1999-2010 Mitsubishi Lan Evo 6-7-8-9-10 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Common Name: Lancer Evo, Evo Codes Chassis Codes: CP9A (Evo VI), CT9A (Evo VII, VIII, IX), CZ4A (Evo X) Engine Codes: 4G63 (Evo VI-IX), 4B11T (Evo X) 👋 Introduction Market Position Segment: High-performance compact sedan / rally homologation special. Reputation: Legendary status in rally racing (WRC) and enthusiast circles for its exceptional handling, turbocharged performance, and advanced All-Wheel Drive system. Competitive Analysis Key Rivals: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (in spirit of performance variants). Key Features Powertrain Highlight: Iconic turbocharged 4G63 engine (Evo VI-IX) and the evolution to the 4B11T (Evo X), mated to sophisticated AWD systems with active differentials. Driving Dynamics: Renowned for sharp steering, excellent chassis control, and the ability to transfer power effectively to all four wheels, providing immense grip and agility. 📋 Manual Details Coverage Areas Covered Generations: Evolution VI, Evolution VII, Evolution VIII, Evolution IX, Evolution X Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: Highly comprehensive, likely exceeding 2000 pages across all covered models and years. Manual Type Type: Workshop Service Repair Manual (FSM) Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, timing belt/chain, lubrication, cooling, fuel delivery, emissions control, turbocharger systems. Transmission: Manual transmission (5-speed and 6-speed) and Automatic transmission (where applicable), clutch system, gearbox overhaul, fluid specifications, driveshafts, differentials (front, center, rear). Emphasis on AYC/ACD/Super AYC systems. Drivetrain: All-Wheel Drive (AWD) system, Active Center Differential (ACD), Active Yaw Control (AYC) / Super Active Yaw Control (Super AYC) system operation and servicing, Limited Slip Differentials (LSD). Suspension: Front and rear suspension components, struts, shock absorbers, springs, bushings, alignment specifications, wheel bearing replacement. Brakes: Hydraulic system, ABS, brake calipers, rotors, pads, brake fluid specifications, bleeding procedures, parking brake. Steering: Power steering system, steering rack, tie rods, steering column, alignment specifications. Electrical: Complete wiring diagrams, lighting, ignition system, charging system, starter, fuse box locations and functions, ECUs, sensors, and control modules. Body: Body panel removal and installation, interior trim, doors, windows, mirrors, bumpers, body repair procedures, corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning system components, refrigerant, service procedures. Safety Systems: Airbag system diagnostics and replacement, seat belt mechanisms. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad service, tire rotation. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for common and complex issues. Repair: Step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension and brake work. Diagnostics: OBD-II diagnostic codes, sensor testing, ECU function testing, specialized system diagnostics (e.g., AYC/ACD). Specifications: Torque specifications for all fasteners, clearances, tolerances, engine data, electrical specifications. Diagrams: Detailed exploded views of components, assembly diagrams, wiring schematics, vacuum routing diagrams. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, complex electrical diagnostics, and advanced drivetrain system servicing. Target Audience: Do-it-yourself enthusiasts and professional mechanics. 📊 Manual Specifications File Format Format: PDF Accessibility: Searchable text within the PDF for quick information retrieval. Print Quality Printability: Fully printable pages for use in the workshop. Zoom Functionality: YES (Zoom In/OUT capabilities) Binding Type Binding: Digital (PDF download, no physical binding) Paper Type Paper Type: N/A (Digital Format) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for archive extraction) Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type Evo Vi Ix: 2.0L Inline-4 DOHC 16-Valve Turbocharged (4G63 MIVEC) Engine Type Evo X: 2.0L Inline-4 DOHC 16-Valve Turbocharged (4B11T MIVEC) Performance Evo Vi Horsepower: Approx. 276 hp (206 kW) @ 6250 rpm (JDM spec, often higher in practice). Torque: Approx. 275 lb-ft (373 Nm) @ 3000 rpm (JDM spec). Performance Evo Vii Horsepower: Approx. 280 hp (209 kW) @ 6500 rpm. Torque: Approx. 289 lb-ft (392 Nm) @ 3500 rpm. Performance Evo Viii Horsepower: Approx. 270-286 hp (201-213 kW) depending on market and specific model (e.g., MR). Torque: Approx. 273-289 lb-ft (370-392 Nm). Performance Evo Ix Horsepower: Approx. 287 hp (214 kW) @ 6400 rpm (MR). Introduction of MIVEC on the 4G63. Torque: Approx. 289 lb-ft (392 Nm) @ 3500 rpm. Performance Evo X Horsepower: Approx. 291 hp (217 kW) @ 6500 rpm (GSR). Introduction of 4B11T (all-aluminum). Torque: Approx. 300 lb-ft (407 Nm) @ 3500 rpm (GSR). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-point injection. Fuel Type: Unleaded Premium (91+ octane recommended). Turbocharger: Water-cooled, twin-scroll turbocharger with intercooler (specifics vary by model/trim). 🔧 Transmission Standard Manual Transmission: 5-speed manual (Evo VI, VII, VIII), 6-speed manual (Evo IX, X GSR). Optional Automatic Transmission: 6-speed Twin Clutch SST (Sportronic Shift Transmission) on select Evo X models. Features AWD System: Mitsubishi's All-Wheel Control (AWC) system, featuring electronically...

