Mitsubishi Lancer Evolution 1999 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Year: 1999 Codes Chassis Code: CP9A 👋 Introduction Market Position Vehicle Segment: Performance Compact Sedan / Rally Homologation Special Target Audience: Enthusiasts, tuners, rally competitors, and owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Direct Competitors: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort Cosworth. Key Features Performance Focus: Engineered for high-performance driving and motorsport applications. AWD System: Advanced All-Wheel Drive (AWD) with Active Yaw Control (AYC) for superior traction and handling. Engine Technology: Robust 4G63T turbocharged inline-4 engine, renowned for its tuning potential and durability. 📋 Manual Details Coverage Areas Coverage Continents: Global (primarily focused on JDM and European markets) Coverage Regions: Japan, Europe Page Count Estimated Page Count: Approx. 2000+ pages (across multiple volumes or sections if compiled) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagnostics, disassembly, assembly, inspection, repair, and overhaul of 4G63T engine components (turbocharger, pistons, crankshaft, camshafts, valve train, cooling system, lubrication system). Engine Management: Engine Control Unit (ECU) operation, sensor diagnostics (MAP, TPS, IAT, Knock, O2), actuator control, fuel injection, ignition timing, emissions control systems. Transmission Manual: RM2A (5-speed) gearbox: inspection, repair, clutch system, gear shift mechanism, lubrication. Transmission AWD: Super Active Yaw Control (S-AYC) system: operation, diagnostics, hydraulic control unit, actuators, sensors. Rear differential, viscous coupling unit (VCU). Braking System: Front Brembo 4-piston calipers, rear 2-piston calipers: hydraulic system, brake fluid, master cylinder, power booster, ABS system diagnostics and repair, rotor and pad replacement. Suspension Steering: MacPherson strut front, multi-link rear suspension: component inspection, alignment specifications, shock absorber replacement, spring replacement, power steering system diagnostics. Electrical System: Wiring diagrams, fuse box locations, component testing, starter, alternator, battery, lighting system, horn, wipers, power windows, central locking. Body Interior: Body panel removal and installation, interior trim components, seat adjustment and removal, door mechanisms, glass replacement. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, climate control operation. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, differential fluid changes. Troubleshooting: Diagnostic flowcharts for common engine performance issues, starting problems, electrical faults, and system malfunctions. Repair Overhaul: Complete engine rebuild procedures, transmission overhaul, turbocharger replacement, clutch replacement, brake caliper rebuilding. Diagnostics: On-Board Diagnostics (OBD-I/OBD-II) system, fault code retrieval and interpretation, live data stream analysis. Installation: Procedures for replacing major components such as the engine, transmission, turbocharger, suspension arms, and braking components. Technical Depth Diagnostic Tools: References to required diagnostic tools, scan tools (MUT-II or equivalent), pressure gauges, multimeters. Torque Specifications: Comprehensive list of all critical torque specifications for engine, drivetrain, suspension, and chassis components. Clearances Tolerances: Detailed specifications for piston-to-wall clearance, bearing clearances, valve lash, gear backlash, and other critical engine and drivetrain tolerances. Wiring Diagrams: Full electrical schematics for all vehicle systems, including engine management, chassis electronics, lighting, and accessories. Special Tools: Identification and use of specialized tools required for specific repair procedures (e.g., piston ring compressor, valve spring compressor, flywheel locking tool). 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Print Readability: Designed for clear printing, ensuring legibility of technical diagrams and specifications. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Completeness Completeness Level: Complete Factory Service Manual (FSM) Searchability Search Functionality: Fully searchable text for quick access to specific information. ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled Displacement: 1997 cc (2.0 Liters) Performance Horsepower: Approx. 276-280 PS (272-276 hp) JDM/European spec Torque: Approx. 343-370 Nm (253-273 lb-ft) JDM/European spec Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (High Octane) Turbocharger: Mitsubishi TD05H-16G (or similar variant), twin-scroll Lubrication Oil Capacity: Approx. 4.5 Liters (with filter) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Model: RM2A Optional Optional Transmission: N/A (Manual transmission standard for Evolution models) Features Drive System: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Transfer Case: Center viscous coupling Gear Ratios Final Drive: Manual 1-5: 3.083 / 2.000 / 1.304 / 0.912 / 0.741; Final Drive: 4.563 (typical) 📐 Dimensions Exterior Length: Approx. 4350 mm (171.3 in) Width: Approx. 1770 mm (69.7 in) Height: Approx. 1415 mm (55.7 in) Wheelbase: Approx. 2600 mm (102.4 in) Track Width Front: Approx. 1500 mm (59.1 in) Track Width Rear: Approx. 1495 mm (58.9 in) Weights Curb Weight: Approx. 1360-1400 kg (2998-3086 lbs) Gross Vehicle Weight: Not explicitly stated, but designed for performance. 🛡️ Safety Features Ratings NHTSA Rating: Not available for this specific early model year in a standardized global format. Euro Ncap Rating: Not available for this specific early model year. Active...
Super Active Yaw Control (S-AYC) system: operation, diagnostics, hydraulic control unit, actuators, sensors. Rear differential, viscous coupling unit (VCU).
Braking System:
Front Brembo 4-piston calipers, rear 2-piston calipers: hydraulic system, brake fluid, master cylinder, power booster, ABS system diagnostics and repair, rotor and pad replacement.
Suspension Steering:
MacPherson strut front, multi-link rear suspension: component inspection, alignment specifications, shock absorber replacement, spring replacement, power steering system diagnostics.
Electrical System:
Wiring diagrams, fuse box locations, component testing, starter, alternator, battery, lighting system, horn, wipers, power windows, central locking.
Body Interior:
Body panel removal and installation, interior trim components, seat adjustment and removal, door mechanisms, glass replacement.
HVAC:
Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, climate control operation.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, differential fluid changes.
Troubleshooting:
Diagnostic flowcharts for common engine performance issues, starting problems, electrical faults, and system malfunctions.
On-Board Diagnostics (OBD-I/OBD-II) system, fault code retrieval and interpretation, live data stream analysis.
Installation:
Procedures for replacing major components such as the engine, transmission, turbocharger, suspension arms, and braking components.
Technical Depth
Diagnostic Tools:
References to required diagnostic tools, scan tools (MUT-II or equivalent), pressure gauges, multimeters.
Torque Specifications:
Comprehensive list of all critical torque specifications for engine, drivetrain, suspension, and chassis components.
Clearances Tolerances:
Detailed specifications for piston-to-wall clearance, bearing clearances, valve lash, gear backlash, and other critical engine and drivetrain tolerances.
Wiring Diagrams:
Full electrical schematics for all vehicle systems, including engine management, chassis electronics, lighting, and accessories.
Special Tools:
Identification and use of specialized tools required for specific repair procedures (e.g., piston ring compressor, valve spring compressor, flywheel locking tool).
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF with clear diagrams and text.
Print Quality
Print Readability:
Designed for clear printing, ensuring legibility of technical diagrams and specifications.
Binding Type
Binding Type:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
Completeness
Completeness Level:
Complete Factory Service Manual (FSM)
Searchability
Search Functionality:
Fully searchable text for quick access to specific information.