1996-2007 Mitsubishi Lancer Evolution 4-9 Service Manuals

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generations Covered: Evolution IV (CN9A), Evolution V (CP9A), Evolution VI (CP9A), Evolution VII (CT9A), Evolution VIII (CT9A), Evolution IX (CT9A) Model Years Covered: 1996-2007 Chassis Codes Covered: CN9A, CP9A, CT9A Codes Engine Codes Common: 4G63 (DOHC 16V Turbocharged), 4G63T (for Evolution IX) Transmission Codes Common: F5M33 (5-speed manual), V5A51 (5-speed automatic - less common on performance models), MR584378 (6-speed manual for Evo VII onwards) 👋 Introduction Market Position Segment: Performance Compact Sedan / Rally Homologation Special. Target Audience: Enthusiasts, tuners, mechanics, and owners of Mitsubishi Lancer Evolution IV through IX models. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Peugeot 206 WRC (during their respective eras). Key Features Performance Focus: Designed for owners who value performance, handling, and technical understanding of their vehicle. Crucial for maintaining and modifying these highly capable machines. Technical Resource: Provides essential information for DIY maintenance, repair, and advanced tuning. A vital resource for preserving the integrity and performance of the Evolution lineage. 📋 Manual Details Coverage Areas Manual Collection: Consolidated service manuals for Evolution IV through IX. Specific Manuals: Mitsubishi Lancer Evolution VII-VIII-IX Workshop Service Manual (2001-2007), 1996-2001 Mitsubishi Lancer Evolution 4-5-6 Service Manuals Page Count Total Pages Approximate: 2500+ pages (for the VII-IX manual alone, likely more when combined with 4-6) Manual Type Type: Workshop Service Manuals / Repair Manuals Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including timing belt, piston/ring, valve train, cylinder head, crankshaft, connecting rods), Fuel system (injection, fuel pump, injectors, fuel tank), Ignition system, Exhaust system, Turbocharger and intercooler systems, Cooling system (radiator, water pump, thermostat), Lubrication system (oil pump, oil filter, oil pan). Drivetrain: Manual transmission (gearbox overhaul, clutch system, shift linkages), Automatic transmission (if applicable to specific models covered), Transfer case, Front differential, Rear differential (including Active Yaw Control - AYC, Super AYC, ACD systems). Chassis And Suspension: Front suspension (MacPherson struts, control arms, anti-roll bar), Rear suspension (multi-link independent suspension), Steering system (power steering pump, rack and pinion), Brakes (hydraulic system, ABS, calipers, rotors, master cylinder, parking brake), Wheels and tires. Electrical And Electronics: Engine Control Unit (ECU) and related sensors (MAP, MAF, TPS, O2, knock), Ignition coils, Starter motor, Alternator, Battery, Lighting system (headlights, taillights, interior lights), Wiper and washer system, Power windows, Central locking, Audio system wiring, Instrument cluster and gauges, Body Control Module (BCM), SRS (Supplemental Restraint System) airbags and control unit. Body And Interior: Body panels (front fenders, hood, doors, trunk lid), Bumpers, Grille, Interior trim, Seats, Dashboard, HVAC (Heating, Ventilation, and Air Conditioning) system, Door mechanisms, Glass replacement. Procedures Included Maintenance: Scheduled maintenance intervals, oil change procedures, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush and replacement, brake fluid change, transmission fluid change, differential fluid change. Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting guides, electrical circuit diagrams and testing, component testing procedures, fuel pressure testing, compression testing. Repair And Overhaul: Engine rebuild procedures, transmission overhaul, turbocharger replacement, differential rebuilds, brake component replacement, suspension component replacement, steering system repair, electrical component repair/replacement. Special Procedures: Timing belt replacement and engine timing procedures, AYC/ACD system calibration and service, turbocharger boost pressure adjustment (where applicable), ECU relearn procedures. Technical Depth Depth: Comprehensive. Covers basic maintenance to full engine and drivetrain rebuilds, including detailed diagnostic information, wiring diagrams, and component specifications. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: Searchable and Printable PDF. High-resolution scans of original factory manuals. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4G63 Inline 4-Cylinder DOHC 16-Valve Turbocharged Displacement: 2.0 Liters (1997cc) Cylinder Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Performance Horsepower Evolution Iv: 280 PS (276 hp; 206 kW) @ 6,000 rpm (JDM Spec) Torque Evolution Iv: 350 N⋅m (258 lb⋅ft) @ 3,000 rpm (JDM Spec) Horsepower Evolution Vi Tme: 280 PS (276 hp; 206 kW) @ 6,500 rpm Torque Evolution Vi Tme: 373 N⋅m (275 lb⋅ft) @ 3,000 rpm Horsepower Evolution Viii: 276 hp (206 kW) @ 6,500 rpm (US Spec) Torque Evolution Viii: 286 lb⋅ft (388 N⋅m) @ 3,500 rpm (US Spec) Horsepower Evolution Ix: 286 hp (213 kW) @ 6,500 rpm (US Spec) Torque Evolution Ix: 289 lb⋅ft (392 N⋅m) @ 3,500 rpm (US Spec) Engine Induction: Turbocharged with Front-Mounted Intercooler (FMIC). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI). Fuel Type: Unleaded Gasoline (typically requires premium octane fuel for optimal performance and engine health). 🔧 Transmission Standard Type: 5-speed Manual Transmission (F5M33 - early models), 6-speed Manual Transmission (Gravel/Asphalt spec dependent - later models). Optional Type: 5-speed Automatic Transmission (V5A51) - available on some specific trims/markets, but less common for performance-oriented models. Features AWD System: Full-Time Four-Wheel Drive with Active Center Differential...

