Mitsubishi Evo 6 1999-2001 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Common Name: Evo 6 Chassis Code: CP9A Generation Generation Code: VI Codes Production Years Covered: 1999, 2000, 2001 👋 Introduction Market Position Market Position: Iconic rally homologation special, renowned for its performance and motorsport heritage. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Peugeot 206 WRC (in rally context), but direct road-going competitors were few in its niche. Key Features Key Features: Advanced AWD system (ACD/AYC), potent turbocharged engine, aggressive aerodynamics, high-performance braking, rally-bred chassis. Manual Value Proposition: Essential resource for maintaining the peak performance and reliability of a complex, high-performance vehicle. 📋 Manual Details Coverage Areas All Models Engines: Yes Page Count Estimated Page Count: Approximately 1500-2000+ (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (Disassembly, assembly, overhaul, component testing, timing, lubrication, cooling) Engine Management Electronic: Yes (ECU diagnostics, sensors, actuators, fuel injection, ignition system, emissions control) Fuel System: Yes (Fuel pump, injectors, fuel lines, fuel tank, pressure regulation) Drivetrain: Yes (Driveshafts, CV joints, differential units, propeller shaft) Suspension: Yes (Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications) Steering: Yes (Power steering system, steering gear, column, tie rods, linkage, hydraulic pump) Brakes: Yes (Hydraulic system, ABS system, calipers, rotors, pads, brake fluid specifications, bleeding procedures, parking brake) Electrical System: Yes (Battery, charging system, starter motor, lighting, wipers, horn, power windows, central locking, fuses, relays) Body And Chassis: Yes (Body panels, doors, hood, trunk, glass, interior trim, chassis components, structural repairs) HVAC: Yes (Heating, Ventilation, and Air Conditioning system components, refrigerant handling, diagnosis) Safety Systems: Yes (SRS airbag system, seatbelt operation and diagnosis) Transmission Transmission Manual: Yes (Disassembly, assembly, component replacement, adjustment, fluid specifications for 5-speed manual transmission) Transmission AWD System: Yes (Active Yaw Control - AYC system diagnostics, repair, and calibration, ACD system diagnostics and repair) Procedures Included Routine Maintenance: Yes (Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspections) Troubleshooting Guides: Yes (Systematic diagnostic procedures for common and uncommon faults) Engine Rebuilding: Yes (Detailed steps for complete engine overhaul) Transmission Repair: Yes (Comprehensive guides for manual transmission overhaul) Electrical Diagnostics: Yes (Wiring diagrams, circuit testing, component diagnosis) Suspension And Steering Repair: Yes (Component replacement, adjustments, alignment procedures) Brake System Service: Yes (Replacement, bleeding, ABS system diagnostics) Bodywork And Trim Repair: Yes (Panel removal/installation, interior component servicing) Technical Depth Technical Depth: Comprehensive (Suitable for professional technicians and advanced DIY enthusiasts) Diagnostic Codes: Yes (Includes OBD-I/OBD-II codes and diagnostic procedures) Torque Specifications: Yes (Detailed torque values for all fasteners) Wiring Diagrams: Yes (Complete electrical schematics) Special Tools: Yes (Lists and describes necessary special tools for specific procedures) 📊 Manual Specifications File Format File Format: PDF Searchable Text: Typically yes for well-produced PDFs, allowing keyword searches Print Quality Print Quality: High resolution suitable for printing individual pages or sections Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (Various iterations for Evo VI) Engine Type: Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled Performance Displacement: 1997 cc Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.8:1 Horsepower Net: 276 bhp (206 kW) @ 6250 rpm (Often underestimated, actual output higher) Torque Net: 373 Nm (275 lb-ft) @ 3000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Multi-point) Fuel Type: Unleaded Premium (95 RON or higher recommended) Turbocharger: Mitsubishi TD05H-16G (or similar variant), ball-bearing turbo Engine Management Engine Control Unit: Factory ECU with engine mapping specific to model variants 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: None (Manual was standard for Evo VI) Features AWD System: Mitsubishi's full-time 4WD with Active Center Differential (ACD) and Active Yaw Control (AYC) on most variants. Gear Ratios: Specific gear ratios detailed in manual, crucial for performance tuning and maintenance. Clutch: Hydraulically operated, single-plate dry clutch 📐 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: Approx. 1360 kg (2998 lbs) depending on trim Gross Vehicle Weight Rating: Specified in manual, important for load limits. Cargo Trunk Volume: Limited by chassis and AWD components, exact figures vary but typically small. 🛡️ Safety Features Ratings Crash Test Ratings: Not typically rated by modern agencies like NCAP as it predates widespread mandatory testing for this class. Focus on inherent design. Active Features Active Handling Systems: ACD (Active Center Differential), AYC (Active Yaw Control) for enhanced traction and cornering stability. ABS: Anti-lock Braking System (typically 4-channel) Passive Features Airbags: Driver and front passenger airbags (SRS) Seatbelts: 3-point seatbelts with...
