Mitsubishi Lancer Evolution 4 5 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: V Codes Chassis Code Evo Iv: CN9A Chassis Code Evo V: CP9A 👋 Introduction Market Position Segment: Performance Sedan / Rally Homologation Special Target Audience: Enthusiasts, DIY mechanics, tuners, and owners of Mitsubishi Lancer Evolution IV and V models Competitive Analysis Rivals: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Audi S3 (8L), Lancia Delta Integrale Key Features Evolution Iv Focus: Introduction of Active Yaw Control (AYC), stronger chassis, improved aerodynamics, larger intercooler Evolution V Focus: Wider track, larger front bumper openings, updated ECU, revised turbocharger, firmer suspension settings, larger wheels/tires Value Proposition Manual Benefit: Provides essential technical data for maintenance, repair, and understanding the advanced systems of these iconic performance vehicles 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital Download (PDF) Page Count: Extensive (Detailed content implies hundreds of pages) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Turbocharger System, Transmission (Manual & Automatic variants) Chassis: Suspension (Front & Rear), Steering System, Drivetrain (4WD System, ACD, AYC), Braking System (ABS) Electrical: Engine Control Unit (ECU), Body Control Module (BCM), Lighting System, Instrumentation, Power Accessories, Audio System, SRS (Airbag) System Body And Interior: Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacements, Spark plug replacement, Belt inspection/replacement, Fluid checks and changes Diagnostics And Troubleshooting: Common issues, DTC (Diagnostic Trouble Code) interpretation, Circuit testing, Component testing, Fault finding guides Repair And Overhaul: Engine disassembly and reassembly, Transmission overhaul, Suspension component replacement, Brake caliper and rotor servicing, Electrical component repair, Turbocharger servicing Technical Adjustments: Alignment specifications, Engine timing, Idle speed adjustments, ACD/AYC system calibration (where applicable) Technical Depth Depth Level: Comprehensive (Covers from basic maintenance to full engine/transmission rebuilds) Diagnostic Capabilities: Detailed wiring diagrams, component locations, diagnostic flowcharts, sensor data interpretation 📊 Manual Specifications File Format Format Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality: Printable at user's discretion, likely high-resolution scans of original factory documentation Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 (various iterations) Engine Type: 2.0L Inline-4, DOHC, 16-valve, Turbocharged Bore X Stroke Evo Iv: 85.0 mm x 88.0 mm Bore X Stroke Evo V: 85.0 mm x 88.0 mm Compression Ratio Evo Iv: 8.5:1 Compression Ratio Evo V: 8.8:1 (typically) Performance Horsepower Evo Iv: 280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese Spec) Torque Evo Iv: 350 Nm (258 lb-ft) at 3,000 rpm (Japanese Spec) Horsepower Evo V: 280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese Spec); Higher output in some export markets Torque Evo V: 373 Nm (275 lb-ft) at 3,000 rpm (Japanese Spec); Higher torque in some export markets Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI) Turbocharger: Mitsubishi TD05HR-16G6-10.5T (or similar variants) Recommended Fuel: Premium Unleaded (95 RON or higher recommended) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (Getrag-based or Mitsubishi F5M51) Optional Transmission Type: 4-speed Automatic Transmission (less common for performance variants) Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC - primarily Evo IV and above) Clutch: Hydraulically actuated, single dry plate Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (refer to specific manual for exact specs) Transfer Case Fluid: API GL-4, SAE 75W-90 (refer to specific manual for exact specs) Rear Differential Fluid: API GL-5, SAE 80W-90 (or 75W-90 depending on LSD type) 📐 Dimensions Exterior Length Evo Iv: 4,350 mm (171.3 in) Width Evo Iv: 1,770 mm (69.7 in) Height Evo Iv: 1,415 mm (55.7 in) Wheelbase Evo Iv: 2,600 mm (102.4 in) Length Evo V: 4,360 mm (171.7 in) Width Evo V: 1,770 mm (69.7 in) Height Evo V: 1,415 mm (55.7 in) Wheelbase Evo V: 2,600 mm (102.4 in) Weights Curb Weight Evo Iv: 1,400 kg (3,086 lb) Curb Weight Evo V: 1,400 kg (3,086 lb) - 1,460 kg (3,219 lb) depending on spec Gross Vehicle Weight Rating: Refer to vehicle VIN plate Wheels And Tires Wheel Size Evo Iv: 17 x 7.5 inches Tire Size Evo Iv: 225/45R17 Wheel Size Evo V: 17 x 8.0 inches Tire Size Evo V: 235/45R17 Bolt Pattern: 5x114.3 mm (5x4.5 inches) Center Bore: 67.1 mm 🛡️ Safety Features Ratings Crash Test Data: Limited official crash test data available for these specific JDM models from common agencies of the era; focus on structural integrity for rally performance Active Features Active Yaw Control: AYC (Active Yaw Control) for torque vectoring to rear wheels, enhancing cornering stability. Active Center Differential: ACD (Active Center Differential) electronically controls torque distribution between front and rear axles. Anti Lock Braking System: ABS (Anti-lock Braking System) standard on most variants. Passive Features Airbags: Driver and passenger front airbags standard on later models and...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generation:

