Mitsubushi LANCER EVOLUTION 4 & 5 1996 1997 1998 Service Repair Workshop Manual And Technical Information Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV & V Production Years: 1996-1998 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their Lancer Evolution IV & V. Competitive Analysis Value Proposition: Provides factory-level technical information at a fraction of the cost of dealership service, empowering owners to perform maintenance and repairs themselves. Key Features Content Scope: Covers all major mechanical, electrical, and body systems specific to the Lancer Evolution IV and V models from 1996-1998. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual and Technical Information Manual Language: English Format: PDF (Portable Document Format) Platform Compatibility: PC, Mac, iPad, Android Tablets, iPhone, Android Phones 📖 Manual Coverage Systems Covered Engine Mechanical: Engine Assembly, Cylinder Head, Crankshaft, Connecting Rods, Pistons, Valve Train, Timing System Engine Lubrication: Oil Pump, Oil Filter, Oil Cooler, Lubrication Passages, Oil Pressure Fuel System: Fuel Pump, Fuel Injectors, Fuel Rail, Fuel Filter, Fuel Tank, Fuel Pressure Regulator, Evaporative Emission Control (EVAP) Engine Cooling: Radiator, Water Pump, Thermostat, Cooling Fan, Coolant Hoses, Coolant Temperature Sensor Intake And Exhaust: Intake Manifold, Throttle Body, Air Filter Assembly, Turbocharger System, Exhaust Manifold, Catalytic Converter, Muffler Engine Electrical: Starter Motor, Alternator, Ignition System (Spark Plugs, Ignition Coils), Battery, Wiring Harnesses Engine And Emission Control: Engine Control Unit (ECU), Oxygen Sensors (O2 Sensors), Idle Air Control (IAC) Valve, EGR System, Ignition Timing Control, Knock Sensor Clutch: Clutch Disc, Pressure Plate, Release Bearing, Clutch Actuator, Clutch Fluid, Clutch Pedal Manual Transmission: Gearbox Assembly, Gear Selection, Gear Ratios, Synchronizers, Bearings, Seals, Transmission Fluid Front Axle: Drive Shafts, CV Joints, Wheel Hubs, Bearings Rear Axle: Differential, Drive Shafts, Wheel Hubs, Bearings Power Plant Mount: Engine Mounts, Transmission Mounts Front Suspension: MacPherson Struts, Control Arms, Stabilizer Bar, Bushings, Ball Joints, Spring Rear Suspension: Multi-link Suspension, Control Arms, Bushings, Ball Joints, Stabilizer Bar, Spring Service Brakes: Brake Discs (Front/Rear), Brake Calipers, Brake Pads, Brake Lines, Brake Fluid, ABS System Parking Brakes: Parking Brake Mechanism, Cables, Rear Brake Components Steering: Steering Rack, Power Steering Pump, Steering Column, Tie Rods, Steering Linkage Body: Body Panels, Doors, Hood, Trunk, Bumpers, Chassis Structure Exterior: Lights (Headlights, Taillights, Fog Lights), Mirrors, Wipers, Washer System, Exterior Trim Electrical Wiring: Wiring Diagrams for all Systems, Fuses, Relays, Connectors Procedures Included Maintenance: Scheduled Maintenance Tasks, Oil Changes, Filter Replacements, Fluid Checks and Replenishments, Brake Pad Replacement, Spark Plug Replacement Troubleshooting: Diagnostic Procedures for Engine, Transmission, Brakes, Electrical Systems; Fault Code Interpretation Repair: Detailed Step-by-Step Repair Instructions for Major Components and Systems, Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Body Panel Repair Technical Depth Depth: Comprehensive, ranging from basic maintenance and fluid changes to complete engine and transmission overhauls. Includes detailed diagnostic procedures and repair specifications. 