Mitsubishi Lancer Evolution IV and V Service Wokshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / Evolution V Chassis Code Evo Iv: CN9A Chassis Code Evo V: CP9A Model Generation Evo Iv: Eighth Generation Lancer (Evo IV) Model Generation Evo V: Eighth Generation Lancer (Evo V) Codes Engine Code Common: 4G63 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution IV and V are iconic rally homologation specials, positioned as high-performance, all-wheel-drive sports sedans for enthusiasts seeking track-day capability and spirited driving on public roads. Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth (earlier era), Audi Quattro (earlier era), rallying-bred compact performance sedans of the late 1990s. Key Features Performance Focus: Emphasis on advanced four-wheel-drive systems (AYC on Evo IV, AYC/ACD on Evo V), turbocharged engines, and stiff chassis for exceptional handling and traction. Rally Heritage: Direct lineage from Mitsubishi's World Rally Championship (WRC) efforts, translating racing technology to production vehicles. Manual Utility Value Proposition: Provides owners and independent mechanics with the authoritative technical documentation needed to maintain, diagnose, and repair these complex performance vehicles, saving significant costs compared to dealership service. 📋 Manual Details Coverage Areas Covered Models: Mitsubishi Lancer Evolution IV (CN9A), Mitsubishi Lancer Evolution V (CP9A) Covered Years Evo Iv: 1996-1997 Covered Years Evo V: 1998-1999 Page Count Estimated Page Count: Comprehensive, likely exceeding 1000 pages across multiple volumes (typical for factory service manuals) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Printability: Printable without restriction Reader Requirement: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, block, pistons, crankshaft, camshafts, valve timing, lubrication system, cooling system, fuel system (mechanical and injection), emission control systems. Engine Management: Ignition system, fuel injection control (ECU diagnostics and component testing), electronic throttle control (drive-by-wire systems specific to the era), sensors and actuators, on-board diagnostics (OBD-II). Transmission Drivetrain: Manual transmission (removal, disassembly, inspection, reassembly, installation), clutch system, transfer case, driveshafts, differentials (front, rear, and center viscous coupling unit - VCUM). Suspension Steering: Front and rear suspension component removal/installation, struts, springs, control arms, anti-roll bars, bushings, power steering system, steering gear, wheel alignment procedures and specifications. Brakes: Brake system components (master cylinder, brake lines, calipers, pads, rotors), ABS system (operation, component testing, bleeding procedures), parking brake. Electrical Electronics: Wiring diagrams, fuse box locations and identification, relay functions, lighting systems, power windows, mirrors, central locking, instrument cluster, horn, wipers/washers, battery, charging system, starter motor. Body Chassis: Body exterior and interior trim removal/installation, doors, hood, trunk, bumpers, glass, seals, frame and chassis components, rust prevention and repair procedures. Climate Control: HVAC system operation, refrigerant handling (R134a), compressor, condenser, evaporator, heater core, blower motor, controls, diagnostic procedures. Safety Features: SRS airbag system (component locations, diagnostic codes, replacement procedures), seat belt mechanisms. Procedures Included General Procedures: Removal, disassembly, inspection, adjustment, reassembly, installation of all major components. Maintenance Procedures: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, belt adjustments/replacements, spark plug replacement, brake pad/rotor replacement. Troubleshooting: Systematic diagnostic charts and procedures for common and uncommon faults, identifying symptoms and pinpointing root causes. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for all critical fasteners across all systems. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and chassis work. 📊 Manual Specifications File Format Quality: High-resolution PDF, suitable for clear viewing and printing. Searchability: Likely text-searchable if created from a digitized factory manual, allowing quick access to specific topics. Print Quality Print Resolution: High, designed for clear reproduction of diagrams and text. Binding Type Binding Type Digital: N/A (Digital PDF) Paper Type Paper Type Digital: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T (DOHC, 16-valve, turbocharged) Engine Displacement: 2.0 Liters (1997 cc) Performance Horsepower Evo Iv: 280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec) Torque Evo Iv: 350 Nm (258 lb-ft) at 3,000 rpm (JDM Spec) Horsepower Evo V: 280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec) Torque Evo V: 373 Nm (275 lb-ft) at 3,000 rpm (JDM Spec) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC) Fuel Type: Unleaded gasoline (premium octane required, typically 95 RON or higher) Turbocharger: Mitsubishi TD05H-16G or TD05HR-16G turbocharger with intercooler Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug or coil-pack setup 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: None offered on these performance models. Features AWD System: Full-time Four-Wheel Drive with Active Yaw Control (AYC) on Evo IV, and Active Center Differential (ACD) coupled with AYC on Evo V. Clutch Type: Hydraulically actuated single-plate dry clutch Fluid Specifications Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (check...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV / Evolution V

