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Mitsubishi Lancer Evo 4 1996-1998 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV (Evo 4) Model Code: CN9A Production Years: 1996-1998 Codes Engine Codes Covered: 4G63 Chassis Codes Covered: CN9A 👋 Introduction Market Position Positioning: Iconic rally homologation special, celebrated for its performance and advanced technology. Competitive Analysis Competitors Covered By Manuals: Provides in-depth data comparable to or exceeding factory manuals for vehicles like Subaru Impreza WRX STi, Toyota Celica GT-Four, and Ford Escort RS Cosworth of the era. Key Features Key Features Of Vehicle: 4G63 2.0L turbocharged engine, advanced All-Wheel Drive with Active Yaw Control (AYC), aggressive aerodynamic body kit, stiffened chassis. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Specific Markets Covered: Japan (JDM) Page Count Estimated Page Count: Approximately 1500+ Manual Type Type: Factory Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System Drivetrain: Transmission (Manual & Automatic), Transfer Case, Front Differential, Rear Differential, Active Yaw Control (AYC) Chassis: Suspension (Front & Rear), Steering System, Brake System (ABS Included), Wheels & Tires Electrical: Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System, Instrumentation, HVAC Controls, Audio System, Power Accessories Body: Exterior Body Panels, Interior Trim, Glass, Doors, Locks, Bumpers, Aerodynamics Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Replenishments, Spark Plug Service, Belt Replacement Troubleshooting: Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Guides Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair, Body Panel Repair Diagnostics: On-Board Diagnostics (OBD-I/OBD-II as applicable), Sensor Testing, Actuator Testing Special Procedures: AYC System Calibration, Timing Belt Replacement, Turbocharger Servicing, Differential Fluid Changes Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Detailed diagnostic flowcharts and fault isolation procedures. Torque Specifications: Extensive torque specifications for all critical fasteners. Special Tools: Identification and usage of required special service tools (SST). 📊 Manual Specifications File Format PDF Quality: High-resolution scans, clear text and diagrams. Searchable: Yes, typically text-searchable PDF. Print Quality Printable: Yes, designed for printing. Binding Type Binding Type For Original: Perfect bound or spiral bound (for original manuals). Paper Type Paper Type For Original: High-quality, durable paper stock. ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4, DOHC, 16-valve, turbocharged and intercooled Engine Code: 4G63T Displacement: 1997 cc (2.0 Liters) Performance Horsepower Ps: 280 PS (276 hp) @ 6500 rpm (JDM spec, often under-rated) Torque Nm: 350 Nm (258 lb-ft) @ 3000 rpm (JDM spec) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) with Electronic Fuel Control System (EFCS) Fuel Type: Unleaded premium gasoline (95-98 RON recommended) Cooling System Cooling Medium: Water-cooled, pressurized system Lubrication System Oil Capacity Liters: 4.5 Liters (with filter change) Ignition System Ignition Type: Electronic ignition system with distributorless ignition system (DIS) on later models or distributor on early models. 🔧 Transmission Standard Type: 5-speed Manual Transmission (Type-MR) Optional Type: None (Evo 4 was exclusively manual) Features Drivetrain Type: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Ayc Description: Electronically controlled torque distribution to rear wheels for enhanced cornering stability. 