Mitsubishi Lancer Evolution 4 5 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation: IV (CN9A) Model Variant: Evolution IV (Evo 4) Product Name: Mitsubishi Lancer Evolution 4 5 Service Repair Manual 👋 Introduction Market Position Market Segment: Performance Compact Sedan / Rally Homologation Special Target Audience: Enthusiasts, owners, tuners, and independent repair shops specializing in high-performance vehicles Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth (during its era) Key Features Rally Heritage: Developed from Mitsubishi's World Rally Championship (WRC) program, emphasizing performance and handling. All Wheel Drive: Advanced full-time four-wheel-drive system with driver-controlled center differential (ACD) and active yaw control (AYC) for superior traction and cornering. Turbocharged Engine: High-revving, turbocharged engine delivering potent power and torque for exhilarating acceleration. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital Download (PDF) Page Count: Not specified, but professional service manuals are typically extensive (estimated 1000+ pages for comprehensive coverage) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system (injection), exhaust system, ignition system, emission control systems Engine Electrical: Engine control module (ECM) diagnosis, sensor identification and testing, wiring diagrams, starting system, charging system Transmission: Manual transmission (5-speed) disassembly, inspection, and reassembly; clutch system service; transfer case and viscous coupling unit (VCU) service Drivetrain: Front and rear differentials, driveshafts, CV joints, wheel bearings, Super Active Yaw Control (AYC) system service Suspension: Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, stabilizer bars, alignment specifications Steering: Power steering system service, steering rack, tie rods, steering column Brakes: Front and rear disc brakes (Brembo on some models), ABS system service, hydraulic system, parking brake Electrical System: Lighting system, horn, wipers and washers, power windows, central locking, instrument cluster, fuse box locations and diagrams, battery service Body And Chassis: Body panel removal and installation, doors, hood, trunk, interior trim, glass replacement, corrosion protection Heating Ventilation Air Conditioning: HVAC system operation, component replacement, refrigerant service (refer to specific regulations) Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, brake fluid flush, coolant flush, belt inspection/replacement Troubleshooting: Diagnostic procedures for common symptoms, fault code interpretation, electrical and mechanical troubleshooting flowcharts Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems Diagnostics: Detailed diagnostic steps for engine performance, emissions, electrical faults, and mechanical issues Rebuilds: Comprehensive engine and transmission overhaul procedures, including specifications for machining and assembly Technical Depth Diagnostic Tools: Information on required diagnostic tools, including OBD-II scanners (though early models may use proprietary connectors/protocols) Torque Specifications: Precise torque values for all critical fasteners (engine, chassis, suspension, brakes) Clearances And Tolerances: Specified internal engine clearances, bearing tolerances, and other critical assembly measurements Wiring Diagrams: Detailed electrical schematics for all vehicle systems, including component identification and wire colors Special Tools: Identification and use of specialized tools required for specific repair procedures 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing for quick information retrieval Printability: Printable, with the ability to print specific sections or the entire manual Digital Access: Instant download upon payment completion Binding Type Binding Type: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 Engine Type: Inline 4-cylinder, turbocharged and intercooled Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Valvetrain: DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder) Performance Horsepower: Approx. 276 hp (206 kW) at 6500 rpm (Japanese domestic market homologation figure) Torque: Approx. 270 lb-ft (366 Nm) at 5000 rpm (Japanese domestic market homologation figure) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential multi-point injectors Fuel Type: Unleaded premium gasoline (95 RON or higher recommended) Turbocharger: Mitsubishi TD05H-16G (or similar variant) with air-to-air intercooler 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Gear Ratios 1St: 3.083:1 Gear Ratios 2Nd: 2.077:1 Gear Ratios 3Rd: 1.471:1 Gear Ratios 4Th: 1.033:1 Gear Ratios 5Th: 0.761:1 Final Drive Ratio: 4.529:1 Optional Optional Transmission: None (Exclusively Manual) Features Drivetrain Configuration: Full-time 4WD with Active Center Differential (ACD) and Active Yaw Control (AYC) Clutch Type: Hydraulically actuated, single dry plate 📐 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) Front Track: 1500 mm (59.1 in) Rear Track: 1495 mm (58.9 in) Weights Curb Weight: Approx. 1450 kg (3197 lbs) - varies by specification Fuel Tank Capacity: 50 Liters (13.2 US Gallons) 🛡️ Safety Features Ratings Crash Test Results: No official NCAP or NHTSA ratings readily available for this specific JDM homologation model from the era. Active Features Active Center Differential: ACD system adjusts front/rear torque split based on acceleration, braking, and steering input. Active Yaw Control: AYC system controls torque...