Codes

Chassis Code Evo Iv:

Chassis Code Evo V:

👋 Introduction

Market Position

Segment:

Performance Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, DIY mechanics, tuners, and owners of Mitsubishi Lancer Evolution IV and V models

Competitive Analysis

Rivals:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Audi S3 (8L), Lancia Delta Integrale

Key Features

Evolution Iv Focus:

Introduction of Active Yaw Control (AYC), stronger chassis, improved aerodynamics, larger intercooler

Evolution V Focus:

Wider track, larger front bumper openings, updated ECU, revised turbocharger, firmer suspension settings, larger wheels/tires

Value Proposition

Manual Benefit:

Provides essential technical data for maintenance, repair, and understanding the advanced systems of these iconic performance vehicles

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

Page Count:

Extensive (Detailed content implies hundreds of pages)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Ignition System, Exhaust System, Turbocharger System, Transmission (Manual & Automatic variants)

Chassis:

Suspension (Front & Rear), Steering System, Drivetrain (4WD System, ACD, AYC), Braking System (ABS)

Electrical:

Engine Control Unit (ECU), Body Control Module (BCM), Lighting System, Instrumentation, Power Accessories, Audio System, SRS (Airbag) System

Body And Interior:

Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System

Procedures Included

Maintenance:

Scheduled maintenance, Oil changes, Filter replacements, Spark plug replacement, Belt inspection/replacement, Fluid checks and changes

Diagnostics And Troubleshooting:

Common issues, DTC (Diagnostic Trouble Code) interpretation, Circuit testing, Component testing, Fault finding guides

Repair And Overhaul:

Engine disassembly and reassembly, Transmission overhaul, Suspension component replacement, Brake caliper and rotor servicing, Electrical component repair, Turbocharger servicing

Technical Adjustments:

Alignment specifications, Engine timing, Idle speed adjustments, ACD/AYC system calibration (where applicable)

Technical Depth

Depth Level:

Comprehensive (Covers from basic maintenance to full engine/transmission rebuilds)

Diagnostic Capabilities:

Detailed wiring diagrams, component locations, diagnostic flowcharts, sensor data interpretation

📊 Manual Specifications

File Format

Format Type:

Searchability:

Searchable text content for quick information retrieval

Print Quality:

Printable at user's discretion, likely high-resolution scans of original factory documentation

Delivery Method:

Instant Download

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63 (various iterations)

Engine Type:

2.0L Inline-4, DOHC, 16-valve, Turbocharged

Bore X Stroke Evo Iv:

85.0 mm x 88.0 mm

Bore X Stroke Evo V:

85.0 mm x 88.0 mm

Compression Ratio Evo Iv:

8.5:1

Compression Ratio Evo V:

8.8:1 (typically)

Performance

Horsepower Evo Iv:

280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese Spec)

Torque Evo Iv:

350 Nm (258 lb-ft) at 3,000 rpm (Japanese Spec)

Horsepower Evo V:

280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese Spec); Higher output in some export markets

Torque Evo V:

373 Nm (275 lb-ft) at 3,000 rpm (Japanese Spec); Higher torque in some export markets

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI)

Turbocharger:

Mitsubishi TD05HR-16G6-10.5T (or similar variants)

Recommended Fuel:

Premium Unleaded (95 RON or higher recommended)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (Getrag-based or Mitsubishi F5M51)

Optional

Transmission Type:

4-speed Automatic Transmission (less common for performance variants)

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Center Differential (ACD) and Active Yaw Control (AYC - primarily Evo IV and above)

Clutch:

Hydraulically actuated, single dry plate

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (refer to specific manual for exact specs)

Transfer Case Fluid:

API GL-4, SAE 75W-90 (refer to specific manual for exact specs)

Rear Differential Fluid:

API GL-5, SAE 80W-90 (or 75W-90 depending on LSD type)

📐 Dimensions

Exterior

Length Evo Iv:

4,350 mm (171.3 in)

Width Evo Iv:

1,770 mm (69.7 in)

Height Evo Iv:

1,415 mm (55.7 in)

Wheelbase Evo Iv:

2,600 mm (102.4 in)

Length Evo V:

4,360 mm (171.7 in)

Width Evo V:

1,770 mm (69.7 in)