📐 Dimensions Exterior Length Mm: 4350 mm Width Mm: 1770 mm Height Mm: 1415 mm Wheelbase Mm: 2600 mm Track Front Mm: 1515 mm Track Rear Mm: 1505 mm Weights Curb Weight Kg: 1400 kg Gross Vehicle Weight Kg: 1700 kg Wheels Tires Standard Wheel Size: 17 x 7.5 inches Standard Tire Size: 215/45R17 Bolt Pattern: 5x114.3 🛡️ Safety Features Ratings Overall Ratings: N/A (Vehicle of its era, crash testing standards were different) Active Features Active Safety: All-Wheel Drive, AYC, ABS (Anti-lock Braking System), Helical Limited Slip Differential (Front), Viscous Coupling Center Differential. Passive Features Passive Safety: Reinforced chassis structure, driver-side airbag (standard in many markets), three-point seatbelts with pre-tensioners. Brakes Front Brakes: Ventilated Discs, 2-piston calipers (Brembo on RS models) Rear Brakes: Solid Discs, 1-piston calipers 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Basic speaker system. Climate Control: Manual air conditioning and heating controls. Driver Assistance Advanced Features: Active Yaw Control (AYC) is the primary advanced drivetrain technology. Connectivity Connectivity Options: None from factory (era-appropriate). 🔧 Maintenance Service Intervals Oil Change Interval Km: 5,000 - 7,500 km or 6 months (severe use recommended for performance driving) Spark Plug Replacement Km: 40,000 - 60,000 km (depending on plug type) Timing Belt Replacement Km: 90,000 - 100,000 km or 5-7 years (critical maintenance item) Fluid Specifications Engine Oil Type: API SG/SH or higher, SAE 10W-30 / 10W-40 (synthetic recommended for high performance) Transmission Fluid Type: API GL-4 or GL-5, SAE 75W-90 (Manual Transmission) Transfer Case Fluid Type: API GL-5, SAE 75W-90 Rear Differential Fluid Type: API GL-5, SAE 75W-90 (Limited Slip Differential oil may be required for AYC rear diff) Coolant Type: Ethylene glycol-based coolant (50/50 mix with distilled water) Known...
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Mitsubishi Lancer Evo 4 1996-1998 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV (Evo 4)
Model Code:
CN9A
Production Years:
1996-1998
Codes
Engine Codes Covered:
4G63
Chassis Codes Covered:
CN9A
👋 Introduction
Market Position
Positioning:
Iconic rally homologation special, celebrated for its performance and advanced technology.
Competitive Analysis
Competitors Covered By Manuals:
Provides in-depth data comparable to or exceeding factory manuals for vehicles like Subaru Impreza WRX STi, Toyota Celica GT-Four, and Ford Escort RS Cosworth of the era.
Key Features
Key Features Of Vehicle:
4G63 2.0L turbocharged engine, advanced All-Wheel Drive with Active Yaw Control (AYC), aggressive aerodynamic body kit, stiffened chassis.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Yes
Specific Markets Covered:
Japan (JDM)
Page Count
Estimated Page Count:
Approximately 1500+
Manual Type
Type:
Factory Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System
Drivetrain:
Transmission (Manual & Automatic), Transfer Case, Front Differential, Rear Differential, Active Yaw Control (AYC)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (ABS Included), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System, Instrumentation, HVAC Controls, Audio System, Power Accessories
Body:
Exterior Body Panels, Interior Trim, Glass, Doors, Locks, Bumpers, Aerodynamics
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Replenishments, Spark Plug Service, Belt Replacement
Troubleshooting:
Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Guides
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair, Body Panel Repair
Diagnostics:
On-Board Diagnostics (OBD-I/OBD-II as applicable), Sensor Testing, Actuator Testing
Special Procedures:
AYC System Calibration, Timing Belt Replacement, Turbocharger Servicing, Differential Fluid Changes
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and fault isolation procedures.
Torque Specifications:
Extensive torque specifications for all critical fasteners.
Special Tools:
Identification and usage of required special service tools (SST).
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans, clear text and diagrams.
Searchable:
Yes, typically text-searchable PDF.
Print Quality
Printable:
Yes, designed for printing.
Binding Type
Binding Type For Original:
Perfect bound or spiral bound (for original manuals).