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Sku: 557532

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Labels: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 4 A Series Car Engines Lan Evo 10 Lan Evo 6 Lan Evo 7 Lan Evo 8 Lan Evo 9 Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Common Name:

Lancer Evo, Evo

Codes

Chassis Codes:

CP9A (Evo VI), CT9A (Evo VII, VIII, IX), CZ4A (Evo X)

Engine Codes:

4G63 (Evo VI-IX), 4B11T (Evo X)

👋 Introduction

Market Position

Segment:

High-performance compact sedan / rally homologation special.

Reputation:

Legendary status in rally racing (WRC) and enthusiast circles for its exceptional handling, turbocharged performance, and advanced All-Wheel Drive system.

Competitive Analysis

Key Rivals:

Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R (in spirit of performance variants).

Key Features

Powertrain Highlight:

Iconic turbocharged 4G63 engine (Evo VI-IX) and the evolution to the 4B11T (Evo X), mated to sophisticated AWD systems with active differentials.

Driving Dynamics:

Renowned for sharp steering, excellent chassis control, and the ability to transfer power effectively to all four wheels, providing immense grip and agility.

📋 Manual Details

Coverage Areas

Covered Generations:

Evolution VI, Evolution VII, Evolution VIII, Evolution IX, Evolution X

Covered Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Page Count

Estimated Page Count:

Highly comprehensive, likely exceeding 2000 pages across all covered models and years.

Manual Type

Type:

Workshop Service Repair Manual (FSM)

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, timing belt/chain, lubrication, cooling, fuel delivery, emissions control, turbocharger systems.

Transmission:

Manual transmission (5-speed and 6-speed) and Automatic transmission (where applicable), clutch system, gearbox overhaul, fluid specifications, driveshafts, differentials (front, center, rear). Emphasis on AYC/ACD/Super AYC systems.

Drivetrain:

All-Wheel Drive (AWD) system, Active Center Differential (ACD), Active Yaw Control (AYC) / Super Active Yaw Control (Super AYC) system operation and servicing, Limited Slip Differentials (LSD).

Suspension:

Front and rear suspension components, struts, shock absorbers, springs, bushings, alignment specifications, wheel bearing replacement.

Brakes:

Hydraulic system, ABS, brake calipers, rotors, pads, brake fluid specifications, bleeding procedures, parking brake.

Steering:

Power steering system, steering rack, tie rods, steering column, alignment specifications.

Electrical:

Complete wiring diagrams, lighting, ignition system, charging system, starter, fuse box locations and functions, ECUs, sensors, and control modules.

Body:

Body panel removal and installation, interior trim, doors, windows, mirrors, bumpers, body repair procedures, corrosion protection.