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Sku: 298566

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Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generation:

IV (CN9A)

Model Variant:

Evolution IV (Evo 4)

Product Name:

Mitsubishi Lancer Evolution 4 5 Service Repair Manual

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Target Audience:

Enthusiasts, owners, tuners, and independent repair shops specializing in high-performance vehicles

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth (during its era)

Key Features

Rally Heritage:

Developed from Mitsubishi's World Rally Championship (WRC) program, emphasizing performance and handling.

All Wheel Drive:

Advanced full-time four-wheel-drive system with driver-controlled center differential (ACD) and active yaw control (AYC) for superior traction and cornering.

Turbocharged Engine:

High-revving, turbocharged engine delivering potent power and torque for exhilarating acceleration.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

Page Count:

Not specified, but professional service manuals are typically extensive (estimated 1000+ pages for comprehensive coverage)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system (injection), exhaust system, ignition system, emission control systems

Engine Electrical:

Engine control module (ECM) diagnosis, sensor identification and testing, wiring diagrams, starting system, charging system

Transmission:

Manual transmission (5-speed) disassembly, inspection, and reassembly; clutch system service; transfer case and viscous coupling unit (VCU) service

Drivetrain:

Front and rear differentials, driveshafts, CV joints, wheel bearings, Super Active Yaw Control (AYC) system service

Suspension:

Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, stabilizer bars, alignment specifications

Steering:

Power steering system service, steering rack, tie rods, steering column

Brakes:

Front and rear disc brakes (Brembo on some models), ABS system service, hydraulic system, parking brake

Electrical System:

Lighting system, horn, wipers and washers, power windows, central locking, instrument cluster, fuse box locations and diagrams, battery service

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, interior trim, glass replacement, corrosion protection

Heating Ventilation Air Conditioning:

HVAC system operation, component replacement, refrigerant service (refer to specific regulations)

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, brake fluid flush, coolant flush, belt inspection/replacement

Troubleshooting:

Diagnostic procedures for common symptoms, fault code interpretation, electrical and mechanical troubleshooting flowcharts

Repair:

Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems

Diagnostics:

Detailed diagnostic steps for engine performance, emissions, electrical faults, and mechanical issues

Rebuilds:

Comprehensive engine and transmission overhaul procedures, including specifications for machining and assembly

Technical Depth

Diagnostic Tools:

Information on required diagnostic tools, including OBD-II scanners (though early models may use proprietary connectors/protocols)

Torque Specifications:

Precise torque values for all critical fasteners (engine, chassis, suspension, brakes)

Clearances And Tolerances:

Specified internal engine clearances, bearing tolerances, and other critical assembly measurements

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including component identification and wire colors

Special Tools:

Identification and use of specialized tools required for specific repair procedures

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick information retrieval

Printability:

Printable, with the ability to print specific sections or the entire manual

Digital Access:

Instant download upon payment completion

Binding Type

Binding Type:

Not applicable (Digital Download)

Paper Type

Paper Type:

Not applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

Inline 4-cylinder, turbocharged and intercooled

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Valvetrain:

DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder)

Performance

Horsepower:

Approx. 276 hp (206 kW) at 6500 rpm (Japanese domestic market homologation figure)

Torque:

Approx. 270 lb-ft (366 Nm) at 5000 rpm (Japanese domestic market homologation figure)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential multi-point injectors

Fuel Type:

Unleaded premium gasoline (95 RON or higher recommended)

Turbocharger:

Mitsubishi TD05H-16G (or similar variant) with air-to-air intercooler

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission

Gear Ratios 1St:

3.083:1

Gear Ratios 2Nd:

2.077:1

Gear Ratios 3Rd:

1.471:1

Gear Ratios 4Th:

1.033:1

Gear Ratios 5Th:

0.761:1

Final Drive Ratio:

4.529:1

Optional

Optional Transmission:

None (Exclusively Manual)

Features

Drivetrain Configuration:

Full-time 4WD with Active Center Differential (ACD) and Active Yaw Control (AYC)

Clutch Type:

Hydraulically actuated, single dry plate

📐 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)

Front Track:

1500 mm (59.1 in)

Rear Track:

1495 mm (58.9 in)

Weights

Curb Weight:

Approx. 1450 kg (3197 lbs) - varies by specification

Fuel Tank Capacity:

50 Liters (13.2 US Gallons)

🛡️ Safety Features

Ratings

Crash Test Results:

No official NCAP or NHTSA ratings readily available for this specific JDM homologation model from the era.