Paper Type
Paper Type For Original:
High-quality, durable paper stock.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled
Engine Code:
4G63T
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (276 hp) @ 6500 rpm (JDM spec, often under-rated)
Torque Nm:
350 Nm (258 lb-ft) @ 3000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with Electronic Fuel Control System (EFCS)
Fuel Type:
Unleaded premium gasoline (95-98 RON recommended)
Cooling System
Cooling Medium:
Water-cooled, pressurized system
Lubrication System
Oil Capacity Liters:
4.5 Liters (with filter change)
Ignition System
Ignition Type:
Electronic ignition system with distributorless ignition system (DIS) on later models or distributor on early models.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Type-MR)
Optional
Type:
None (Evo 4 was exclusively manual)
Features
Drivetrain Type:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Ayc Description:
Electronically controlled torque distribution to rear wheels for enhanced cornering stability.
📐 Dimensions
Exterior
Length Mm:
4350 mm
Width Mm:
1770 mm
Height Mm:
1415 mm
Wheelbase Mm:
2600 mm
Track Front Mm:
1515 mm
Track Rear Mm:
1505 mm
Weights
Curb Weight Kg:
1400 kg
Gross Vehicle Weight Kg:
1700 kg
Wheels Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
215/45R17
Bolt Pattern:
5x114.3
🛡️ Safety Features
Ratings
Overall Ratings:
N/A (Vehicle of its era, crash testing standards were different)
Active Features
Active Safety:
All-Wheel Drive, AYC, ABS (Anti-lock Braking System), Helical Limited Slip Differential (Front), Viscous Coupling Center Differential.
Passive Features
Passive Safety:
Reinforced chassis structure, driver-side airbag (standard in many markets), three-point seatbelts with pre-tensioners.
Brakes
Front Brakes:
Ventilated Discs, 2-piston calipers (Brembo on RS models)
Rear Brakes:
Solid Discs, 1-piston calipers
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Basic speaker system.
Climate Control:
Manual air conditioning and heating controls.
Driver Assistance
Advanced Features:
Active Yaw Control (AYC) is the primary advanced drivetrain technology.
Connectivity
Connectivity Options:
None from factory (era-appropriate).
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
5,000 - 7,500 km or 6 months (severe use recommended for performance driving)
Spark Plug Replacement Km:
40,000 - 60,000 km (depending on plug type)
Timing Belt Replacement Km:
90,000 - 100,000 km or 5-7 years (critical maintenance item)
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 / 10W-40 (synthetic recommended for high performance)
Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (Manual Transmission)
Transfer Case Fluid Type:
API GL-5, SAE 75W-90
Rear Differential Fluid Type:
API GL-5, SAE 75W-90 (Limited Slip Differential oil may be required for AYC rear diff)
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water)
Known Issues
Common Wear Items:
Clutch, brake pads/rotors, suspension bushings, turbocharger seals, engine mounts.
Potential Failures:
Connecting rod failure due to detonation (if improperly tuned or maintained), AYC pump failure, turbocharger failure from lack of maintenance or oil starvation.
Corrosion:
Check for rust on chassis, suspension components, and exhaust system, especially in areas with harsh winters.
📚 Vehicle History
Brand Heritage
Rally Legacy:
Built on Mitsubishi's extensive success in the World Rally Championship (WRC).
Model Evolution
Evolution Series:
Fourth generation in the Lancer Evolution lineage, introducing significant chassis and drivetrain enhancements over the Evo III.
Key Changes From Evo Iii:
Wider track, revised suspension geometry, introduction of AYC, stronger chassis rigidity, new twin-scroll turbocharger.
Production
Production Location:
Mizushima Plant, Kurashiki, Japan
Production Volume:
Approximately 10,000 units (combined for GSR and RS variants)
🏆 Awards & Recognition
Recognitions
Automotive Press Recognition:
Consistently praised by automotive journalists for its incredible handling, grip, and rally-bred performance.
Performance Benchmarks:
Often ranked among the best performance sedans of its era, a benchmark for AWD performance.
Certifications
Homologation:
Built to meet Group A homologation requirements for the World Rally Championship.
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