📊 Manual Specifications File Format File Type: PDF (Adobe Acrobat) Searchability: Likely searchable text, enabling quick navigation to specific topics. Print Quality Printability: Printable by individual pages or the full document. Binding Type Digital Access: Downloadable file for digital viewing and storage. Paper Type N A: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Evo Iv: 4G63 (DOHC Turbocharged Inline-4) Engine Code Evo V: 4G63 (DOHC Turbocharged Inline-4, often with revised internals and turbocharger) Performance Displacement Evo Iv: 1997 cc (2.0 Liters) Horsepower Evo Iv: Approx. 280 PS (276 hp) at 6,500 rpm (JDM spec, often higher in reality) Torque Evo Iv: Approx. 35 kg-m (253 lb-ft) at 3,000 rpm (JDM spec) Displacement Evo V: 1997 cc (2.0 Liters) Horsepower Evo V: Approx. 280 PS (276 hp) at 6,500 rpm (JDM spec, with slight increases in boost and internal revisions) Torque Evo V: Approx. 35.2 kg-m (255 lb-ft) at 3,000 rpm (JDM spec) Fuel System Fuel Type: Unleaded Gasoline (Premium/High Octane Recommended) Injection System: Electronic Fuel Injection (EFI) with Sequential Injection Turbocharger Type: Mitsubishi TD05HR-16G (Twin-Scroll Turbocharger) 🔧 Transmission Standard Type Evo Iv: 5-Speed Manual Transmission Type Evo V: 5-Speed Manual Transmission (often with revised gear ratios for improved acceleration) Optional Availability: No automatic transmission offered for these performance-oriented models. Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Viscous Coupling Center Differential 📐 Dimensions Exterior Length Evo Iv: Approx. 4,350 mm (171.3 in) Width Evo Iv: Approx. 1,770 mm (69.7 in) Height Evo Iv: Approx. 1,415 mm (55.7 in) Wheelbase Evo Iv: Approx. 2,600 mm (102.4 in) Length Evo V: Approx. 4,365 mm (171.9 in) Width Evo V: Approx. 1,770 mm (69.7 in) Height Evo V: Approx. 1,415 mm (55.7 in) Wheelbase Evo V: Approx. 2,600 mm (102.4 in) Weights Curb Weight Evo Iv: Approx. 1,350 kg (2,976 lbs) Curb Weight Evo V: Approx. 1,360 kg (2,998 lbs) 🛡️ Safety Features Ratings NHTSA Ratings: Not specifically rated by NHTSA for these years/models in the same way as modern vehicles, but designed with rally-inspired safety features. Active Features ABS:...
DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their Lancer Evolution IV & V.
Competitive Analysis
Value Proposition:
Provides factory-level technical information at a fraction of the cost of dealership service, empowering owners to perform maintenance and repairs themselves.
Key Features
Content Scope:
Covers all major mechanical, electrical, and body systems specific to the Lancer Evolution IV and V models from 1996-1998.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual and Technical Information Manual
Detailed Step-by-Step Repair Instructions for Major Components and Systems, Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Body Panel Repair
Technical Depth
Depth:
Comprehensive, ranging from basic maintenance and fluid changes to complete engine and transmission overhauls. Includes detailed diagnostic procedures and repair specifications.
📊 Manual Specifications
File Format
File Type:
PDF (Adobe Acrobat)
Searchability:
Likely searchable text, enabling quick navigation to specific topics.
Print Quality
Printability:
Printable by individual pages or the full document.
Binding Type
Digital Access:
Downloadable file for digital viewing and storage.
