Mitsubishi Evolution X Evo 10 2010 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution X (Evo 10) Year: 2010 Codes Chassis Code: CZ4A Engine Code Prefix: 4B1 👋 Introduction Market Position Vehicle Segment: Compact Sports Sedan / Rally Homologation Special Target Demographic: Enthusiast drivers, performance car buyers, rally sport fans Competitive Analysis Key Competitors: Subaru WRX STI, Mitsubishi Lancer Ralliart (lesser performance), Ford Focus RS (later generations), VW Golf R Key Features Performance Attributes: All-wheel drive, turbocharged engine, sophisticated suspension and drivetrain management systems (ACD, AYC, S-AYC), powerful braking system Rally Heritage: Direct lineage from Mitsubishi's WRC (World Rally Championship) winning Lancer Evolution models Handling Dynamics: Renowned for exceptional grip, agility, and driver feedback 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Download Page Count Estimate: 2000+ Pages (typical for comprehensive factory manuals) Target Audience: Professional Technicians, Advanced DIY Enthusiasts 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, inspection, assembly, torque specifications, timing, lubrication, cooling system, turbocharger system Engine Management And Emissions: ECM, sensors (O2, MAP, MAF, etc.), actuators, fuel injection, ignition system, evaporative emission control (EVAP), EGR, OBD-II diagnostics Transmission Manual: Gears, clutch, synchronizers, shift forks, lubrication, overhaul, troubleshooting (e.g., Getrag 6-speed) Transmission Automatic Or Dct: SST (Super-Sport Transmission) details, mechatronics, torque converter, hydraulic control, programming, fluid specifications Drivetrain And Axles: Front and rear differentials, ACD (Active Center Differential), AYC (Active Yaw Control) system, driveshafts, CV joints, propeller shaft Suspension And Steering: Front struts, rear shocks, springs, control arms, bushings, steering rack, power steering system, wheel alignment specifications Brakes And Wheel Hub: Brake system components (calipers, rotors, pads, ABS, EBD, brake booster, master cylinder), parking brake, wheel bearings, hub assemblies, bolt pattern Body And Exterior: Body panel removal and installation, doors, hood, trunk, bumpers, fenders, spoilers, glass, seals, weatherstripping, paint codes Interior And Trim: Dashboard, seats, door panels, headliner, carpeting, HVAC controls, airbags, seatbelts Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn Climate Control HVAC: A/C system components, refrigerant, compressor, condenser, evaporator, heater core, blower motor, controls Safety Systems: Airbag system (SRS), seatbelt pre-tensioners, impact sensors, ABS, traction control, stability control (ASC) Infotainment And Audio: Radio, speakers, navigation system (if equipped), amplifier, antenna Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement Diagnostic Procedures: Troubleshooting charts, fault code interpretation (DTCs), symptom-based diagnostics, wiring harness testing Major Component Overhaul: Engine rebuild, transmission rebuild, differential overhaul, turbocharger replacement Component Replacement: Step-by-step instructions for replacing parts like alternators, starters, fuel pumps, radiators, brake calipers, suspension arms, etc. Calibration And Programming: ECU re-flashing, transmission control module (TCM) programming, steering angle sensor calibration, throttle body relearn procedures Structural Repairs: Frame straightening, body panel replacement, welding procedures (if applicable to the manual's scope) Electrical Troubleshooting: Using multimeters, oscilloscopes, interpreting wiring diagrams, diagnosing circuit faults Technical Depth Depth Level: Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Tools References: Information on necessary diagnostic tools, scan tools, and specialized equipment Torque Specifications: Detailed torque values for all fasteners across various systems Clearances And Tolerances: Specific measurements for component clearances during assembly and rebuilds 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text within PDF for quick information retrieval Print Quality Image Resolution: High-resolution for clear diagrams, schematics, and photographic illustrations Printability: Optimized for printing individual sections or the entire manual Binding Type Binding Type Physical Equivalent: Digital Download (printable equivalent of a factory service manual binder) Paper Type Paper Type Physical Equivalent: Digital Download (equivalent to high-quality, durable paper) ⚙️ Engine Specifications Primary Engine Engine Family: 4B1 Engine Code: 4B11T Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled Displacement: 2.0 Liters (1998 cc) Bore X Stroke: 86.0 mm x 86.0 mm Compression Ratio: 9.0:1 Performance Horsepower Hp: 291 hp @ 6,500 rpm (US Market GSR/MR) Torque Lb-Ft: 300 lb-ft @ 3,500 rpm (US Market GSR/MR) Redline Rpm: 7,000 rpm Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Turbocharger Type: MHI TD05H-15G or similar Mitsubishi Heavy Industries turbocharger Fluid Specifications Engine Oil Type: SAE 5W-30 API SN, ILSAC GF-5 (or equivalent ester-based synthetic) Engine Oil Capacity Liters: 4.5 Liters (4.8 US Quarts) with filter change Coolant Type: Long-life coolant, ethylene glycol based (e.g., Mitsubishi DiaQueen Super Long Life Coolant) 🔧 Transmission Standard Manual Transmission: 6-speed manual (Getrag MT-340 / MS-A) Optional Dct Transmission: 6-speed Twin-Clutch Sportronic Shift Transmission (TC-SST) - Optional on MR and some GSR trims Features Acd System: Active Center Differential (ACD) - electronically controlled for variable torque split between front and rear axles Ayc System: Active Yaw Control (AYC) - rear differential system (or S-AYC in later versions) to control torque distribution between rear wheels for improved cornering Fluid...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution X (Evo 10)

