Mitsubishi Lancer Evo 6 1999 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Year: 1999 Codes Chassis Code: CP9A Engine Code: 4G63 👋 Introduction Market Position Segment: Performance Rally Homologation Special / Sport Compact Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four Key Features Performance Focus: Iconic rally-bred performance, advanced all-wheel-drive system (AYC, ACD), powerful turbocharged engine Manual Value: Essential for owners and enthusiasts seeking to maintain, repair, or optimize the performance of this specialized vehicle 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, maintenance, and repair Page Count Estimated Pages: Varies by specific edition, typically 500-1000+ pages for comprehensive factory service manuals Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, turbocharger system, drivetrain, manual transmission, AWD system Chassis: Suspension (front and rear), steering system, braking system (including ABS), wheel alignment Electrical: Engine control module (ECM), body control module (BCM), lighting, instruments, audio system, power accessories, wiring diagrams Body: Exterior body panels, interior trim, HVAC system, safety systems (airbags) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), component testing Repair: Component removal and installation, engine rebuilds, transmission overhaul, bodywork repairs, electrical system repairs Technical Data: Torque specifications, clearances, wiring schematics, diagnostic flowcharts Technical Depth Depth: Full factory-level detail, including step-by-step instructions, exploded views, and detailed diagrams for complete overhaul and advanced diagnostics 📊 Manual Specifications File Format Digital Format: PDF (typically high-resolution, searchable text) Print Quality Quality: High-quality reproductions with clear diagrams and text for printed versions Binding Type Binding: Digital (no binding), Printed (coil-bound, spiral-bound, or perfect-bound for durability) Paper Type Paper: For printed manuals: Durable, often glossy or semi-gloss paper to withstand workshop environments ⚙️ Engine Specifications Primary Engine Engine Type: 4G63T (DOHC, 16-valve, Inline-4, turbocharged) Performance Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 (JDM), 8.8:1 (Export) Horsepower: 276 hp (206 kW) @ 6500 rpm (JDM - 'Gentleman's Agreement'), 280-300 hp for export variants Torque: 350 Nm (258 lb-ft) @ 3000 rpm (JDM), 350-370 Nm for export variants Fuel System Fuel Type: Unleaded gasoline (premium unleaded recommended, 95-98 RON/91-93 AKI) Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI) Turbocharger: Mitsubishi TD05HR-16G 8cm² twin-scroll turbocharger Engine Management Ignition System: Electronic ignition with distributor and coil packs Engine Control: ECU (Engine Control Unit) with various sensor inputs (MAP, MAF, TPS, O2, Knock) 🔧 Transmission Standard Type: 6-speed manual transmission (Type RS, GSR-RS) Optional Type: 5-speed manual transmission (GSR) Features AWD System: Full-time 4WD with Active Yaw Control (AYC) and Active Center Differential (ACD) Clutch: Hydraulically operated, single-plate, dry-type clutch Fluid Specs Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (check manual for exact specification) Transfer Case Fluid: API GL-5, SAE 75W-90 (check manual for exact specification) Rear Differential Fluid: API GL-5, SAE 75W-90 (check manual for exact specification) 📐 Dimensions Exterior Length: 4350 mm (171.3 in) Width: 1770 mm (69.7 in) Height: 1415 mm (55.7 in) Wheelbase: 2600 mm (102.4 in) Track Width Front: 1515 mm (59.6 in) Track Width Rear: 1505 mm (59.3 in) Weights Curb Weight: Approximately 1350-1400 kg (2976-3086 lbs), depending on trim Gross Vehicle Weight Rating: Not commonly specified for performance models, but would be higher than curb weight 🛡️ Safety Features Ratings Crash Test Data: Limited specific crash test data available from independent agencies for this era's homologation specials; rely on manufacturer design and safety features Active Features Braking System: Four-wheel disc brakes with ventilated front and rear rotors, ABS (Anti-lock Braking System) Traction Control: Standard on many models, integrated with AWD system AWD System Safety: AYC and ACD contribute to vehicle stability and grip in various conditions Passive Features Airbags: Driver and front passenger airbags Seatbelts: Three-point inertia-reel seatbelts with pretensioners Chassis Construction: Reinforced body structure for rigidity and crash protection 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with cassette and CD player (optional), 4-6 speaker system Instrumentation: Digital odometer, tachometer, boost gauge (on some models), comprehensive warning lights Driver Assistance Traction Control: Traction control system often integrated with AWD Connectivity Original Connectivity: Limited by era; basic radio and power accessories. No modern Bluetooth or USB connectivity. 🔧 Maintenance Service Intervals Oil Change: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (synthetic oil recommended) Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on driving conditions Spark Plug Replacement: Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type Timing Belt Replacement: Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years (critical maintenance item) Fluid Specifications Engine Oil: API SJ, ILSAC GF-2, SAE 10W-30 or 10W-40 (check manual for specific viscosity recommendations based on climate)...