Paper Type
N A:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Evo Iv:
4G63 (DOHC Turbocharged Inline-4)
Engine Code Evo V:
4G63 (DOHC Turbocharged Inline-4, often with revised internals and turbocharger)
Performance
Displacement Evo Iv:
1997 cc (2.0 Liters)
Horsepower Evo Iv:
Approx. 280 PS (276 hp) at 6,500 rpm (JDM spec, often higher in reality)
Torque Evo Iv:
Approx. 35 kg-m (253 lb-ft) at 3,000 rpm (JDM spec)
Displacement Evo V:
1997 cc (2.0 Liters)
Horsepower Evo V:
Approx. 280 PS (276 hp) at 6,500 rpm (JDM spec, with slight increases in boost and internal revisions)
Torque Evo V:
Approx. 35.2 kg-m (255 lb-ft) at 3,000 rpm (JDM spec)
Electronic Fuel Injection (EFI) with Sequential Injection
Turbocharger
Type:
Mitsubishi TD05HR-16G (Twin-Scroll Turbocharger)
🔧 Transmission
Standard
Type Evo Iv:
5-Speed Manual Transmission
Type Evo V:
5-Speed Manual Transmission (often with revised gear ratios for improved acceleration)
Optional
Availability:
No automatic transmission offered for these performance-oriented models.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Viscous Coupling Center Differential
📐 Dimensions
Exterior
Length Evo Iv:
Approx. 4,350 mm (171.3 in)
Width Evo Iv:
Approx. 1,770 mm (69.7 in)
Height Evo Iv:
Approx. 1,415 mm (55.7 in)
Wheelbase Evo Iv:
Approx. 2,600 mm (102.4 in)
Length Evo V:
Approx. 4,365 mm (171.9 in)
Width Evo V:
Approx. 1,770 mm (69.7 in)
Height Evo V:
Approx. 1,415 mm (55.7 in)
Wheelbase Evo V:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight Evo Iv:
Approx. 1,350 kg (2,976 lbs)
Curb Weight Evo V:
Approx. 1,360 kg (2,998 lbs)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not specifically rated by NHTSA for these years/models in the same way as modern vehicles, but designed with rally-inspired safety features.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) for enhanced cornering stability and traction.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners.
Chassis Construction:
Reinforced chassis and safety cell for occupant protection.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player and CD capability (optional on some trims). Speaker count varies.
Driver Assistance
Traction Control:
While not traditional traction control, the advanced AWD system with AYC significantly enhances traction and stability.
Connectivity
N A:
No modern connectivity features like Bluetooth or USB ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km (3,000-4,500 miles) or 6 months, whichever comes first, under normal to hard driving conditions.
Spark Plug Replacement:
Every 40,000-50,000 km (25,000-30,000 miles), depending on plug type.
Timing Belt Replacement:
Every 80,000-100,000 km (50,000-60,000 miles) or 5-7 years.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or ACEA A2/A3, viscosity grade 10W-30 or 10W-40 (check manual for specific recommendations based on climate).
Transmission Fluid Type:
GL-4 or GL-5 gear oil, SAE 75W-90 (manual transmission).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Reliability:
The 4G63 engine is generally robust, but prone to issues like turbocharger wear, piston ring failure (detonation damage), and head gasket failure if overheated or poorly maintained.
Ayc System:
AYC pump and sensor failures can occur, leading to reduced handling performance and warning lights. Replacement parts can be scarce.
Rust And Corrosion:
As with many vehicles of this era, rust can be an issue, particularly in the wheel arches, sills, and underbody.
Clutch Wear:
High-performance driving can lead to accelerated clutch wear.
📚 Vehicle History
Brand Heritage
Rally Roots:
The Lancer Evolution lineage is deeply intertwined with Mitsubishi's success in the World Rally Championship (WRC), with the Evo IV and V being direct descendants of rally-bred technology.
Model Evolution
Evo Iv Introduction:
Introduced in August 1996, featuring a more powerful 4G63 engine, improved AYC system, and a distinctive aggressive styling with larger aero components.
Evo V Introduction:
Launched in January 1998, the Evo V featured wider bodywork (fenders), larger wheels and tires, revised suspension geometry, a larger turbocharger, and an improved AYC system, offering enhanced handling and stability.
Production
Production Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Numbers:
Limited production runs, highly sought after by enthusiasts worldwide.
🏆 Awards & Recognition
Recognitions
Performance Credentials:
Universally acclaimed for their motorsport pedigree and exceptional performance on both road and track. Often lauded in automotive enthusiast circles.
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