HVAC:

Heating, Ventilation, and Air Conditioning system components, refrigerant, service procedures.

Safety Systems:

Airbag system diagnostics and replacement, seat belt mechanisms.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad service, tire rotation.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common and complex issues.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension and brake work.

Diagnostics:

OBD-II diagnostic codes, sensor testing, ECU function testing, specialized system diagnostics (e.g., AYC/ACD).

Specifications:

Torque specifications for all fasteners, clearances, tolerances, engine data, electrical specifications.

Diagrams:

Detailed exploded views of components, assembly diagrams, wiring schematics, vacuum routing diagrams.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, complex electrical diagnostics, and advanced drivetrain system servicing.

Target Audience:

Do-it-yourself enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

Format:

Accessibility:

Searchable text within the PDF for quick information retrieval.

Print Quality

Printability:

Fully printable pages for use in the workshop.

Zoom Functionality:

YES (Zoom In/OUT capabilities)

Binding Type

Binding:

Digital (PDF download, no physical binding)

Paper Type

Paper Type:

N/A (Digital Format)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for archive extraction)

Operating System Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type Evo Vi Ix:

2.0L Inline-4 DOHC 16-Valve Turbocharged (4G63 MIVEC)

Engine Type Evo X:

2.0L Inline-4 DOHC 16-Valve Turbocharged (4B11T MIVEC)

Performance Evo Vi

Horsepower:

Approx. 276 hp (206 kW) @ 6250 rpm (JDM spec, often higher in practice).

Torque:

Approx. 275 lb-ft (373 Nm) @ 3000 rpm (JDM spec).

Performance Evo Vii

Horsepower:

Approx. 280 hp (209 kW) @ 6500 rpm.

Torque:

Approx. 289 lb-ft (392 Nm) @ 3500 rpm.

Performance Evo Viii

Horsepower:

Approx. 270-286 hp (201-213 kW) depending on market and specific model (e.g., MR).

Torque:

Approx. 273-289 lb-ft (370-392 Nm).

Performance Evo Ix

Horsepower:

Approx. 287 hp (214 kW) @ 6400 rpm (MR). Introduction of MIVEC on the 4G63.

Torque:

Approx. 289 lb-ft (392 Nm) @ 3500 rpm.

Performance Evo X

Horsepower:

Approx. 291 hp (217 kW) @ 6500 rpm (GSR). Introduction of 4B11T (all-aluminum).

Torque:

Approx. 300 lb-ft (407 Nm) @ 3500 rpm (GSR).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Multi-point injection.

Fuel Type:

Unleaded Premium (91+ octane recommended).

Turbocharger:

Water-cooled, twin-scroll turbocharger with intercooler (specifics vary by model/trim).

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (Evo VI, VII, VIII), 6-speed manual (Evo IX, X GSR).

Optional

Automatic Transmission:

6-speed Twin Clutch SST (Sportronic Shift Transmission) on select Evo X models.

Features

AWD System:

Mitsubishi's All-Wheel Control (AWC) system, featuring electronically controlled Active Center Differential (ACD) and Active Yaw Control (AYC) or Super AYC for enhanced traction and cornering ability.

Gear Ratios:

Specific gear ratios vary by transmission type and model year, detailed in the manual.

Fluid Specifications

Manual Trans Fluid Evo Vi Ix:

API GL-4, SAE 75W-85 or 75W-90 recommended (check manual for precise specs).

Manual Trans Fluid Evo X:

Refer to manual for specific GL-4/GL-5 requirements and viscosity.

Transfer Case Fluid:

Specific Mitsubishi-specified gear oil.

Rear Differential Fluid:

API GL-5, SAE 80W-90 or 75W-90 recommended (check manual for specifics, especially for LSDs).

📐 Dimensions

Exterior

Length:

Approx. 4350-4505 mm (varies by generation/model).

Width:

Approx. 1770-1810 mm.

Height:

Approx. 1430-1450 mm.

Wheelbase:

Approx. 2600-2635 mm.

Weights

Curb Weight:

Approx. 1450-1570 kg.