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Tags: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Car Cars Lancer Evolution 4 Lancer Evolution 5 Lancer Evolution 6 Lancer Evolution 7 Lancer Evolution 8 Lancer Evolution 9 Misc Mitsubishi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generations Covered:

Evolution IV (CN9A), Evolution V (CP9A), Evolution VI (CP9A), Evolution VII (CT9A), Evolution VIII (CT9A), Evolution IX (CT9A)

Model Years Covered:

1996-2007

Chassis Codes Covered:

CN9A, CP9A, CT9A

Codes

Engine Codes Common:

4G63 (DOHC 16V Turbocharged), 4G63T (for Evolution IX)

Transmission Codes Common:

F5M33 (5-speed manual), V5A51 (5-speed automatic - less common on performance models), MR584378 (6-speed manual for Evo VII onwards)

👋 Introduction

Market Position

Segment:

Performance Compact Sedan / Rally Homologation Special.

Target Audience:

Enthusiasts, tuners, mechanics, and owners of Mitsubishi Lancer Evolution IV through IX models.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Escort Cosworth, Peugeot 206 WRC (during their respective eras).

Key Features

Performance Focus:

Designed for owners who value performance, handling, and technical understanding of their vehicle. Crucial for maintaining and modifying these highly capable machines.

Technical Resource:

Provides essential information for DIY maintenance, repair, and advanced tuning. A vital resource for preserving the integrity and performance of the Evolution lineage.

📋 Manual Details

Coverage Areas

Manual Collection:

Consolidated service manuals for Evolution IV through IX.

Specific Manuals:

Mitsubishi Lancer Evolution VII-VIII-IX Workshop Service Manual (2001-2007), 1996-2001 Mitsubishi Lancer Evolution 4-5-6 Service Manuals

Page Count

Total Pages Approximate:

2500+ pages (for the VII-IX manual alone, likely more when combined with 4-6)

Manual Type

Type:

Workshop Service Manuals / Repair Manuals

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (including timing belt, piston/ring, valve train, cylinder head, crankshaft, connecting rods), Fuel system (injection, fuel pump, injectors, fuel tank), Ignition system, Exhaust system, Turbocharger and intercooler systems, Cooling system (radiator, water pump, thermostat), Lubrication system (oil pump, oil filter, oil pan).

Drivetrain:

Manual transmission (gearbox overhaul, clutch system, shift linkages), Automatic transmission (if applicable to specific models covered), Transfer case, Front differential, Rear differential (including Active Yaw Control - AYC, Super AYC, ACD systems).

Chassis And Suspension:

Front suspension (MacPherson struts, control arms, anti-roll bar), Rear suspension (multi-link independent suspension), Steering system (power steering pump, rack and pinion), Brakes (hydraulic system, ABS, calipers, rotors, master cylinder, parking brake), Wheels and tires.