Chassis Code Evo Iv:

Chassis Code Evo V:

Model Generation Evo Iv:

Eighth Generation Lancer (Evo IV)

Model Generation Evo V:

Eighth Generation Lancer (Evo V)

Codes

Engine Code Common:

👋 Introduction

Market Position

Positioning:

The Mitsubishi Lancer Evolution IV and V are iconic rally homologation specials, positioned as high-performance, all-wheel-drive sports sedans for enthusiasts seeking track-day capability and spirited driving on public roads.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Escort RS Cosworth (earlier era), Audi Quattro (earlier era), rallying-bred compact performance sedans of the late 1990s.

Key Features

Performance Focus:

Emphasis on advanced four-wheel-drive systems (AYC on Evo IV, AYC/ACD on Evo V), turbocharged engines, and stiff chassis for exceptional handling and traction.

Rally Heritage:

Direct lineage from Mitsubishi's World Rally Championship (WRC) efforts, translating racing technology to production vehicles.

Manual Utility

Value Proposition:

Provides owners and independent mechanics with the authoritative technical documentation needed to maintain, diagnose, and repair these complex performance vehicles, saving significant costs compared to dealership service.

📋 Manual Details

Coverage Areas

Covered Models:

Mitsubishi Lancer Evolution IV (CN9A), Mitsubishi Lancer Evolution V (CP9A)

Covered Years Evo Iv:

1996-1997

Covered Years Evo V:

1998-1999

Page Count

Estimated Page Count:

Comprehensive, likely exceeding 1000 pages across multiple volumes (typical for factory service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language

Language:

English

Format

File Format:

Compatibility:

All Versions of Windows & Mac

Printability:

Printable without restriction

Reader Requirement:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal/installation, cylinder head, block, pistons, crankshaft, camshafts, valve timing, lubrication system, cooling system, fuel system (mechanical and injection), emission control systems.

Engine Management:

Ignition system, fuel injection control (ECU diagnostics and component testing), electronic throttle control (drive-by-wire systems specific to the era), sensors and actuators, on-board diagnostics (OBD-II).

Transmission Drivetrain:

Manual transmission (removal, disassembly, inspection, reassembly, installation), clutch system, transfer case, driveshafts, differentials (front, rear, and center viscous coupling unit - VCUM).

Suspension Steering:

Front and rear suspension component removal/installation, struts, springs, control arms, anti-roll bars, bushings, power steering system, steering gear, wheel alignment procedures and specifications.

Brakes:

Brake system components (master cylinder, brake lines, calipers, pads, rotors), ABS system (operation, component testing, bleeding procedures), parking brake.

Electrical Electronics:

Wiring diagrams, fuse box locations and identification, relay functions, lighting systems, power windows, mirrors, central locking, instrument cluster, horn, wipers/washers, battery, charging system, starter motor.

Body Chassis:

Body exterior and interior trim removal/installation, doors, hood, trunk, bumpers, glass, seals, frame and chassis components, rust prevention and repair procedures.