Year:

Codes

Chassis Code:

Engine Code Prefix:

👋 Introduction

Market Position

Vehicle Segment:

Compact Sports Sedan / Rally Homologation Special

Target Demographic:

Enthusiast drivers, performance car buyers, rally sport fans

Competitive Analysis

Key Competitors:

Subaru WRX STI, Mitsubishi Lancer Ralliart (lesser performance), Ford Focus RS (later generations), VW Golf R

Key Features

Performance Attributes:

All-wheel drive, turbocharged engine, sophisticated suspension and drivetrain management systems (ACD, AYC, S-AYC), powerful braking system

Rally Heritage:

Direct lineage from Mitsubishi's WRC (World Rally Championship) winning Lancer Evolution models

Handling Dynamics:

Renowned for exceptional grip, agility, and driver feedback

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count Estimate:

2000+ Pages (typical for comprehensive factory manuals)

Target Audience:

Professional Technicians, Advanced DIY Enthusiasts

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, inspection, assembly, torque specifications, timing, lubrication, cooling system, turbocharger system

Engine Management And Emissions:

ECM, sensors (O2, MAP, MAF, etc.), actuators, fuel injection, ignition system, evaporative emission control (EVAP), EGR, OBD-II diagnostics

Transmission Manual:

Gears, clutch, synchronizers, shift forks, lubrication, overhaul, troubleshooting (e.g., Getrag 6-speed)

Transmission Automatic Or Dct:

SST (Super-Sport Transmission) details, mechatronics, torque converter, hydraulic control, programming, fluid specifications

Drivetrain And Axles:

Front and rear differentials, ACD (Active Center Differential), AYC (Active Yaw Control) system, driveshafts, CV joints, propeller shaft

Suspension And Steering:

Front struts, rear shocks, springs, control arms, bushings, steering rack, power steering system, wheel alignment specifications

Brakes And Wheel Hub:

Brake system components (calipers, rotors, pads, ABS, EBD, brake booster, master cylinder), parking brake, wheel bearings, hub assemblies, bolt pattern

Body And Exterior:

Body panel removal and installation, doors, hood, trunk, bumpers, fenders, spoilers, glass, seals, weatherstripping, paint codes

Interior And Trim:

Dashboard, seats, door panels, headliner, carpeting, HVAC controls, airbags, seatbelts

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn

Climate Control HVAC:

A/C system components, refrigerant, compressor, condenser, evaporator, heater core, blower motor, controls

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, impact sensors, ABS, traction control, stability control (ASC)

Infotainment And Audio:

Radio, speakers, navigation system (if equipped), amplifier, antenna

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement

Diagnostic Procedures:

Troubleshooting charts, fault code interpretation (DTCs), symptom-based diagnostics, wiring harness testing

Major Component Overhaul:

Engine rebuild, transmission rebuild, differential overhaul, turbocharger replacement

Component Replacement:

Step-by-step instructions for replacing parts like alternators, starters, fuel pumps, radiators, brake calipers, suspension arms, etc.

