Mitsubishi Lancer Evolution 6 Evo Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Model Variant: GSR, RS Generation Generation Code: CP9A Generation Years: 1999-2001 Codes Chassis Code: CP9A Engine Code: 4G63T 👋 Introduction Market Position Market Position: Performance Rally Homologation Special / Sports Sedan Competitive Analysis Competitive Analysis: Directly competed with vehicles like Subaru Impreza WRX STI, Ford Focus RS, and other high-performance AWD sedans of its era. Key Features Key Features: Iconic turbocharged 4G63T engine, advanced All-Wheel Drive (AYC, ACD, Super AYC in later models), potent braking systems, and rally-bred chassis dynamics. The Evo VI is renowned for its aggressive styling and performance pedigree. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive (Mechanical, Electrical, Body, Chassis, Fuel, Emissions, Diagnostics, Troubleshooting) Page Count Page Count: Not Specified (Digital Format) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine Service and Overhauling, Fuel System, Induction System, Emission Control, Mechanical Systems, Control System, Transmission, Differentials, Chassis, Steering, Suspension, Brakes, ABS, Body, Wiring Diagrams Procedures Included Procedures Included: General Information, Engine Repair and Rebuild, Transmission Overhaul, Drivetrain Component Service, Brake System Maintenance and Repair, Suspension and Steering Alignment, Electrical System Diagnosis, Bodywork and Panel Repair, Troubleshooting and Diagnostics, Routine Maintenance, Component Testing, Wiring Harness Repair Engine Overhauling Procedures: Full engine disassembly and reassembly, piston and ring installation, crankshaft and connecting rod bearing replacement, cylinder head gasket replacement, valve guide and seat service, turbocharger overhaul and replacement. Transmission Procedures: Manual transmission clutch replacement, gearset inspection and repair, synchromesh ring replacement, differential overhaul (front and rear), ACD and AYC unit servicing. Chassis Procedures: Suspension component replacement (struts, springs, control arms, bushings), wheel bearing replacement, steering rack overhaul, power steering system service, chassis alignment specifications and procedures. Brake Procedures: Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS system component testing and bleeding procedures, parking brake adjustment. Electrical Procedures: Detailed wiring diagrams for all vehicle systems, troubleshooting guides for electrical faults, component testing procedures for sensors, actuators, and control modules, starter and alternator service, battery testing and replacement. Technical Depth Technical Depth: Detailed factory-level procedures, including component removal/installation, disassembly/assembly, adjustments, diagnostics, and specifications. Torque Settings: Comprehensive list of all critical torque specifications for engine, transmission, suspension, brake, and body components. Diagnostic Techniques: Specific diagnostic flowcharts and procedures for common and complex faults, including engine misfires, fuel delivery issues, sensor faults, and transmission problems. Includes guidance on using diagnostic tools. Manual Usefulness Owner Benefit: Empowers owners to understand their vehicle's systems, accurately diagnose problems, and communicate effectively with technicians, potentially saving on repair costs and ensuring quality workmanship. Professional Benefit: Provides independent repair shops with factory-level data, ensuring accurate repairs and maintaining customer satisfaction for high-performance vehicles. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, suitable for printing individual pages as needed. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Primary Engine: 4G63T (DOHC, 16-valve, turbocharged inline-4) Performance Horsepower: 276 hp (206 kW) at 6,500 rpm (Japanese Spec - 'Gentleman's Agreement') Torque: 275 lb-ft (373 Nm) at 3,000 rpm (Japanese Spec) Fuel System Fuel System: Multi-point Fuel Injection (MPI) with Electronic Fuel Pump Induction Induction: Mitsubishi TD05H-16G Turbocharger with Intercooler Engine Management Engine Management: ECI-Multi (Electronic Controlled Ignition - Multi Point) Bore Stroke Bore Stroke: 85.0 mm x 94.0 mm Displacement Displacement: 1997 cc (2.0 Liters) Compression Ratio Compression Ratio: 8.5:1 Ignition System Ignition System: Electronic Ignition (Distributorless Ignition System - DI/DIS on some models) Cooling System Cooling System: Pressurized liquid cooling with engine-driven fan and large capacity radiator/intercooler for enhanced cooling under demanding conditions. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: N/A (Manual Only) Features Drivetrain: All-Wheel Drive (AWD) with Active Center Differential (ACD), Active Yaw Control (AYC - standard on GSR, optional on RS), and optional Super Active Yaw Control (Super AYC on T.M. Edition) Gear Ratios Gear Ratios 1St: 3.133 Gear Ratios 2Nd: 2.036 Gear Ratios 3Rd: 1.370 Gear Ratios 4Th: 1.000 Gear Ratios 5Th: 0.767 Gear Ratios Reverse: 3.153 Final Drive Ratio: 4.556 📐 Dimensions Exterior Length: 4,350 mm (171.3 in) Width: 1,770 mm (69.7 in) Height: 1,415 mm (55.7 in) Wheelbase: 2,600 mm (102.4 in) Front Track: 1,495 mm (58.9 in) Rear Track: 1,490 mm (58.7 in) Weights Curb Weight: Approx. 1,350-1,400 kg (2,976-3,086 lb) depending on trim Gross Vehicle Weight: Approx. 1,750 kg (3,858 lb) 🛡️ Safety Features Ratings Safety Ratings: JNCAP: Frontal impact 4 stars, Side impact 4 stars (typical for the era) Ntsa Rating: Not officially rated by NHTSA in most markets due to its low-volume, performance-oriented nature and homologation purpose. Active Features Active Features: Anti-lock Braking System (ABS), Active Center Differential (ACD), Active Yaw Control (AYC) Passive Features Passive...