API GL-4 or GL-5, SAE 75W-90 (check manual for exact specification)
Transfer Case Fluid:
API GL-5, SAE 75W-90 (check manual for exact specification)
Rear Differential Fluid:
API GL-5, SAE 75W-90 (check manual for exact specification)
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Track Width Front:
1515 mm (59.6 in)
Track Width Rear:
1505 mm (59.3 in)
Weights
Curb Weight:
Approximately 1350-1400 kg (2976-3086 lbs), depending on trim
Gross Vehicle Weight Rating:
Not commonly specified for performance models, but would be higher than curb weight
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific crash test data available from independent agencies for this era's homologation specials; rely on manufacturer design and safety features
Active Features
Braking System:
Four-wheel disc brakes with ventilated front and rear rotors, ABS (Anti-lock Braking System)
Traction Control:
Standard on many models, integrated with AWD system
AWD System Safety:
AYC and ACD contribute to vehicle stability and grip in various conditions
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners
Chassis Construction:
Reinforced body structure for rigidity and crash protection
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette and CD player (optional), 4-6 speaker system
Instrumentation:
Digital odometer, tachometer, boost gauge (on some models), comprehensive warning lights
Driver Assistance
Traction Control:
Traction control system often integrated with AWD
Connectivity
Original Connectivity:
Limited by era; basic radio and power accessories. No modern Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (synthetic oil recommended)
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on driving conditions
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type
Timing Belt Replacement:
Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years (critical maintenance item)
Fluid Specifications
Engine Oil:
API SJ, ILSAC GF-2, SAE 10W-30 or 10W-40 (check manual for specific viscosity recommendations based on climate)
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water (Mitsubishi Super Long Life Coolant recommended)
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific type and replacement interval)
Power Steering Fluid:
ATF Dexron II or III (check manual for exact specification)
Known Issues
Engine:
Head gasket failure (especially with aggressive tuning), turbocharger wear, piston ring wear
AWD System:
AYC pump failure, ACD issues (can be expensive to repair)
Electrical:
Corrosion in wiring harnesses, starter motor issues
Cooling System:
Radiator leaks, thermostat issues
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's extensive WRC (World Rally Championship) heritage, with the Lancer Evolution series being a direct result of homologation requirements
Model Evolution
Evolution Series:
The Evo VI represented a significant evolution from the Evo V, featuring revised styling, improved cooling, and enhanced AYC/ACD systems
Evo Vi Variants:
Key variants include GSR, RS, RS Sprint (limited edition), Tommi Mäkinen Edition (TME)
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rally Heritage Awards:
Numerous WRC championship titles and victories for the Lancer Evolution series, establishing its performance pedigree
Ratings
Performance Magazine Ratings:
Consistently rated highly by automotive journalists for its handling, acceleration, and rally-inspired driving experience
Certifications
Homologation:
Built to homologate the Lancer for Group A rally racing, demonstrating its purpose-built performance capabilities
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