Electrical And Electronics:

Engine Control Unit (ECU) and related sensors (MAP, MAF, TPS, O2, knock), Ignition coils, Starter motor, Alternator, Battery, Lighting system (headlights, taillights, interior lights), Wiper and washer system, Power windows, Central locking, Audio system wiring, Instrument cluster and gauges, Body Control Module (BCM), SRS (Supplemental Restraint System) airbags and control unit.

Body And Interior:

Body panels (front fenders, hood, doors, trunk lid), Bumpers, Grille, Interior trim, Seats, Dashboard, HVAC (Heating, Ventilation, and Air Conditioning) system, Door mechanisms, Glass replacement.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil change procedures, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush and replacement, brake fluid change, transmission fluid change, differential fluid change.

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting guides, electrical circuit diagrams and testing, component testing procedures, fuel pressure testing, compression testing.

Repair And Overhaul:

Engine rebuild procedures, transmission overhaul, turbocharger replacement, differential rebuilds, brake component replacement, suspension component replacement, steering system repair, electrical component repair/replacement.

Special Procedures:

Timing belt replacement and engine timing procedures, AYC/ACD system calibration and service, turbocharger boost pressure adjustment (where applicable), ECU relearn procedures.

Technical Depth

Depth:

Comprehensive. Covers basic maintenance to full engine and drivetrain rebuilds, including detailed diagnostic information, wiring diagrams, and component specifications.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Searchable and Printable PDF. High-resolution scans of original factory manuals.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4G63 Inline 4-Cylinder DOHC 16-Valve Turbocharged

Displacement:

2.0 Liters (1997cc)

Cylinder Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Performance

Horsepower Evolution Iv:

280 PS (276 hp; 206 kW) @ 6,000 rpm (JDM Spec)

Torque Evolution Iv:

350 N⋅m (258 lb⋅ft) @ 3,000 rpm (JDM Spec)

Horsepower Evolution Vi Tme:

280 PS (276 hp; 206 kW) @ 6,500 rpm

Torque Evolution Vi Tme:

373 N⋅m (275 lb⋅ft) @ 3,000 rpm

Horsepower Evolution Viii:

276 hp (206 kW) @ 6,500 rpm (US Spec)

Torque Evolution Viii:

286 lb⋅ft (388 N⋅m) @ 3,500 rpm (US Spec)

Horsepower Evolution Ix:

286 hp (213 kW) @ 6,500 rpm (US Spec)

Torque Evolution Ix:

289 lb⋅ft (392 N⋅m) @ 3,500 rpm (US Spec)

Engine Induction:

Turbocharged with Front-Mounted Intercooler (FMIC).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI).

Fuel Type:

Unleaded Gasoline (typically requires premium octane fuel for optimal performance and engine health).

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (F5M33 - early models), 6-speed Manual Transmission (Gravel/Asphalt spec dependent - later models).

Optional

Type:

5-speed Automatic Transmission (V5A51) - available on some specific trims/markets, but less common for performance-oriented models.

Features

AWD System:

Full-Time Four-Wheel Drive with Active Center Differential (ACD) and optional Active Yaw Control (AYC) or Super AYC (on VII onwards) for enhanced traction and cornering.

Clutch Type:

Hydraulically Operated Single Dry Plate Clutch (manual transmission).

📐 Dimensions

Exterior

Length:

Approx. 4,360 - 4,490 mm (171.7 - 176.8 in) depending on generation and body kit.

Width:

Approx. 1,770 - 1,780 mm (69.7 - 70.1 in).

Height:

Approx. 1,400 - 1,445 mm (55.1 - 56.9 in).

Wheelbase:

Approx. 2,600 - 2,605 mm (102.4 - 102.6 in).

Weights

Curb Weight:

Approx. 1,350 - 1,450 kg (2,976 - 3,197 lb) depending on specification.

Gross Weight:

Varies by model, typically around 1,800 kg (3,968 lb).

🛡️ Safety Features

Ratings

Crash Test Data:

Specific crash test ratings vary by market and year. Early models were not subjected to modern stringent testing standards. Later models (e.g., Evo VII-IX) would have benefited from improved safety structures.

Active Features

Traction Control:

Active Center Differential (ACD), Active Yaw Control (AYC) / Super AYC, All-Wheel Drive (AWD).