Climate Control:

HVAC system operation, refrigerant handling (R134a), compressor, condenser, evaporator, heater core, blower motor, controls, diagnostic procedures.

Safety Features:

SRS airbag system (component locations, diagnostic codes, replacement procedures), seat belt mechanisms.

Procedures Included

General Procedures:

Removal, disassembly, inspection, adjustment, reassembly, installation of all major components.

Maintenance Procedures:

Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, belt adjustments/replacements, spark plug replacement, brake pad/rotor replacement.

Troubleshooting:

Systematic diagnostic charts and procedures for common and uncommon faults, identifying symptoms and pinpointing root causes.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Torque Specifications:

Precise torque values for all critical fasteners across all systems.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and chassis work.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, suitable for clear viewing and printing.

Searchability:

Likely text-searchable if created from a digitized factory manual, allowing quick access to specific topics.

Print Quality

Print Resolution:

High, designed for clear reproduction of diagrams and text.

Binding Type

Binding Type Digital:

N/A (Digital PDF)

Paper Type

Paper Type Digital:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T (DOHC, 16-valve, turbocharged)

Engine Displacement:

2.0 Liters (1997 cc)

Performance

Horsepower Evo Iv:

280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec)

Torque Evo Iv:

350 Nm (258 lb-ft) at 3,000 rpm (JDM Spec)

Horsepower Evo V:

280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec)

Torque Evo V:

373 Nm (275 lb-ft) at 3,000 rpm (JDM Spec)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC)

Fuel Type:

Unleaded gasoline (premium octane required, typically 95 RON or higher)

Turbocharger:

Mitsubishi TD05H-16G or TD05HR-16G turbocharger with intercooler

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with coil-on-plug or coil-pack setup

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

None offered on these performance models.

Features

AWD System:

Full-time Four-Wheel Drive with Active Yaw Control (AYC) on Evo IV, and Active Center Differential (ACD) coupled with AYC on Evo V.

Clutch Type:

Hydraulically actuated single-plate dry clutch

Fluid Specifications

Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (check manual for specific viscosity and OEM recommendation)

Transfer Case Fluid:

Refer to manual, typically same as transmission fluid or specialized LSD fluid for front diff.

Rear Differential Fluid:

API GL-5, SAE 80W-90 or 75W-90 (check for LSD additive if equipped with LSD)

📐 Dimensions

Exterior

Length Evo Iv:

4,350 mm (171.3 in)

Width Evo Iv:

1,770 mm (69.7 in)

Height Evo Iv:

1,415 mm (55.7 in)

Wheelbase Evo Iv:

2,600 mm (102.4 in)

Track Width Front Evo Iv:

1,515 mm (59.6 in)

Track Width Rear Evo Iv:

1,505 mm (59.3 in)

Length Evo V:

4,350 mm (171.3 in)

Width Evo V:

1,770 mm (69.7 in)

Height Evo V:

1,415 mm (55.7 in)

Wheelbase Evo V:

2,600 mm (102.4 in)

Weights

Curb Weight Evo Iv:

Approx. 1,400 kg (3,086 lb)

Curb Weight Evo V:

Approx. 1,400 kg (3,086 lb)

Gross Vehicle Weight Rating:

Refer to vehicle placard or manual

Towing Capacity:

Not recommended or specified

🛡️ Safety Features

Ratings

Crash Test Ratings:

No standardized ratings like NHTSA or Euro NCAP were prevalent or consistently applied to these homologation specials in the same way as mainstream vehicles of the era. Focus was on structural integrity for rally use.

Active Features

Braking System:

Four-wheel disc brakes, ventilated front and rear. ABS (Anti-lock Braking System) standard.

Traction Control:

Advanced All-Wheel Drive (AYC, ACD) systems contribute to traction and stability.

Passive Features

Airbags:

Driver and front passenger airbags standard.

Seatbelts:

Three-point seatbelts with pretensioners.

Chassis Structure:

Reinforced chassis and safety cage for enhanced occupant protection.

