Mitsubishi Lancer Evolution 6 Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo VI) Codes Chassis Code: CP9A Engine Code Primary: 4G63T 👋 Introduction Market Position Market Segment: Performance Sedan / Rally Homologation Special Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione. Key Features Rally Heritage: Developed for WRC homologation, showcasing advanced all-wheel-drive and turbocharged engine technology. Performance Focus: Engineered for high performance with a focus on handling, acceleration, and driver engagement. Manual Usefulness Target Audience: Enthusiasts, DIY mechanics, professional technicians working on the Lancer Evolution VI. 📋 Manual Details Coverage Areas Manual Type: Workshop Manual / Service Manual Format: PDF Language: English Estimated Page Count: Detailed, likely several hundred pages covering all aspects 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing belt/chain, lubrication system (oil pump, filter), cooling system (radiator, water pump, fan), fuel system (injectors, fuel pump, tank), ignition system, emission control systems (charcoal canister). Engine Management: Engine control system (ECU diagnostics, sensor data - e.g., Knock Sensor, Camshaft Position Sensor), SFI System, Turbocharger operation and troubleshooting. Drivetrain: Manual Transaxle System (clutch system, clutch master/release cylinders, clutch pedal, transmission assembly, input/output shafts, torque converter clutch if applicable for specific variants), Drive Shafts (front/rear), Differential Case Assy. Suspension Steering: Front Suspension System (arms, stabilizer bar, shock absorber, coil spring), Rear Suspension System (arms, stabilizer bar, shock absorber, coil spring), Wheel and Tire System (alignment specifications, tire pressure), Steering System (power steering, steering column, steering sensor). Brakes: Brake System (master cylinder, booster, brake lines, calipers, pads, discs), Parking Brake (cable, lever), ABS/Skid Control System (sensors, actuators). Electrical: Wiring Diagrams, Wire Harness Repair, Starting System (starter motor, switch), Charging System (generator/alternator), Ignition System, Lighting System (headlamps, tail lamps, markers), Combination Meter, Audio & Visual System, Power Window Control System, Power Door Lock Control System, Power Mirror Control System, Sun Roof System. Body Interior Exterior: Body Repair, Hood, Doors (front/rear, glass, weatherstripping), Bumpers (front/rear), Roof Headlining, Windshield Glass, Wiper and Washer System (motors, blades, nozzles), Heater & Air Conditioner, Instrument Panel, Seats, Restraint Systems (airbags, seat belts). Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs (engine coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, drive belt inspection and replacement, battery maintenance, wiper blade replacement, air filter replacement. Troubleshooting: Diagnosis of common issues based on symptoms, electrical system fault finding using wiring diagrams, engine performance diagnostics, brake system issues, suspension noise diagnosis. Repair Rebuild: Engine component overhaul (pistons, rings, bearings), cylinder head reconditioning, transmission rebuilds, brake caliper and master cylinder replacement, suspension component replacement (shocks, arms), body panel repair, electrical component replacement. Diagnostics: Detailed diagnostic procedures for all major systems, including use of scan tools (OBD-II), sensor testing, circuit testing, and component testing. Technical Specifications: Torque specifications for all fasteners, valve clearance settings, engine timing procedures, wheel alignment angles, fluid capacities and specifications, tire size recommendations, electrical resistance values. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF for quick information retrieval. Print Quality Printability: Designed to be printable, allowing users to create hard copies of specific sections. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Displacement: 1998 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Performance Horsepower Ps: 276 PS (approx. 272 hp) at 6500 rpm (JDM/European specification) Torque Nm: 373 Nm (approx. 275 lb-ft) at 3000 rpm (JDM/European specification) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with electronic control Fuel Type: Unleaded Gasoline (Octane rating typically 95-98 RON recommended) Cooling System Coolant Type: Ethylene Glycol based coolant (typically a 50/50 mix with distilled water) Lubrication System Engine Oil Type: Synthetic or Semi-Synthetic 5W-30 or 10W-40 (refer to manual for specific viscosity based on climate) Engine Oil Capacity: Approx. 4.5 Liters (with filter change) 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission Optional Transmission Type: None (Evo VI exclusively featured a manual transmission) Features Differentials: Active front differential, electronically controlled multi-plate center differential (AYC - Active Yaw Control), Mechanical rear limited-slip differential (LSD). Fluid Specifications Manual Transmission Fluid: GL-4 or GL-5 Gear Oil (e.g., Mitsubishi DiaQueen LSD Gear Oil SAE 75W-90) Fluid Capacity Manual Transmission Fluid Capacity: Approx. 2.0 - 2.3 Liters 📐 Dimensions Exterior Length: Approx. 4,350 mm Width: Approx. 1,770 mm Height: Approx. 1,405 mm Wheelbase: Approx. 2,600 mm Weights Curb Weight: Approx. 1,360 kg Gross Vehicle Weight Rating: Typically around 1,700 kg 🛡️ Safety Features Ratings Crash Test Results: Specific ratings vary by region and testing body; generally considered a robustly built vehicle for its era, but safety standards have evolved significantly. Passive Features Airbags: Driver and front passenger airbags (standard), optional side airbags on some models. Seat...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VI (Evo VI)

