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Mitsubishi Lancer Evolution 4 and 5 Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation Code: Evo IV (CN9A), Evo V (CP9A) Codes Chassis Codes: CN9A (Evo IV), CP9A (Evo V) 👋 Introduction Market Position Positioning: The Lancer Evolution IV and V represent a significant era for Mitsubishi's rally-bred performance sedan, targeting enthusiasts and motorsport competitors. These manuals are essential for owners and mechanics maintaining these iconic vehicles. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four. The Evo IV and V were distinguished by their advanced Active Yaw Control (AYC) systems and potent turbocharged engines. Key Features Manual Features: Highly detailed, step-by-step procedures, comprehensive wiring diagrams, torque specifications, special tool requirements, diagnostic flowcharts, exploded views of components. 📋 Manual Details Coverage Areas Models Covered: Mitsubishi Lancer Evolution IV (1996-1997), Mitsubishi Lancer Evolution V (1998-1999) Page Count Estimated Page Count: Extensive (typically several hundred pages per vehicle, often split into multiple volumes) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger system, engine control system (ECU/ECM), manual transmission, automatic transmission (if applicable for specific markets/trims), clutch system, driveshafts, differentials. Chassis: Suspension systems (front and rear), steering system, braking system (including ABS, EBD), wheel and tire system, driveline components. Electrical: Wiring diagrams, lighting systems, starting system, charging system, instrument panel, audio system, power windows, power door locks, supplemental restraint system (SRS/Airbags), climate control systems, sensors, actuators. Body: Body repair, exterior trim, interior trim, doors, windows, roof, bumpers, hood, trunk lid, glass replacement, sealing. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements, spark plug replacement, belt replacement, brake fluid flush. Troubleshooting: Diagnostic procedures for common issues, fault code interpretation, electrical system diagnostics, engine performance diagnostics. Repair: Engine overhaul, transmission overhaul, brake component replacement, suspension component replacement, electrical component repair/replacement, body panel repair. Installation: Component installation procedures (e.g., turbocharger replacement, suspension upgrades). Technical Depth Depth: Comprehensive. Covers from basic maintenance and inspection to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High resolution, suitable for printing clear diagrams and text. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format, printable on standard paper) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63 DOHC Turbocharged Inline-4 Displacement: 2.0 Liters (1997 cc) Performance Horsepower Evo Iv: 280 PS (276 hp; 206 kW) @ 6500 rpm (JDM, officially limited) Torque Evo Iv: 350 Nm (258 lb-ft) @ 3000 rpm (JDM, officially limited) Horsepower Evo V: 280 PS (276 hp; 206 kW) @ 6500 rpm (JDM, officially limited); Often higher in non-JDM markets or unofficial tunes. Torque Evo V: 373 Nm (275 lb-ft) @ 3000 rpm (JDM, officially limited) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Electronic Control Unit (ECU) Turbocharger: Mitsubishi TD05H-16G (Evo IV), TD05HR-16G (Evo V), Intercooled Turbocharger Maintenance Oil Type: API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific ambient temperature recommendations) Oil Capacity: Approx. 4.5 - 5.0 Liters (with filter change) Spark Plugs: NGK BKR6E-11 or equivalent (check manual for exact part number and gap) Known Issues Common Problems: Head gasket failure (especially with aggressive tuning), turbocharger wear, oil slinger failure, piston ring wear, connecting rod issues at high power levels. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transaxle Optional Transmission Type: N/A (Manual transmission was standard for performance focus) Features Drive Type: All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Front Helical Limited-Slip Differential (LSD) Maintenance Manual Transmission Fluid Type: API GL-4 or GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendations) Transfer Case Fluid Type: API GL-4 or GL-5, SAE 75W-90 (check manual) Rear Differential Fluid Type: API GL-5, SAE 90 (check manual for specific AYC unit requirements) 📐 Dimensions Exterior Length Evo Iv: 4350 mm (171.3 in) Width Evo Iv: 1770 mm (69.7 in) Height Evo Iv: 1415 mm (55.7 in) Wheelbase Evo Iv: 2600 mm (102.4 in) Length Evo V: 4365 mm (171.9 in) Width Evo V: 1770 mm (69.7 in) Height Evo V: 1415 mm (55.7 in) Wheelbase Evo V: 2600 mm (102.4 in) Weights Curb Weight Evo Iv: Approx. 1370 kg (3020 lb) Curb Weight Evo V: Approx. 1400 kg (3086 lb) 🛡️ Safety Features Ratings NHTSA Ratings: Not directly applicable for the era and market, as comprehensive testing standards were different. Active Features Active Safety: AYC (Active Yaw Control), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), optional LSD (Limited-Slip Differential). Passive Features Passive Safety: Driver and passenger front airbags, reinforced safety cell, side-impact protection beams. 💡 Technology Features Infotainment Audio System: Factory AM/FM/Cassette/CD player (varies by market and trim). Manual covers removal, installation, and basic troubleshooting of audio...
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Mitsubishi Lancer Evolution 4 and 5 Workshop Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Generation Code:
Evo IV (CN9A), Evo V (CP9A)
Codes
Chassis Codes:
CN9A (Evo IV), CP9A (Evo V)
👋 Introduction
Market Position
Positioning:
The Lancer Evolution IV and V represent a significant era for Mitsubishi's rally-bred performance sedan, targeting enthusiasts and motorsport competitors. These manuals are essential for owners and mechanics maintaining these iconic vehicles.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four. The Evo IV and V were distinguished by their advanced Active Yaw Control (AYC) systems and potent turbocharged engines.
Key Features
Manual Features:
Highly detailed, step-by-step procedures, comprehensive wiring diagrams, torque specifications, special tool requirements, diagnostic flowcharts, exploded views of components.