Mitsubishi TD05H-16G (or similar variant), ball-bearing turbo
Engine Management
Engine Control Unit:
Factory ECU with engine mapping specific to model variants
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
None (Manual was standard for Evo VI)
Features
AWD System:
Mitsubishi's full-time 4WD with Active Center Differential (ACD) and Active Yaw Control (AYC) on most variants.
Gear Ratios:
Specific gear ratios detailed in manual, crucial for performance tuning and maintenance.
Clutch:
Hydraulically operated, single-plate dry clutch
📐 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:
Approx. 1360 kg (2998 lbs) depending on trim
Gross Vehicle Weight Rating:
Specified in manual, important for load limits.
Cargo
Trunk Volume:
Limited by chassis and AWD components, exact figures vary but typically small.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not typically rated by modern agencies like NCAP as it predates widespread mandatory testing for this class. Focus on inherent design.
Active Features
Active Handling Systems:
ACD (Active Center Differential), AYC (Active Yaw Control) for enhanced traction and cornering stability.
ABS:
Anti-lock Braking System (typically 4-channel)
Passive Features
Airbags:
Driver and front passenger airbags (SRS)
Seatbelts:
3-point seatbelts with pre-tensioners
Chassis Design:
Reinforced body structure for rally homologation.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory radio/cassette/CD player. Limited by era, focus is on mechanical performance.
Driver Assistance
Driver Assistance Features:
ACD and AYC are the primary advanced driver assistance systems, focused on performance driving dynamics.
Connectivity
Connectivity Options:
None by modern standards (no Bluetooth, USB, etc.)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, especially under spirited driving conditions. Manual specifies factory intervals.
Air Filter Replacement:
Every 15,000-20,000 km (10,000-12,000 miles) or as needed based on driving environment.
Spark Plug Replacement:
Every 30,000-40,000 km (20,000-25,000 miles) for standard plugs; check manual for platinum/iridium recommendations.
Timing Belt Replacement:
Every 90,000-100,000 km (55,000-60,000 miles) or 5-7 years. Crucial due to interference engine design.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or ACEA A2/A3, Viscosity SAE 10W-30 or 10W-40 recommended. Consult manual for specific high-performance oil grades.
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water). Mitsubishi Super Long Life Coolant (or equivalent).
Transmission Fluid Type:
Manual Transmission Fluid (MTF) - Refer to manual for specific GL-4 or GL-5 rating and viscosity. Typically SAE 75W-90.
Differential Fluid Type:
Gear Oil GL-5, SAE 80W-90 for front and rear differentials. ACD/AYC fluids specified separately in manual.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Known Issues
Known Issues:
Weak clutch upgrades may be needed for hard use. AYC pump failure. Turbocharger wear with high mileage/poor maintenance. Crankshaft thrust bearing issues if oil starvation occurs. Piston ring land failure on heavily modified engines.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a strong motorsport lineage, particularly in the World Rally Championship (WRC).
Model Evolution
Evolution Series Origin:
The Lancer Evolution series was created to homologate the Lancer for Group A rallying.
Evo Vi Distinction:
Introduced in January 1999. Featured revised styling, improved cooling, larger turbocharger (often TD05H-16G), stronger pistons, and updated AYC/ACD systems. Tommi Mäkinen Edition (TME) released in 2000 with specific upgrades.
Production
Production Period:
1999-2001
Production Location:
Japan
Motorsport Success:
The Evo VI chassis and variants were highly successful in WRC, with Tommi Mäkinen winning four consecutive WRC drivers' championships from 1996-1999 (though his first title was in an Evo IV).
🏆 Awards & Recognition
Recognitions
Motorsport Awards:
Mitsubishi Lancer Evolution series is a multiple World Rally Championship (WRC) winning platform.
Ratings
Performance Ratings:
Consistently rated as one of the best driver's cars and homologation specials of its era by automotive publications.