Mitsubishi Lancer Evolution 6 1999-2001 Repair Service
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo VI) Production Years Covered: 1999, 2000, 2001 Codes Chassis Code: CP9A Engine Code Primary: 4G63 Generation Generation Name: CP9A (Sixth Generation) 👋 Introduction Market Position Vehicle Class: Iconic Rally Homologation Special, High-Performance Compact Sedan Reputation: Renowned for its rally pedigree, advanced technology (AYC, ACD), and potent 4G63 engine. Competitive Analysis Primary Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth (in its era), other Group A rally homologation specials. Key Features Drivetrain: Advanced electronically controlled all-wheel-drive system with Active Center Differential (ACD) and Active Yaw Control (AYC). Engine: Legendary 2.0L turbocharged inline-4 4G63 engine, known for its robustness and tuning potential. Aerodynamics: Aggressive body kit, large rear wing, and functional vents for enhanced aerodynamic performance. Interior: Driver-focused cockpit with supportive Recaro seats and performance-oriented instrumentation. 📋 Manual Details Coverage Areas Market Segment: Performance Sedan / Rally Homologation Special Target Audience: Professional Technicians, Experienced DIY Mechanics Page Count Estimated Page Count: Extensive (Typical factory service manuals for this era are 1000+ pages) Manual Type Manual Type: Comprehensive Service & Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, repair, and reassembly of the 4G63 engine (including turbocharger, intercooler, fuel injection, ignition) Engine Electrical: Wiring diagrams, ECU diagnosis, sensor testing, starter, alternator, battery system Transmission: Manual Transmission (F5M51) service, clutch system, driveline components (driveshafts, differentials) Drivetrain: AYC (Active Yaw Control) system, ACD (Active Center Differential) system, viscous coupling unit, transfer case Suspension: Front and rear suspension systems (MacPherson strut front, multi-link rear), springs, dampers, bushings, alignment specifications Brakes: Brake system (front and rear discs, ABS), hydraulic components, brake pad and rotor replacement, bleeding procedures Steering: Power steering system, steering rack, tie rods, linkage components Fuel System: Fuel pump, injectors, fuel tank, lines, pressure regulation Cooling System: Radiator, cooling fan, water pump, thermostat, coolant specifications Exhaust System: Catalytic converter, mufflers, piping, emissions components HVAC: Heating, Ventilation, and Air Conditioning system service, refrigerant handling Body And Chassis: Body panel removal/installation, interior trim, structural components, rust prevention Electrical Body: Lighting systems, power windows, door locks, wipers, horn, instrument cluster Procedures Included Maintenance: Scheduled maintenance tasks, fluid checks and changes, filter replacements, tune-ups Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts Repair Disassembly: Step-by-step instructions for component removal and disassembly Repair Assembly: Step-by-step instructions for component reassembly and installation Cleaning And Inspection: Procedures for cleaning and inspecting parts for wear and damage Torque Specifications: Critical torque values for fasteners across all systems Wiring Diagrams: Detailed electrical schematics for all vehicle circuits Technical Depth Depth Level: Comprehensive factory-level detail, suitable for engine rebuilds and complex system repairs 📊 Manual Specifications File Format Print Quality: Full Printable (Indicates pages can be printed with clarity) Zoom Functionality: YES (Allows for detailed examination of diagrams and text) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software Requirements: Adobe PDF Reader, WinZip (or equivalent decompression software) Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 4G63T (Inline-4, DOHC, 16-valve, Turbocharged with Intercooler) Displacement: 1997 cc (2.0 Liters) Performance Horsepower Ps: 280 PS (approx. 276 hp) at 6,500 rpm (Japanese Spec) Torque Kgf M: 34.5 kgf-m (approx. 249 lb-ft) at 3,000 rpm (Japanese Spec) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G6-10.5T (or similar variant) Intercooler: Front-mounted, larger capacity than Evo V. Fuel Type Recommended Fuel: Premium Unleaded Gasoline (95 RON or higher) 🔧 Transmission Standard Transmission Type: 5-speed Manual (F5M51) Optional Optional Transmission: N/A (Manual transmission was standard) Features Drivetrain Configuration: All-Wheel Drive (AWD) with Active Center Differential (ACD) Ayc System: Active Yaw Control (AYC) for improved cornering stability and agility. 📐 Dimensions Exterior Length: 4,350 mm (171.3 in) Width: 1,770 mm (69.7 in) Height: 1,435 mm (56.5 in) Wheelbase: 2,600 mm (102.4 in) Weights Curb Weight: Approx. 1,360 kg (2,998 lbs) Gross Vehicle Weight Rating: Not readily available, consult specific market documentation. Wheels Tires Wheel Size Standard: 17 x 7.5 inches Tire Size Standard: 215/40R17 (or similar performance-oriented tire) Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Vehicle not typically subjected to standardized crash testing regimes of modern vehicles, focus on homologation for motorsport). Active Features ABS: Standard Anti-lock Braking System Ayc: Active Yaw Control (enhances stability and handling) Acd: Active Center Differential (electronically controlled torque distribution) Passive Features Airbags: Driver and Passenger Airbags Seatbelts: Three-point front and rear seatbelts, pre-tensioners Chassis Reinforcement: Reinforced body structure for rigidity and safety 💡 Technology Features Infotainment Head Unit: Typically an aftermarket or dealer-installed unit, original units were basic AM/FM/CD or Cassette. Driver Assistance Advanced Features: ACD and AYC systems are primary driver assistance features for performance and...