Gross Weight:

Varies by model, specified in manual.

Cargo

Trunk Capacity:

Approx. 260-290 liters (small due to AWD components).

🛡️ Safety Features

Ratings

NHTSA Ratings:

Varies by market and specific test year. Early models may not have extensive official ratings compared to modern vehicles. Manual will detail safety system designs.

Active Features

Active Safety:

ABS (Anti-lock Braking System), AYC/ACD/Super AYC, Traction Control System (TCL), Electronic Brakeforce Distribution (EBD).

Passive Features

Passive Safety:

Driver and passenger front airbags, side airbags (on some models), reinforced chassis structure, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory cassette/CD players, premium sound systems (e.g., Rockford Fosgate on some models). Manual covers basic operation and speaker replacement.

Navigation:

Optional GPS navigation systems on later models. Manual may cover system basics.

Driver Assistance

Cruise Control:

Available on most models.

Traction Control:

Standard on all models, integrated with AWC system.

Connectivity

OBD Ii:

Standard OBD-II port for diagnostics and emissions testing. Manual details specific diagnostic trouble codes (DTCs).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,750 - 5,000 miles (6,000 - 8,000 km) or 6 months, depending on driving conditions. Enthusiast driving may warrant more frequent changes. Refer to manual.

Timing Belt Replacement:

Critical component. Usually recommended every 60,000 - 100,000 miles (96,000 - 160,000 km) or 5-7 years. Check manual for specific intervals. Failure is catastrophic.

Spark Plug Replacement:

Typically every 30,000 - 60,000 miles depending on plug type (platinum/iridium). Refer to manual.

Coolant Flush:

Every 2-4 years or 30,000-50,000 miles.

Fluid Specifications

Engine Oil:

Viscosity varies (e.g., 5W-30, 10W-30, 10W-40). API SM/SN or equivalent. Refer to manual for exact specification and capacity (approx. 4.5-5.0 liters).

Brake Fluid:

DOT 3 or DOT 4.

Coolant:

Ethylene Glycol-based, long-life coolant (pink or similar color for later models). 50/50 mix with distilled water. Capacity approx. 7-8 liters.

Known Issues

Engine 4G63 Reliability:

Generally very robust, but prone to issues with overheating if cooling system is neglected. Head gasket failures can occur with aggressive tuning or overheating. Timing belt failure is catastrophic.

Ayc Acd Issues:

Electronics and pumps for these systems can fail over time. Fluid leaks from seals are also possible. Manual provides diagnostic procedures.

Rust Corrosion:

Can affect body panels, wheel wells, and undercarriage, especially in areas with road salt. Regular underbody inspection is recommended.

Clutch Wear:

High-performance clutch can wear faster with aggressive driving. Replacement procedures are detailed.

📚 Vehicle History

Brand Heritage

Rally Heritage:

Deeply rooted in World Rally Championship (WRC) success, with multiple driver and manufacturer titles, influencing the car's performance and engineering philosophy.

Model Evolution

Key Changes Vi Vii:

Chassis refinement, improved aerodynamics, introduction of Active Center Differential (ACD) on Evo VII.

Key Changes Vii Viii:

Introduction of Active Yaw Control (AYC) on Evo VIII, bilateral-intake intercooler, revised engine and transmission options.

Key Changes Viii Ix:

Introduction of MIVEC variable valve timing on the 4G63 engine, more powerful turbo, revised AYC/ACD, 6-speed manual transmission.

Key Changes Ix X:

Complete redesign: new platform, new all-aluminum 4B11T engine, introduction of the Super All Wheel Control (S-AWC) system with ACD and AYC, optional TC-SST dual-clutch transmission.

Production

Production Period:

1999-2010 for models covered by this manual. Evolution lineage began earlier.

Manufacturing Locations:

Primarily Japan.

🏆 Awards & Recognition

Recognitions

Rally Championships:

Numerous WRC Manufacturer's and Driver's Championships, solidifying its performance pedigree.

Car And Driver Best Handling:

Frequently cited by automotive publications for its exceptional handling and performance capabilities.