Braking System:

Anti-lock Braking System (ABS), Brembo performance brake systems (optional/standard on higher trims and later models).

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional on some models.

Body Structure:

Reinforced chassis and body structure designed for rally homologation and high-performance driving.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/CD stereos with cassette players were standard. Higher trims and later models offered upgraded speaker systems and Nakamichi or Rockford Fosgate audio (depending on market).

Navigation:

Rarely factory-equipped; primarily an aftermarket addition for this era.

Driver Assistance

Traction And Stability:

Advanced AWD, ACD, AYC/Super AYC. No electronic stability control (ESC) in the modern sense until later iterations outside this scope.

Other Features:

Keyless entry, power accessories, limited slip differentials (front/rear, depending on model).

Connectivity

Integration:

Minimal connectivity by modern standards. Primarily focused on vehicle performance systems.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type used. High-performance driving necessitates more frequent changes.

Timing Belt:

Replace every 60,000 - 90,000 miles (96,000 - 145,000 km). Critical component; failure leads to catastrophic engine damage.

Spark Plugs:

Replace every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (standard vs. iridium).

Coolant:

Flush and replace coolant every 2-3 years or 30,000-45,000 miles (48,000-72,000 km).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 - 4.7 Liters (4.8 - 5.0 US Quarts) with filter change (refer to manual for specific engine variant).

Engine Oil Viscosity:

5W-30, 10W-30, or 10W-40 (depending on climate and oil formulation; consult manual for precise recommendations).

Transmission Fluid Type:

Manual: API GL-4 or GL-5 SAE 75W-90 synthetic gear oil. Automatic: ATF SP-III or equivalent. Transfer Case/AYC Fluid: Consult manual for specific Mitsubishi fluids or equivalents.

Coolant Type:

Mitsubishi Super Long Life Coolant (LLC) or equivalent (e.g., ethylene glycol-based antifreeze, typically pink or red).

Known Issues

Engine:

Head gasket failures (especially on heavily modified engines), piston ring land failures (under extreme stress), turbocharger wear, cracked exhaust manifolds.

Drivetrain:

Clutch wear, transmission synchro wear (especially 2nd and 3rd gear), AYC pump failures, differential failures (under high load/abuse).

Suspension And Chassis:

Worn bushings, premature wheel bearing failure, strut mounting issues, corrosion on chassis components (especially in areas with road salt).

Electrical:

Corrosion on electrical connectors, alternator failure, power window motor issues, ABS sensor failures.

📚 Vehicle History

Brand Heritage

Motorsport Connection:

Directly derived from Mitsubishi's highly successful World Rally Championship (WRC) Lancer models. Built for homologation and competition.

Model Evolution

Evolution Iv:

Introduced October 1996. Featured improved suspension, a larger turbocharger, and a more robust powertrain. Active Yaw Control (AYC) introduced.

Evolution V:

Introduced January 1998. Wider body, updated aerodynamics, improved chassis stiffness, larger wheels (17-inch), and larger Brembo brakes. Increased torque.

Evolution Vi:

Introduced October 1999. Further revisions to the 4G63 engine (stronger pistons, different turbocharger), improved cooling, revised AYC. Special editions like Tommi Mäkinen Edition (TME) offered.

Evolution Vii:

Introduced February 2001. Complete redesign on the larger Lancer platform (CT9A chassis). Featured Active Center Differential (ACD) and revised AYC (Super AYC). New 6-speed manual transmission option.

Evolution Viii:

Introduced January 2003. Introduced to the North American market. Further refinements to ACD and AYC, updated interior and exterior styling. Twin-scroll turbocharger for faster spool.

Evolution Ix:

Introduced January 2005. Introduced MIVEC (Mitsubishi Innovative Valve timing Electronic Control) system to the 4G63 engine for improved efficiency and torque across the rev range. Updated aero, new wheels, and interior revisions. Turbocharged 4G63 became 4G63T.

Production

Manufacturing Location:

Japan (primarily Mitsubishi's Mizushima Plant)

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

Widely lauded by automotive press for its performance, handling, and rally-bred capabilities. Consistently ranked among the best performance cars of its era.

Rally Heritage:

Achieved significant success in the World Rally Championship, cementing its reputation as a true driver's car.