📋 Manual Details
Coverage Areas
Models Covered:
Mitsubishi Lancer Evolution IV (1996-1997), Mitsubishi Lancer Evolution V (1998-1999)
Page Count
Estimated Page Count:
Extensive (typically several hundred pages per vehicle, often split into multiple volumes)
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger system, engine control system (ECU/ECM), manual transmission, automatic transmission (if applicable for specific markets/trims), clutch system, driveshafts, differentials.
Chassis:
Suspension systems (front and rear), steering system, braking system (including ABS, EBD), wheel and tire system, driveline components.
Electrical:
Wiring diagrams, lighting systems, starting system, charging system, instrument panel, audio system, power windows, power door locks, supplemental restraint system (SRS/Airbags), climate control systems, sensors, actuators.
Body:
Body repair, exterior trim, interior trim, doors, windows, roof, bumpers, hood, trunk lid, glass replacement, sealing.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements, spark plug replacement, belt replacement, brake fluid flush.
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation, electrical system diagnostics, engine performance diagnostics.
Repair:
Engine overhaul, transmission overhaul, brake component replacement, suspension component replacement, electrical component repair/replacement, body panel repair.
Installation:
Component installation procedures (e.g., turbocharger replacement, suspension upgrades).
Technical Depth
Depth:
Comprehensive. Covers from basic maintenance and inspection to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution, suitable for printing clear diagrams and text.
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format, printable on standard paper)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63 DOHC Turbocharged Inline-4
Displacement:
2.0 Liters (1997 cc)
Performance
Horsepower Evo Iv:
280 PS (276 hp; 206 kW) @ 6500 rpm (JDM, officially limited)
Torque Evo Iv:
350 Nm (258 lb-ft) @ 3000 rpm (JDM, officially limited)
Horsepower Evo V:
280 PS (276 hp; 206 kW) @ 6500 rpm (JDM, officially limited); Often higher in non-JDM markets or unofficial tunes.
Torque Evo V:
373 Nm (275 lb-ft) @ 3000 rpm (JDM, officially limited)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Control Unit (ECU)
Turbocharger:
Mitsubishi TD05H-16G (Evo IV), TD05HR-16G (Evo V), Intercooled Turbocharger
Maintenance
Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific ambient temperature recommendations)
Oil Capacity:
Approx. 4.5 - 5.0 Liters (with filter change)
Spark Plugs:
NGK BKR6E-11 or equivalent (check manual for exact part number and gap)
Known Issues
Common Problems:
Head gasket failure (especially with aggressive tuning), turbocharger wear, oil slinger failure, piston ring wear, connecting rod issues at high power levels.
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transaxle
Optional
Transmission Type:
N/A (Manual transmission was standard for performance focus)
Features
Drive Type:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Front Helical Limited-Slip Differential (LSD)
Maintenance
Manual Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (check manual for specific Mitsubishi recommendations)
Transfer Case Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (check manual)
Rear Differential Fluid Type:
API GL-5, SAE 90 (check manual for specific AYC unit requirements)
📐 Dimensions
Exterior
Length Evo Iv:
4350 mm (171.3 in)
Width Evo Iv:
1770 mm (69.7 in)
Height Evo Iv:
1415 mm (55.7 in)
Wheelbase Evo Iv:
2600 mm (102.4 in)
Length Evo V:
4365 mm (171.9 in)
Width Evo V:
1770 mm (69.7 in)
Height Evo V:
1415 mm (55.7 in)
Wheelbase Evo V:
2600 mm (102.4 in)
Weights
Curb Weight Evo Iv:
Approx. 1370 kg (3020 lb)
Curb Weight Evo V:
Approx. 1400 kg (3086 lb)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not directly applicable for the era and market, as comprehensive testing standards were different.
Active Features
Active Safety:
AYC (Active Yaw Control), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), optional LSD (Limited-Slip Differential).
Passive Features
Passive Safety:
Driver and passenger front airbags, reinforced safety cell, side-impact protection beams.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette/CD player (varies by market and trim). Manual covers removal, installation, and basic troubleshooting of audio components.
Driver Assistance
Driver Assistance:
AYC system is the primary advanced technology, actively managing torque distribution to improve cornering grip. ABS and EBD are also standard.
Connectivity
Connectivity:
Limited by the era; primarily focused on vehicle performance systems rather than external connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 6 months, whichever comes first (or more frequently for hard driving).
Timing Belt Replacement:
Every 90,000 km or 5 years (critical for the 4G63 engine; includes tensioner and idler pulleys).
Coolant Flush Interval:
Every 2 years or 40,000 km.
Fluid Specifications
Engine Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent (e.g., Peak Long Life Antifreeze/Coolant, Prestone Long Life).
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific recommendations).
Power Steering Fluid:
Dexron II or equivalent ATF (check manual).
Known Issues
Common Problems:
AYC pump failure, AYC fluid leaks, turbo hose failures, cracked exhaust manifolds, differential issues (especially with hard use), clutch wear.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's extensive success in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series, making it a homologation special.
Model Evolution
Evo Iv Development:
Introduced significant updates including the AYC system, revised engine management, and a redesigned front bumper and grille. Featured a staggered pedal box layout.
Evo V Development:
Further evolution with wider body panels, increased track width, larger intercooler, revised suspension geometry, larger wheels (17-inch), and improved engine cooling. The AYC system was refined.
Production
Production Years:
Evo IV: 1996-1997; Evo V: 1998-1999
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Awards:
The Lancer Evolution platform has a legendary status in motorsport, achieving numerous WRC and regional rally championships.
Automotive Awards:
The Evo IV and V were widely praised by automotive journalists for their handling, performance, and advanced technology, often winning 'performance car of the year' awards in their respective markets.
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