Active Features

Active Center Differential:

ACD system adjusts front/rear torque split based on acceleration, braking, and steering input.

Active Yaw Control:

AYC system controls torque distribution between rear wheels to enhance cornering stability.

Anti-Lock Braking System:

Standard ABS on all models

Passive Features

Airbags:

Driver's airbag standard, passenger airbag optional or standard depending on market and trim.

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners (front)

Body Structure:

Reinforced unibody construction with crumple zones

💡 Technology Features

Infotainment

Infotainment System:

Basic factory radio (AM/FM, cassette/CD player). Aftermarket upgrades are very common.

Driver Assistance

Driver Assistance Features:

ABS, ACD, AYC. No advanced electronic driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.

Connectivity

Connectivity Features:

Limited to basic audio system connectivity (e.g., antenna).

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first. Severe use may require more frequent changes.

Spark Plugs:

Every 30,000 - 40,000 km (20,000 - 25,000 miles) depending on type (copper vs. iridium).

Timing Belt:

Every 90,000 - 100,000 km (55,000 - 60,000 miles) or 5-7 years. Critical component, replacement highly recommended with water pump and tensioners.

Coolant Flush:

Every 2 years or 40,000 km (25,000 miles)

Brake Fluid Flush:

Every 2 years or 30,000 km (20,000 miles)

Fluid Specifications

Engine Oil Type:

API SG/SH/SJ, ILSAC GF-2/GF-3 or higher. Viscosity: 10W-30 or 10W-40 is common, check manual for specific climate recommendations. Synthetic oil recommended for high-performance driving.

Engine Oil Capacity:

Approx. 4.5 Liters (4.8 US Quarts) with filter change.

Transmission Fluid Type:

API GL-4 or GL-5 hypoid gear oil. Viscosity: 75W-90 or 80W-90. Specific Mitsubishi recommendation for AYC unit may differ.

Transmission Fluid Capacity:

Approx. 2.2 Liters (2.3 US Quarts) for manual transmission. AYC unit capacity varies.

Coolant Type:

Ethylene glycol-based antifreeze, mixed with distilled water (50/50 ratio). Color may vary by manufacturer; consult manual.

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for exact specification).

Known Issues

Engine Oil Sludge:

Can occur with irregular oil changes, especially in heavily modified or track-driven engines. Regular maintenance is crucial.

Ayc Pump Failure:

The AYC hydraulic pump can fail over time, leading to the AYC warning light and loss of its function. Repair or replacement is often required.

Clutch Wear:

As a performance vehicle with aggressive driving, clutch wear is a common maintenance item.

Turbocharger Rebuild/Replacement:

Due to high operating temperatures and boost pressures, turbocharger longevity can be affected by maintenance and driving style.

Acd System Issues:

While generally robust, the ACD unit can sometimes develop issues related to its solenoid or electronic control, often indicated by a warning light.

📚 Vehicle History

Brand Heritage

Motorsport Origins:

Mitsubishi has a long and successful history in motorsport, particularly in the World Rally Championship (WRC).

Model Evolution

Evolution Series Introduction:

The Lancer Evolution series began in 1992 as a homologation special for WRC Group A regulations.

Evo Iv Introduction:

The Evolution IV was introduced in August 1996, marking a significant technological leap with the introduction of ACD and AYC.

Evo Iv Chassis Code:

Production

Production Years:

1996-1998 (for the CN9A chassis)

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Market Focus:

Primarily Japan Domestic Market (JDM), with limited homologation for export markets.

🏆 Awards & Recognition

Recognitions

Rally Homologation:

The Lancer Evolution IV was a critical homologation model for Mitsubishi's WRC campaigns, directly contributing to their rally prestige.

Performance Credentials:

Widely recognized in the automotive press of its time for exceptional handling, grip, and performance, often praised for its 'rally car for the road' feel.