Height Evo V:

1,415 mm (55.7 in)

Wheelbase Evo V:

2,600 mm (102.4 in)

Weights

Curb Weight Evo Iv:

1,400 kg (3,086 lb)

Curb Weight Evo V:

1,400 kg (3,086 lb) - 1,460 kg (3,219 lb) depending on spec

Gross Vehicle Weight Rating:

Refer to vehicle VIN plate

Wheels And Tires

Wheel Size Evo Iv:

17 x 7.5 inches

Tire Size Evo Iv:

225/45R17

Wheel Size Evo V:

17 x 8.0 inches

Tire Size Evo V:

235/45R17

Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Center Bore:

67.1 mm

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official crash test data available for these specific JDM models from common agencies of the era; focus on structural integrity for rally performance

Active Features

Active Yaw Control:

AYC (Active Yaw Control) for torque vectoring to rear wheels, enhancing cornering stability.

Active Center Differential:

ACD (Active Center Differential) electronically controls torque distribution between front and rear axles.

Anti Lock Braking System:

ABS (Anti-lock Braking System) standard on most variants.

Passive Features

Airbags:

Driver and passenger front airbags standard on later models and export markets.

Seatbelts:

3-point seatbelts with pre-tensioners (front)

Chassis Design:

Reinforced chassis and safety cage elements due to rally homologation requirements.

💡 Technology Features

Infotainment

Audio System:

Factory fitted CD/Radio system with AM/FM tuner. Upgradeable for modern audio sources.

Instrumentation:

Comprehensive gauge cluster including tachometer, speedometer, boost gauge, and warning lights for AYC/ACD systems.

Driver Assistance

Performance Electronics:

Integration of AYC and ACD systems to enhance driving dynamics and traction in varying conditions.

Connectivity

Original Features:

Limited original connectivity; primarily focused on mechanical and performance systems. Modern aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-10,000 km (3,000-6,000 miles) or 6 months, depending on driving conditions (refer to manual)

Air Filter Replacement:

Every 15,000-30,000 km (9,000-18,000 miles) or as needed based on inspection.

Spark Plug Replacement:

Every 30,000-60,000 km (18,000-36,000 miles) for standard plugs; higher for iridium or platinum plugs.

Timing Belt Replacement:

Every 90,000-100,000 km (56,000-62,000 miles) or 5-7 years. Crucial due to interference engine design.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 Liters (4.8 US Quarts) with filter change.

Engine Oil Viscosity:

10W-30 or 10W-40 API SG/SH/SJ (refer to manual for specific recommendations and temperature ranges)

Coolant Type:

Ethylene glycol-based antifreeze (Mitsubishi Super Long Life Coolant or equivalent)

Known Issues

Engine Bearing Wear:

Rod bearing failure can occur, especially in modified or hard-driven engines. Regular oil analysis and proper warm-up/cool-down are critical.

Turbocharger Failure:

Oil starvation or carbon buildup can lead to turbocharger failure. Proper maintenance and ensuring oil flow are key.

Ayc Pump Failure:

The AYC hydraulic pump can fail over time, leading to loss of yaw control functionality. Regular fluid checks and system diagnostics are recommended.

Rust And Corrosion:

Areas like fender lips, rear quarter panels, and suspension components can be susceptible to rust, especially in regions with harsh weather.

Clutch Wear:

High-performance nature of the car means the clutch can wear faster than standard vehicles, especially with aggressive driving.

📚 Vehicle History

Brand Heritage

Mitsubishi Motorsport:

Mitsubishi's rich history in rally motorsport, culminating in multiple WRC manufacturer and driver championships, directly influenced the Lancer Evolution lineage.

Model Evolution

Evo I To Iii:

The foundation laid by the first three generations of Lancer Evolution established its reputation as a formidable rally car and potent road-going performance machine.

Evo Iv Introduction:

Launched in August 1996, the Evo IV marked a significant technological leap with the introduction of AYC and a redesigned chassis based on the larger Mitsubishi Galant platform.

Evo V Introduction:

Released in January 1998, the Evo V was an evolution of the IV, featuring a wider track, flared fenders, larger wheels, and mechanical refinements to improve handling and performance further, often referred to as the 'World Rally Car homologation' model.

Production

Production Period Evo Iv:

August 1996 – August 1998

Production Period Evo V:

January 1998 – January 1999

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

🏆 Awards & Recognition

Recognitions

Motorsport Dominance:

These models were the basis for successful rally cars, demonstrating their engineering prowess. The Evolution lineage consistently won championships in the World Rally Championship.

Performance Acclaim:

Widely praised by automotive press for their exhilarating performance, handling, and advanced all-wheel-drive systems, cementing their 'legend' status.