Performance Rally Homologation Special / Sports Sedan
Competitive Analysis
Competitive Analysis:
Directly competed with vehicles like Subaru Impreza WRX STI, Ford Focus RS, and other high-performance AWD sedans of its era.
Key Features
Key Features:
Iconic turbocharged 4G63T engine, advanced All-Wheel Drive (AYC, ACD, Super AYC in later models), potent braking systems, and rally-bred chassis dynamics. The Evo VI is renowned for its aggressive styling and performance pedigree.
Engine Service and Overhauling, Fuel System, Induction System, Emission Control, Mechanical Systems, Control System, Transmission, Differentials, Chassis, Steering, Suspension, Brakes, ABS, Body, Wiring Diagrams
Procedures Included
Procedures Included:
General Information, Engine Repair and Rebuild, Transmission Overhaul, Drivetrain Component Service, Brake System Maintenance and Repair, Suspension and Steering Alignment, Electrical System Diagnosis, Bodywork and Panel Repair, Troubleshooting and Diagnostics, Routine Maintenance, Component Testing, Wiring Harness Repair
Engine Overhauling Procedures:
Full engine disassembly and reassembly, piston and ring installation, crankshaft and connecting rod bearing replacement, cylinder head gasket replacement, valve guide and seat service, turbocharger overhaul and replacement.
Transmission Procedures:
Manual transmission clutch replacement, gearset inspection and repair, synchromesh ring replacement, differential overhaul (front and rear), ACD and AYC unit servicing.
Chassis Procedures:
Suspension component replacement (struts, springs, control arms, bushings), wheel bearing replacement, steering rack overhaul, power steering system service, chassis alignment specifications and procedures.
Brake Procedures:
Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS system component testing and bleeding procedures, parking brake adjustment.
Electrical Procedures:
Detailed wiring diagrams for all vehicle systems, troubleshooting guides for electrical faults, component testing procedures for sensors, actuators, and control modules, starter and alternator service, battery testing and replacement.
Technical Depth
Technical Depth:
Detailed factory-level procedures, including component removal/installation, disassembly/assembly, adjustments, diagnostics, and specifications.
Torque Settings:
Comprehensive list of all critical torque specifications for engine, transmission, suspension, brake, and body components.
Diagnostic Techniques:
Specific diagnostic flowcharts and procedures for common and complex faults, including engine misfires, fuel delivery issues, sensor faults, and transmission problems. Includes guidance on using diagnostic tools.
Manual Usefulness
Owner Benefit:
Empowers owners to understand their vehicle's systems, accurately diagnose problems, and communicate effectively with technicians, potentially saving on repair costs and ensuring quality workmanship.
