿ“Š Manual Specifications
File Format
Searchability:
Fully searchable PDF text
Printability:
Printable, allowing for hard copy reference
Quality:
High-resolution scans of original factory documentation
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
โš™๏ธ Engine Specifications
Primary Engine
Engine Code:
4G63T
Configuration:
2.0L (1997cc) DOHC MIVEC Turbocharged Inline-4
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Cylinder Head:
DOHC 16-valve with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system
Turbocharger:
Mitsubishi TD05HR-16G or similar twin-scroll turbocharger with intercooler
Performance
Horsepower:
Approx. 276 hp (206 kW) @ 6500 rpm (JDM Spec, often underestimated)
Torque:
Approx. 275 lb-ft (373 Nm) @ 3000 rpm (JDM Spec)
Fuel System
Injection:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (95-98 RON)
Fuel Pump:
High-flow electric fuel pump
๐Ÿ”ง Transmission
Standard
Type:
5-speed Manual
Gear Ratios:
Specific ratios for RZ and RS models available in manual
Optional
Transmission Options:
None (Manual transmission was standard across all Evo VI variants)
Features
Driver Selectable Modes:
N/A (No driver selectable modes for transmission)
Clutch:
Hydraulically actuated single-plate or twin-plate clutch (RZ models)
๐Ÿ“ Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Track Width Front:
Approx. 1,470 mm (57.9 in)
Track Width Rear:
Approx. 1,465 mm (57.7 in)
Weights
Curb Weight:
Approx. 1,240 - 1,300 kg (2,734 - 2,866 lbs) depending on trim
Gross Vehicle Weight:
Refer to vehicle placard or manual
Cargo
Trunk Volume:
Approx. 0.275 mยณ (9.7 cu ft)
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Results:
N/A (Modern crash testing standards were less prevalent at time of release for such vehicles; focus on inherent design safety)
Active Features
Braking System:
ABS (Anti-lock Braking System) with EBD (Electronic Brakeforce Distribution)
Traction Control:
AYC (Active Yaw Control) system and ACD (Active Center Differential)
Stability Control:
N/A (No specific Electronic Stability Control system as understood today)
Passive Features
Airbags:
Driver and front passenger airbags (standard on most models)
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners
Body Structure:
Reinforced safety cell, energy-absorbing crumple zones
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium sound system.
Navigation:
N/A (Navigation systems were not commonly integrated in this era of performance cars).
Driver Assistance
Driver Aids:
Active Yaw Control (AYC) and Active Center Differential (ACD) are key technological features managing power distribution and handling.
Connectivity
Connectivity Features:
N/A (Basic connectivity features like power windows, central locking typical of the era).
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6 months, depending on driving conditions. High-performance driving may necessitate more frequent changes.
Timing Belt Replacement:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-7 years. Critical for the 4G63T engine.
Spark Plug Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) depending on plug type. Use high-quality iridium or platinum plugs.
Coolant Flush:
Every 2 years or 40,000 km (25,000 miles).
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on ambient temperature). Synthetic oil highly recommended.
Transmission Fluid:
API GL-4 or GL-5 SAE 75W-90 (gearbox oil). Specific AYC fluid for rear differential/AYC unit (check manual for exact specification).
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 high-performance brake fluid.
Power Steering Fluid:
Mitsubishi Genuine Power Steering Fluid or equivalent Dexron II/III ATF.
Known Issues
Engine Oil Consumption:
Can occur if engine is heavily used or worn; check oil levels regularly.
Ayc Pump Failure:
The AYC hydraulic pump can fail over time, leading to warning lights and loss of the AYC system's function. Replacement is often required.
Clutch Wear:
High-performance nature of the vehicle can lead to accelerated clutch wear, especially with aggressive driving.
Timing Belt:
Critical component; failure can lead to catastrophic engine damage. Adhering to replacement intervals is paramount.
Exhaust Manifold Cracks:
Cast iron exhaust manifolds can develop cracks due to heat cycles; a common upgrade is to a tubular stainless steel manifold.
Rust:
As with many vehicles of this era, rust can be an issue, particularly in areas with harsh winters. Chassis and wheel arches are common areas.
๐Ÿ“š Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors Corporation has a deep and successful history in motorsport, particularly in the World Rally Championship (WRC), which heavily influenced the Lancer Evolution lineage.
Model Evolution
Evo Lineage:
The Evolution VI (CP9A) followed the highly successful Evo IV and V, building upon their mechanical and aerodynamic advancements. It introduced further refinements and a more aggressive styling.
Key Changes From Evo V:
Revised front bumper, redesigned headlights and fog lights, larger rear spoiler, upgraded turbocharger, improved cooling system, and mechanical tweaks to suspension and AYC.
Special Editions:
Tommi Mรคkinen Edition (TME) - launched in 2000, commemorating five-time WRC champion Tommi Mรคkinen. Featured specific styling, mechanical upgrades (e.g., improved turbo, suspension tuning), and often a reduced steering ratio.
Production
Production Years:
1999 - 2001
Production Locations:
Japan
๐Ÿ† Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution series, including the Evo VI, is a legend in rallying, winning numerous WRC championships and rallies, solidifying its reputation for performance and durability.
Critical Acclaim:
Widely praised by automotive journalists and enthusiasts for its exceptional handling, braking, and potent powertrain, often cited as one of the best driver's cars of its generation.
Certifications
Homologation:
The Evo VI was built to homologate Mitsubishi for Group A racing in the World Rally Championship.
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