💡 Technology Features

Infotainment

Head Unit:

Factory fitted AM/FM stereo with CD player and/or cassette tape, typically with equalizer and amplified sound system. Aftermarket upgrades are common.

Speakers:

Multi-speaker system, often including component speakers in front doors and coaxial speakers in the rear.

Driver Assistance

Standard Anti-lock Braking System.

AWD Control:

Advanced AYC (Evo IV) and AYC/ACD (Evo V) systems are the primary dynamic driver assistance features, electronically controlling torque distribution.

Connectivity

Connectivity Features:

Limited by modern standards. Primarily focused on audio playback. No integrated Bluetooth, USB, or smartphone mirroring from the factory.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km (3,100 miles) or 6 months, whichever comes first (recommended for performance driving).

Engine Oil Filter:

Replace with every oil change.

Air Filter:

Inspect every 5,000 km, replace as needed or every 15,000 km (9,300 miles).

Spark Plugs:

Replace every 30,000 km (18,600 miles), use recommended iridium or platinum plugs.

Coolant Flush:

Every 2 years or 40,000 km (24,800 miles).

Timing Belt:

Replace every 90,000 km (56,000 miles) or 6 years. Critically important due to interference engine design.

Brake Fluid Flush:

Every 2 years or 30,000 km (18,600 miles), especially important for performance driving.

Fluid Specifications

Engine Oil:

SAE 10W-30 or 10W-40 synthetic recommended for performance, API SG/SH/SJ or higher. Check manual for specific API classification and viscosity range based on climate.

Engine Coolant:

Ethylene glycol based coolant (typically a 50/50 mix with distilled water). Use Mitsubishi Super Long Life Coolant (SLLC) or equivalent. Do not mix coolant types.

Brake Fluid:

DOT 3 or DOT 4, high-performance fluid (e.g., DOT 4 racing fluid) recommended for spirited driving.

Known Issues

Engine Reliability:

The 4G63T is generally robust, but requires diligent maintenance. Common issues include turbocharger wear, oil consumption, and potential for head gasket failure if consistently overheated or abused without proper cooling system maintenance.

Ayc Acd Reliability:

AYC/ACD system sensors and hydraulic pumps can fail over time, leading to warning lights and compromised handling. Regular fluid changes and system checks are crucial.

Rust:

Common to many Japanese performance cars of this era, rust can affect wheel arches, sills, and the undercarriage, especially in regions with road salt. Thorough inspection and preventative treatment are advised.

Clutch Wear:

High-performance clutches can wear faster with aggressive driving, leading to slipping.

📚 Vehicle History

Brand Heritage

Rally Program:

Mitsubishi's long and successful history in the World Rally Championship (WRC), culminating in multiple driver and manufacturer titles, heavily influenced the development of the Lancer Evolution series.

Model Evolution

Evolution Iv Introduction:

Introduced in August 1996, featuring a significant redesign and the introduction of Active Yaw Control (AYC) for improved cornering performance.

Evolution V Introduction:

Launched in January 1998, with wider bodywork, revised suspension, larger brakes, a titanium-alloy turbocharger, and the addition of Active Center Differential (ACD) alongside AYC, further enhancing dynamic capabilities and meeting new WRC regulations.

Distinction Evo Iv V:

While sharing the same generation, the Evo V is a significant evolution of the Evo IV, with most mechanical and aerodynamic improvements focused on the latter.

Production

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Years Evo Iv:

1996-1997

Production Years Evo V:

1998-1999

🏆 Awards & Recognition

Recognitions

Rally Success:

The Lancer Evolution series, including the IV and V, achieved significant success in WRC, which directly translated to positive brand perception and desirability among enthusiasts.

Automotive Journalism:

Consistently praised by automotive publications for its performance, handling, and technological advancements in its class.

Cult Status:

Achieved a significant cult following among automotive enthusiasts worldwide due to its rally heritage, performance capabilities, and tunability.