Calibration And Programming:

ECU re-flashing, transmission control module (TCM) programming, steering angle sensor calibration, throttle body relearn procedures

Structural Repairs:

Frame straightening, body panel replacement, welding procedures (if applicable to the manual's scope)

Electrical Troubleshooting:

Using multimeters, oscilloscopes, interpreting wiring diagrams, diagnosing circuit faults

Technical Depth

Depth Level:

Comprehensive Factory Level - Covers everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Tools References:

Information on necessary diagnostic tools, scan tools, and specialized equipment

Torque Specifications:

Detailed torque values for all fasteners across various systems

Clearances And Tolerances:

Specific measurements for component clearances during assembly and rebuilds

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text within PDF for quick information retrieval

Print Quality

Image Resolution:

High-resolution for clear diagrams, schematics, and photographic illustrations

Printability:

Optimized for printing individual sections or the entire manual

Binding Type

Binding Type Physical Equivalent:

Digital Download (printable equivalent of a factory service manual binder)

Paper Type

Paper Type Physical Equivalent:

Digital Download (equivalent to high-quality, durable paper)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Engine Code:

4B11T

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled

Displacement:

2.0 Liters (1998 cc)

Bore X Stroke:

86.0 mm x 86.0 mm

Compression Ratio:

9.0:1

Performance

Horsepower Hp:

291 hp @ 6,500 rpm (US Market GSR/MR)

Torque Lb-Ft:

300 lb-ft @ 3,500 rpm (US Market GSR/MR)

Redline Rpm:

7,000 rpm

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Turbocharger Type:

MHI TD05H-15G or similar Mitsubishi Heavy Industries turbocharger

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API SN, ILSAC GF-5 (or equivalent ester-based synthetic)

Engine Oil Capacity Liters:

4.5 Liters (4.8 US Quarts) with filter change

Coolant Type:

Long-life coolant, ethylene glycol based (e.g., Mitsubishi DiaQueen Super Long Life Coolant)

🔧 Transmission

Standard

Manual Transmission:

6-speed manual (Getrag MT-340 / MS-A)

Optional

Dct Transmission:

6-speed Twin-Clutch Sportronic Shift Transmission (TC-SST) - Optional on MR and some GSR trims

Features

Acd System:

Active Center Differential (ACD) - electronically controlled for variable torque split between front and rear axles

Ayc System:

Active Yaw Control (AYC) - rear differential system (or S-AYC in later versions) to control torque distribution between rear wheels for improved cornering

Fluid Specifications

Manual Transmission Fluid Type:

API GL-4 or GL-5, SAE 75W-90 (specific Mitsubishi recommendation often DiaQueen Super Multi Gear Oil)

Dct Transmission Fluid Type:

Specific Mitsubishi DiaQueen SST Fluid (critical for proper operation and longevity)

📐 Dimensions

Exterior

Length:

4,510 mm (177.6 in)

Width:

1,810 mm (71.3 in)

Height:

1,475 mm (58.1 in)

Wheelbase:

2,635 mm (103.7 in)

Front Track:

1,545 mm (60.8 in)

Rear Track:

1,540 mm (60.6 in)

Cargo

Trunk Volume Cu Ft:

Approx. 10.5 cu ft (may vary slightly by trim/region)

Weights

Curb Weight Kg:

Approx. 1,450 kg - 1,550 kg (3,197 - 3,417 lbs) depending on transmission and trim

Gross Vehicle Weight Rating Gvwr Kg:

Approx. 1,945 kg (4,288 lbs)

Wheels And Tires

Wheel Size Standard:

18 x 8.5 inches (GSR)

Wheel Size Optional Performance:

18 x 8.5 inches (MR - often BBS forged wheels)

Wheel Bolt Pattern:

5x114.3mm (5x4.5 inches)

Tire Size Standard:

245/40R18

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

5-Star (2010 model year, specific tests apply)