Codes

Chassis Code:

Engine Code Primary:

4G63T

👋 Introduction

Market Position

Market Segment:

Performance Sedan / Rally Homologation Special

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione.

Key Features

Rally Heritage:

Developed for WRC homologation, showcasing advanced all-wheel-drive and turbocharged engine technology.

Performance Focus:

Engineered for high performance with a focus on handling, acceleration, and driver engagement.

Manual Usefulness

Target Audience:

Enthusiasts, DIY mechanics, professional technicians working on the Lancer Evolution VI.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Manual / Service Manual

Format:

Language:

English

Estimated Page Count:

Detailed, likely several hundred pages covering all aspects

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing belt/chain, lubrication system (oil pump, filter), cooling system (radiator, water pump, fan), fuel system (injectors, fuel pump, tank), ignition system, emission control systems (charcoal canister).

Engine Management:

Engine control system (ECU diagnostics, sensor data - e.g., Knock Sensor, Camshaft Position Sensor), SFI System, Turbocharger operation and troubleshooting.

Drivetrain:

Manual Transaxle System (clutch system, clutch master/release cylinders, clutch pedal, transmission assembly, input/output shafts, torque converter clutch if applicable for specific variants), Drive Shafts (front/rear), Differential Case Assy.

Suspension Steering:

Front Suspension System (arms, stabilizer bar, shock absorber, coil spring), Rear Suspension System (arms, stabilizer bar, shock absorber, coil spring), Wheel and Tire System (alignment specifications, tire pressure), Steering System (power steering, steering column, steering sensor).

Brakes:

Brake System (master cylinder, booster, brake lines, calipers, pads, discs), Parking Brake (cable, lever), ABS/Skid Control System (sensors, actuators).

Electrical:

Wiring Diagrams, Wire Harness Repair, Starting System (starter motor, switch), Charging System (generator/alternator), Ignition System, Lighting System (headlamps, tail lamps, markers), Combination Meter, Audio & Visual System, Power Window Control System, Power Door Lock Control System, Power Mirror Control System, Sun Roof System.

Body Interior Exterior:

Body Repair, Hood, Doors (front/rear, glass, weatherstripping), Bumpers (front/rear), Roof Headlining, Windshield Glass, Wiper and Washer System (motors, blades, nozzles), Heater & Air Conditioner, Instrument Panel, Seats, Restraint Systems (airbags, seat belts).

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs (engine coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, drive belt inspection and replacement, battery maintenance, wiper blade replacement, air filter replacement.

Troubleshooting:

Diagnosis of common issues based on symptoms, electrical system fault finding using wiring diagrams, engine performance diagnostics, brake system issues, suspension noise diagnosis.

Repair Rebuild:

Engine component overhaul (pistons, rings, bearings), cylinder head reconditioning, transmission rebuilds, brake caliper and master cylinder replacement, suspension component replacement (shocks, arms), body panel repair, electrical component replacement.

Diagnostics:

Detailed diagnostic procedures for all major systems, including use of scan tools (OBD-II), sensor testing, circuit testing, and component testing.

Technical Specifications:

Torque specifications for all fasteners, valve clearance settings, engine timing procedures, wheel alignment angles, fluid capacities and specifications, tire size recommendations, electrical resistance values.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable PDF for quick information retrieval.

Print Quality

Printability:

Designed to be printable, allowing users to create hard copies of specific sections.