Heating, Ventilation, and Air Conditioning system service, refrigerant handling
Body And Chassis:
Body panel removal/installation, interior trim, structural components, rust prevention
Electrical Body:
Lighting systems, power windows, door locks, wipers, horn, instrument cluster
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid checks and changes, filter replacements, tune-ups
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts
Repair Disassembly:
Step-by-step instructions for component removal and disassembly
Repair Assembly:
Step-by-step instructions for component reassembly and installation
Cleaning And Inspection:
Procedures for cleaning and inspecting parts for wear and damage
Torque Specifications:
Critical torque values for fasteners across all systems
Wiring Diagrams:
Detailed electrical schematics for all vehicle circuits
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for engine rebuilds and complex system repairs
📊 Manual Specifications
File Format
Print Quality:
Full Printable (Indicates pages can be printed with clarity)
Zoom Functionality:
YES (Allows for detailed examination of diagrams and text)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (or equivalent decompression software)
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T (Inline-4, DOHC, 16-valve, Turbocharged with Intercooler)
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Ps:
280 PS (approx. 276 hp) at 6,500 rpm (Japanese Spec)
Torque Kgf M:
34.5 kgf-m (approx. 249 lb-ft) at 3,000 rpm (Japanese Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Turbocharger:
Mitsubishi TD05HR-16G6-10.5T (or similar variant)
Intercooler:
Front-mounted, larger capacity than Evo V.
Fuel Type
Recommended Fuel:
Premium Unleaded Gasoline (95 RON or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (F5M51)
Optional
Optional Transmission:
N/A (Manual transmission was standard)
Features
Drivetrain Configuration:
All-Wheel Drive (AWD) with Active Center Differential (ACD)
Ayc System:
Active Yaw Control (AYC) for improved cornering stability and agility.
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,435 mm (56.5 in)
Wheelbase:
2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,360 kg (2,998 lbs)
Gross Vehicle Weight Rating:
Not readily available, consult specific market documentation.
Wheels Tires
Wheel Size Standard:
17 x 7.5 inches
Tire Size Standard:
215/40R17 (or similar performance-oriented tire)
Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Vehicle not typically subjected to standardized crash testing regimes of modern vehicles, focus on homologation for motorsport).
Active Features
ABS:
Standard Anti-lock Braking System
Ayc:
Active Yaw Control (enhances stability and handling)
Acd:
Active Center Differential (electronically controlled torque distribution)
Passive Features
Airbags:
Driver and Passenger Airbags
Seatbelts:
Three-point front and rear seatbelts, pre-tensioners
Chassis Reinforcement:
Reinforced body structure for rigidity and safety
💡 Technology Features
Infotainment
Head Unit:
Typically an aftermarket or dealer-installed unit, original units were basic AM/FM/CD or Cassette.
Driver Assistance
Advanced Features:
ACD and AYC systems are primary driver assistance features for performance and stability.
Connectivity
Original Connectivity:
Limited to basic radio and speaker systems; no integrated Bluetooth or navigation as standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km (3,000-4,500 miles) or 6 months, depending on driving conditions.
Air Filter Replacement:
Inspect every 10,000-15,000 km (6,000-9,000 miles), replace as needed.
Spark Plug Replacement:
Refer to manual, typically around 40,000-60,000 km (25,000-37,000 miles) for performance plugs.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 recommended (consult manual for exact specifications, high-performance oils are advised).
Engine Oil Capacity:
Approximately 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene Glycol based, long-life coolant. Consult manual for specific mix ratio and Mitsubishi part numbers.
Transmission Fluid Type:
API GL-4 or GL-5 SAE 75W-90 Hypoid Gear Oil for manual transmission.
Differential Fluid Type:
API GL-5 SAE 75W-90 Hypoid Gear Oil for front and rear differentials. ACD/AYC fluid specifications are highly specialized and critical, consult manual.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Wear:
Ring land failure on piston tops with aggressive tuning or detonation; oil starvation on hard cornering if oil levels are low or baffled properly.
Ayc System:
Potential for pump or motor failure; requires specialized fluid and maintenance.
Clutch Wear:
Wear is dependent on driving style; performance clutches may have shorter lifespans.
Rust Perforation:
Areas prone to rust include wheel arches, sills, and strut towers, especially in regions with salt exposure.
Turbocharger Maintenance:
Requires proper warm-up and cool-down cycles to prevent bearing damage; oil changes are critical.
📚 Vehicle History
Brand Heritage
Motorsport Influence:
Directly derived from Mitsubishi's successful World Rally Championship (WRC) Lancer Evolution models.