IIHS Frontal Offset Score:

Good (2010 model year)

Active Features

Anti-lock Braking System

Electronic Brakeforce Distribution

Active Stability Control (Traction Control System)

Active Center Differential

Active Yaw Control

Passive Features

Srs Airbags:

Driver and front passenger airbags, front side impact airbags, full-length side curtain airbags

Seatbelts:

3-point front seatbelts with pre-tensioners and force limiters, rear 3-point seatbelts

Body Structure:

Reinforced Impact Safety Evolution (RISE) body structure

💡 Technology Features

Infotainment

Audio System Standard:

AM/FM/CD/MP3 stereo with 6 speakers, auxiliary input

Audio System Optional:

Rockford Fosgate premium audio system with subwoofer, Bluetooth connectivity (availability varies by trim and market)

Navigation System:

Optional HDD-based navigation system with touch screen (often integrated with Rockford Fosgate system)

Driver Assistance

Active Dynamics Control:

ACD (Active Center Differential) and AYC (Active Yaw Control) are core performance technology features.

Sport Mode:

TC-SST transmission features manual shift mode and sport mode settings for enhanced driver engagement.

Connectivity

Bluetooth:

Available for hands-free calling and audio streaming on higher trims or with optional packages.

Key Tech Features

Keyless Entry And Start:

Standard on MR trims and optional on GSR, featuring a proximity key and push-button start.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions recommended for performance vehicles)

Engine Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for iridium-tipped plugs

Transmission Fluid Change Manual:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) - highly recommended to check frequently

Transmission Fluid Change Dct:

Every 24,000 miles (39,000 km) or 24 months for TC-SST fluid change (critical)

Transfer Case Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km)

Rear Differential Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km)

Known Issues

Clutch Wear Manual:

High-performance clutches can wear faster under aggressive driving. Dual-mass flywheel can also be a wear item.

Turbocharger Failure:

Can occur due to oil starvation, improper cooling, or debris ingestion. Regular oil changes are crucial.

Engine Internal Wear:

While robust, sustained high-boost operation without proper maintenance can lead to premature wear of rings and bearings.

Dct Tc Sst Issues:

Mechatronic unit failures, clutch pack wear, and solenoid issues can occur, especially if fluid maintenance is neglected. Requires specialized knowledge for repair.

Acd Ayc System Faults:

Can experience electrical issues or solenoid failures, leading to error codes and loss of functionality. Requires specialized diagnostic tools.

Exhaust Manifold Cracking:

Some early 4B11T engines experienced exhaust manifold cracking due to heat cycling. Aftermarket solutions are available.

Bilstein Strut Leaks:

Performance dampers (e.g., Bilstein on MR models) can develop leaks over time, especially with aggressive use.

📚 Vehicle History

Brand Heritage

Rally Success:

Mitsubishi's extensive history and multiple championships in the World Rally Championship (WRC) directly influenced the Lancer Evolution lineage.

Model Evolution

Evolution Series Origin:

The Evo nameplate dates back to the Group A homologation specials required for WRC competition, starting with the Lancer Evolution I in 1992.

Evolution X Introduction:

The tenth generation (Evolution X) was introduced in 2007 and marked a significant redesign, moving to the new GS platform and featuring a new engine (4B11T) and advanced electronics like ACD and AYC.

Model Year 2010 Updates:

The 2010 model year saw minor updates, often related to trim levels (e.g., GSR, MR) and potentially feature packaging. The core mechanicals remained consistent with the initial Evo X.

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Period For Cz4A:

2007 - 2015 (globally, with regional variations)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

While the Evo X itself didn't consistently make the 10Best list, its predecessors and the performance car segment it represents are often featured or discussed in such awards.

Motortrend Car Of The Year:

The Evo X competed in this segment, and while it may not have won the overall award, it was highly regarded for its performance credentials.

Ratings

Track Performance Reviews:

Consistently praised by automotive journalists for its exceptional handling, braking, and all-weather performance on track and in rally-inspired conditions.

Certifications

Emissions Compliance:

Meets EPA and CARB (California Air Resources Board) emissions standards for the model year, as detailed within the manual.