Professional Benefit:
Provides independent repair shops with factory-level data, ensuring accurate repairs and maintaining customer satisfaction for high-performance vehicles.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages as needed.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
4G63T (DOHC, 16-valve, turbocharged inline-4)
Performance
Horsepower:
276 hp (206 kW) at 6,500 rpm (Japanese Spec - 'Gentleman's Agreement')
Torque:
275 lb-ft (373 Nm) at 3,000 rpm (Japanese Spec)
Fuel System
Fuel System:
Multi-point Fuel Injection (MPI) with Electronic Fuel Pump
Induction
Induction:
Mitsubishi TD05H-16G Turbocharger with Intercooler
Engine Management
Engine Management:
ECI-Multi (Electronic Controlled Ignition - Multi Point)
Bore Stroke
Bore Stroke:
85.0 mm x 94.0 mm
Displacement
Displacement:
1997 cc (2.0 Liters)
Compression Ratio
Compression Ratio:
8.5:1
Ignition System
Ignition System:
Electronic Ignition (Distributorless Ignition System - DI/DIS on some models)
Cooling System
Cooling System:
Pressurized liquid cooling with engine-driven fan and large capacity radiator/intercooler for enhanced cooling under demanding conditions.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
N/A (Manual Only)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Center Differential (ACD), Active Yaw Control (AYC - standard on GSR, optional on RS), and optional Super Active Yaw Control (Super AYC on T.M. Edition)
Gear Ratios
Gear Ratios 1St:
3.133
Gear Ratios 2Nd:
2.036
Gear Ratios 3Rd:
1.370
Gear Ratios 4Th:
1.000
Gear Ratios 5Th:
0.767
Gear Ratios Reverse:
3.153
Final Drive Ratio:
4.556
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,600 mm (102.4 in)
Front Track:
1,495 mm (58.9 in)
Rear Track:
1,490 mm (58.7 in)
Weights
Curb Weight:
Approx. 1,350-1,400 kg (2,976-3,086 lb) depending on trim
Gross Vehicle Weight:
Approx. 1,750 kg (3,858 lb)
🛡️ Safety Features
Ratings
Safety Ratings:
JNCAP: Frontal impact 4 stars, Side impact 4 stars (typical for the era)
Ntsa Rating:
Not officially rated by NHTSA in most markets due to its low-volume, performance-oriented nature and homologation purpose.
Active Features
Active Features:
Anti-lock Braking System (ABS), Active Center Differential (ACD), Active Yaw Control (AYC)
Passive Features
Passive Features:
Front Airbags, Optional Side Airbags, Reinforced Chassis Structure
💡 Technology Features
Infotainment
Infotainment:
Typically featured a basic AM/FM/CD stereo system. Navigation was not standard.
Driver Assistance
Driver Assistance:
ABS, ACD, AYC
Connectivity
Connectivity:
Limited by modern standards, typically only basic audio input (e.g., cassette adapter or optional CD changer).
🔧 Maintenance
Service Intervals
Service Intervals:
Oil Change: Every 5,000-7,500 km (3,000-5,000 miles) or 6 months. Spark Plugs: Inspect at 30,000 km, replace at 60,000-100,000 km. Timing Belt: Replace every 90,000-100,000 km. Coolant: Flush and replace every 2 years.
Fluid Specifications
Engine Oil:
API SG/SH/SJ, SAE 5W-30 or 5W-40 (synthetic recommended). Capacity: 4.5 Liters (4.8 US Quarts) with filter.
Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 Gear Oil. Capacity: 2.2 Liters (2.3 US Quarts).
Transfer Case Fluid:
API GL-4 or GL-5, SAE 75W-90 Gear Oil. Capacity: 0.5 Liters (0.5 US Quarts).
Rear Differential Fluid:
API GL-5, SAE 75W-90 Gear Oil. Capacity: 1.1 Liters (1.2 US Quarts).
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant) with a 50/50 mix with distilled water.
Power Steering Fluid:
Dexron III ATF (Automatic Transmission Fluid) or equivalent power steering fluid.
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid.
Known Issues
Known Issues:
Subframe rust, early turbocharger failure if not maintained, differential wear (especially AYC unit), potential for piston ring land failure under extreme misuse or high mileage without proper servicing.
Ignition Coil Failure:
Ignition coils can be a wear item and prone to failure, leading to misfires. Regular inspection and replacement are recommended.
Fuel Pump Wear:
Fuel pumps can wear out over time, leading to intermittent starting issues or a loss of power. Testing fuel pressure is crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a strong heritage in rallying, with the Lancer Evolution lineage being directly influenced by their World Rally Championship (WRC) success.
Model Evolution
Model Evolution:
The Evo VI was a significant evolution of the Evo V, featuring revised styling (particularly the bumper and fog lights for better airflow) and mechanical enhancements for improved cooling and handling. It also introduced the limited-edition Tommi Mäkinen Edition (T.M. Edition) with unique tuning and styling.
Tommi Makinen Edition:
The Evo VI T.M. Edition (introduced in 2000) featured a quicker steering rack, upgraded turbocharger (slightly higher output), improved AYC system, front bumper modifications, and unique interior/exterior styling, celebrating Mäkinen's WRC championships.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Recognitions:
Highly acclaimed by automotive journalists and enthusiasts for its performance, handling, and rally-bred capabilities. Often cited as one of the greatest rally homologation cars.