Mitsubishi Lancer Evolution IV-V Workshop Service Repair Manual 1996-1998
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V Codes Chassis Codes Ev4: CN9A Chassis Codes Ev5: CP9A 👋 Introduction Market Position Market Segment: High-performance rally-bred sedan, iconic JDM homologation special. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione. Key Features Vehicle Distinguishing Features: Advanced all-wheel-drive system with Active Yaw Control (AYC), powerful turbocharged engine, aggressive aerodynamics, rally-inspired chassis. Manual Value Proposition: Essential resource for owners and technicians seeking to maintain, repair, and understand the complex systems of the Evo IV/V. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive workshop service and repair for Mitsubishi Lancer Evolution IV and V models. Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust, emissions control. Transmission Drivetrain: Manual transmission (5-speed), Active Yaw Control (AYC) system, transfer case, differentials (front, rear, center). Suspension Steering: Front and rear suspension components, power steering system, steering gearbox, alignment specifications. Braking System: Front and rear brake system (including ABS), brake components, hydraulic system, bleeding procedures. Electrical System: Starter, alternator, battery, lighting system, instrumentation, power windows, mirrors, central locking, ECU diagnostics, wiring diagrams. Body Interior: Body construction, interior trim, seating, HVAC system, exterior panels, glass, doors, bumpers. Procedures Included Maintenance Procedures: Routine maintenance (oil changes, filter replacements), scheduled servicing, component inspection and replacement. Repair Procedures: Detailed step-by-step repair instructions for all major vehicle systems, including engine teardown, transmission rebuild, brake caliper replacement, suspension bush replacement, etc. Troubleshooting Diagnostics: Diagnostic charts, fault code interpretation (OBD-II), troubleshooting guides for common issues, component testing procedures. Technical Depth Technical Depth: Advanced diagnostics, component-level repair, full engine and transmission overhaul, electrical system tracing, chassis alignment. 📊 Manual Specifications File Format File Format Details: Likely a PDF with searchable text, allowing for easy navigation and keyword searches. Print Quality Print Quality Considerations: Digital format allows for high-resolution diagrams and clear text, suitable for printing specific sections. Binding Type Binding Type Considerations: Not applicable for digital format; for printed versions, typically comb-bound or perfect-bound. Paper Type Paper Type Considerations: Not applicable for digital format; for printed versions, typically quality paper stock suitable for workshop use. ⚙️ Engine Specifications Primary Engine Engine Code Ev4 Ev5: 4G63T (DOHC, 16-valve, turbocharged inline-4) Engine Displacement: 2.0 Liters (1997 cc) Performance Horsepower Ev4 Ps: 280 PS (JDM specification, electronically limited) Horsepower Ev5 Ps: 280 PS (JDM specification, electronically limited) Torque Ev4 Nm: 352 Nm (35.9 kgf-m; 259 lb-ft) at 3000 rpm (JDM) Torque Ev5 Nm: 373 Nm (38.0 kgf-m; 275 lb-ft) at 3000 rpm (JDM) Fuel System Fuel Injection Type: Electronic Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G6-10.5T (twin-scroll) Recommended Fuel: High-octane unleaded gasoline (95 RON or higher recommended) 🔧 Transmission Standard Transmission Type Std: 5-speed manual transmission Optional Transmission Type Opt: N/A (Manual only) Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Ayc Operation: Hydraulic system controlling torque split to rear wheels for enhanced cornering stability. 📐 Dimensions Exterior Length Mm Ev4: 4350 Length Mm Ev5: 4350 Width Mm: 1770 Height Mm: 1415 Wheelbase Mm: 2600 Weights Curb Weight Kg Ev4: 1450 Curb Weight Kg Ev5: 1450 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Homologation special, primary focus on performance and motorsport regulations). Active Features ABS: Standard Anti-lock Braking System (ABS) Ayc: Active Yaw Control (AYC) for enhanced traction and stability. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Infotainment System Features: Basic AM/FM radio, cassette player, optional CD player. Focus is on performance, not advanced infotainment. Driver Assistance Driver Assistance Systems: Active Yaw Control (AYC) is the primary driver assistance technology enhancing handling. Connectivity Connectivity Features: Minimal; primarily focused on mechanical and electronic systems related to performance. 🔧 Maintenance Service Intervals Oil Change Interval Km: 5,000 - 7,500 km (or 6 months, whichever comes first) Air Filter Replacement Km: 20,000 - 30,000 km Spark Plug Replacement Km: 40,000 - 60,000 km (depending on plug type) Timing Belt Replacement Km: 80,000 - 100,000 km (critical component, refer to manual for specific interval) Fluid Specifications Engine Oil Specification: API SG or SH, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature) Coolant Specification: Ethylene glycol-based antifreeze (Mitsubishi DiaQueen Super Long Life Coolant recommended) mixed 50/50 with distilled water. Transmission Fluid Type: API GL-4, SAE 75W-90 (manual transmission) Differential Fluid Type: API GL-5, SAE 80W-90 or 75W-90 (front and rear differentials) Ayc Fluid Type: Mitsubishi DiaQueen ATF SP-III or equivalent. Known Issues Common Issues Engine: Head gasket failure (especially with high boost/heat), piston ring wear, turbocharger wear, connecting rod issues (weakening over time). Common Issues Drivetrain: AYC pump failure, clutch wear, gearbox synchro wear, differential bearing issues. Common...
Detailed step-by-step repair instructions for all major vehicle systems, including engine teardown, transmission rebuild, brake caliper replacement, suspension bush replacement, etc.
Troubleshooting Diagnostics:
Diagnostic charts, fault code interpretation (OBD-II), troubleshooting guides for common issues, component testing procedures.
Technical Depth
Technical Depth:
Advanced diagnostics, component-level repair, full engine and transmission overhaul, electrical system tracing, chassis alignment.
📊 Manual Specifications
File Format
File Format Details:
Likely a PDF with searchable text, allowing for easy navigation and keyword searches.
Print Quality
Print Quality Considerations:
Digital format allows for high-resolution diagrams and clear text, suitable for printing specific sections.
Binding Type
Binding Type Considerations:
Not applicable for digital format; for printed versions, typically comb-bound or perfect-bound.
Paper Type
Paper Type Considerations:
Not applicable for digital format; for printed versions, typically quality paper stock suitable for workshop use.
Mitsubishi's extensive World Rally Championship (WRC) heritage directly influenced the development of the Lancer Evolution series.
Model Evolution
Evo Iv Introduction:
Introduced in August 1996, featuring a revised 4G63 engine, improved AYC system, and a distinctive aggressive styling with a large rear wing.
Evo V Introduction:
Launched in January 1998, featuring wider bodywork, larger wheels and tires, revised suspension geometry, larger intercooler, and a torque increase for the 4G63 engine.
Production
Production Years:
1996-1998
Production Locations:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Accolades:
The Lancer Evolution platform has a storied history in the World Rally Championship, achieving numerous driver and manufacturer titles.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its exceptional handling, grip, and driver engagement.
Certifications
Homologation Status:
Developed as a homologation special for Group A rallying, requiring production of a certain number of street-legal vehicles.