Binding Type

Binding Type:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled

Displacement:

1998 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Performance

Horsepower Ps:

276 PS (approx. 272 hp) at 6500 rpm (JDM/European specification)

Torque Nm:

373 Nm (approx. 275 lb-ft) at 3000 rpm (JDM/European specification)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with electronic control

Fuel Type:

Unleaded Gasoline (Octane rating typically 95-98 RON recommended)

Cooling System

Coolant Type:

Ethylene Glycol based coolant (typically a 50/50 mix with distilled water)

Lubrication System

Engine Oil Type:

Synthetic or Semi-Synthetic 5W-30 or 10W-40 (refer to manual for specific viscosity based on climate)

Engine Oil Capacity:

Approx. 4.5 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Optional

Transmission Type:

None (Evo VI exclusively featured a manual transmission)

Features

Differentials:

Active front differential, electronically controlled multi-plate center differential (AYC - Active Yaw Control), Mechanical rear limited-slip differential (LSD).

Fluid Specifications

Manual Transmission Fluid:

GL-4 or GL-5 Gear Oil (e.g., Mitsubishi DiaQueen LSD Gear Oil SAE 75W-90)

Fluid Capacity

Manual Transmission Fluid Capacity:

Approx. 2.0 - 2.3 Liters

📐 Dimensions

Exterior

Length:

Approx. 4,350 mm

Width:

Approx. 1,770 mm

Height:

Approx. 1,405 mm

Wheelbase:

Approx. 2,600 mm

Weights

Curb Weight:

Approx. 1,360 kg

Gross Vehicle Weight Rating:

Typically around 1,700 kg

🛡️ Safety Features

Ratings

Crash Test Results:

Specific ratings vary by region and testing body; generally considered a robustly built vehicle for its era, but safety standards have evolved significantly.

Passive Features

Airbags:

Driver and front passenger airbags (standard), optional side airbags on some models.

Seat Belts:

3-point inertia-reel seat belts with pre-tensioners and force limiters (front), 3-point belts (rear).

Chassis Construction:

Reinforced unibody structure with crumple zones.

Active Features

Anti-lock Braking System (ABS) with EBD (Electronic Brakeforce Distribution)

Traction Control:

Active Skid Control (often integrated with AYC system)

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player, often with premium speaker options. Typically 1-DIN unit.

Driver Assistance

ABS And Traction Control:

Integral ABS and Active Skid Control systems contribute to dynamic stability and control.

Connectivity

Connectivity Options:

Limited by era; basic antenna and speaker wiring. No integrated Bluetooth or USB connectivity in factory form.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions. Performance driving may necessitate more frequent changes.

Spark Plug Replacement:

Usually around 30,000 - 60,000 miles (48,000 - 96,000 km) for iridium spark plugs, potentially sooner for standard plugs.

Timing Belt Replacement:

Mitsubishi typically recommended timing belt replacement every 60,000 - 90,000 miles (96,000 - 145,000 km) or 5-7 years. This is a critical maintenance item for the 4G63T engine.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid Type:

Dexron II/III ATF or specific power steering fluid (refer to manual)

Fluid Capacities

Engine Coolant Capacity:

Approx. 7.5 Liters

Known Issues

Engine Reliability:

The 4G63T engine is generally robust, but common issues can include turbocharger wear, piston ring land failure under extreme stress (especially with aggressive tuning), and coolant leaks from the oil cooler or hoses.

Drivetrain Wear:

Clutch wear is common given the performance-oriented nature of the car. AYC pump and sensors can be prone to failure over time.

Suspension Components:

Bushings and ball joints can wear out due to spirited driving and the demands placed on the suspension.

Parts Identification

Oil Filter Part Number Example:

Mitsubishi MD135956 or equivalent aftermarket (e.g., Wix 51356, K&N HP-3001)

📚 Vehicle History

Brand Heritage

Motorsport Roots:

Mitsubishi's extensive experience in rallying, particularly with the Lancer platform, heavily influenced the development of the Evolution series.

Model Evolution

Evolution Series Origin:

The Lancer Evolution was created to homologate the Lancer for Group A racing in the World Rally Championship.

Evo Vi Development:

Evo VI was a significant update from the Evo V, featuring a revised turbocharger, intercooler, pistons, and a larger exhaust system, alongside improvements to the AYC system. The Tommi Mäkinen Edition was a special variant celebrating his WRC championships.

Production

Production Years:

1999 - 2001

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorsport Achievements:

The Lancer Evolution VI, particularly the Tommi Mäkinen Edition, celebrated Mitsubishi's four consecutive WRC manufacturer's titles (1996-1999). The Evo VI itself was a dominant force in rally racing.

Ratings

Performance Reviews:

Consistently praised by automotive journalists and enthusiasts for its exceptional handling, all-wheel-drive traction, and potent turbocharged engine.