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Mitsubushi LANCER EVO 6 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI (Evo 6) Codes Chassis Code: CP9A Engine Code Primary: 4G63T 👋 Introduction Market Position Vehicle Segment: Performance Sedan / Rally Homologation Special Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Key Features Manual Value Proposition: Provides detailed, year-specific repair information for a high-performance vehicle, crucial for enthusiasts and professional mechanics. Vehicle Description: Renowned for its rally racing pedigree, advanced all-wheel-drive system, and potent turbocharged engine. 📋 Manual Details Coverage Areas General Repair: All Workshop Repair Procedures Electrical: Electrical Diagrams Included Service Procedures: Comprehensive Service Procedures Page Count Estimated Page Count: Varies (Estimate based on comprehensive coverage: 800-1200 pages) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Delivery Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Engine Removal/Installation, Cylinder Head/Valve, Cylinder/Piston, Crankcase, Crankshaft/Primary shaft, Lubrication, Fuel System Transmission: Clutch, Gearshift Linkage, Sub transmission, Transmission, Crankshaft/Primary shaft (related to gearbox) Suspension Steering: Front Wheel/Suspension, Rear Wheel/Suspension Brakes: Hydraulic Brake Electrical Charging: Battery/Charging System, Ignition System, Electric Starter, Switches General Maintenance: Inspection and Adjustment, Lubrication, Fluid Capacities Body Chassis: Implied through comprehensive repair procedures Procedures Included Maintenance: Routine Service, Fluid Changes, Filter Replacements, Adjustments Repair Rebuild: Engine Rebuilding, Component Overhauls, Drivetrain Repairs, Brake System Repairs Diagnostics: Troubleshooting Sections, Diagnostic Flowcharts (implied) Wiring: Re-wiring Procedures, Electrical Diagrams Technical Depth Depth: Comprehensive Workshop Level (from basic maintenance to complete engine and drivetrain rebuilds) 📊 Manual Specifications File Format Compatibility: PC/MAC Compatible Interactivity: Zoom In/Out Functionality Searchability: PDF format typically allows for text search of keywords within the manual. Print Quality Print Option: Print Specific Pages or Entire Manual Binding Type Binding: Digital (PDF - no physical binding) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged and Intercooled Engine Code: 4G63T (MIVEC system absent in this generation) Performance Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 Horsepower Ps: 280 PS (206 kW) @ 6500 rpm (JDM spec) Torque Nm: 350 Nm (258 lb-ft) @ 3000 rpm (JDM spec) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) with Electronic Fuel Control (ECU) Fuel Type: Unleaded Premium Gasoline (Octane Rating: 98 RON recommended) Cooling System Cooling Type: Water-Cooled, Pressurized System with Thermostatic Control 🔧 Transmission Standard Type: 5-Speed Manual (MLP-310F) Optional Type: N/A (Manual transmission standard for performance focus) Features Drivetrain: All-Wheel Drive (AWD) with Active Yaw Control (AYC) Type II and Front Helical LSD Transfer Case: Mechanical Transfer Case with Center Differential 📐 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) Weights Curb Weight: Approx. 1360 kg (2998 lbs) Gross Vehicle Weight Rating: Not Specified (typically above curb weight) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Vehicle not subjected to extensive modern crash testing standards of the time) Active Features Braking: Front: Ventilated Discs (e.g., Brembo 4-piston calipers on RS model), Rear: Ventilated Discs (e.g., Brembo 2-piston calipers on RS model) Traction Control: Active Yaw Control (AYC) Type II, All-Wheel Drive (AWD) Passive Features Airbags: Driver and Passenger Airbags (Standard) Seatbelts: 3-point Inertia Reel Seatbelts with Pretensioners 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM/CD player with speaker system. Driver Assistance Handling Systems: Active Yaw Control (AYC) Type II, Limited Slip Differentials (Front Helical), MacPherson Strut Front Suspension, Multi-link Rear Suspension. Connectivity Exterior Features: Large rear wing, front fog lights, iconic wide body kit, aluminum hood with vent. 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe use: 2,500 km / 3 months) Air Filter: Inspect every 10,000 km (6,200 miles), replace as needed or at 20,000 km (12,400 miles) Spark Plugs: Replace every 20,000 km (12,400 miles) for standard plugs, potentially longer for iridium plugs (check manual for specifics). Fluid Specifications Engine Oil: API SG or SH, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature) Coolant: Ethylene Glycol based antifreeze coolant (50% mix with distilled water). Capacity approx. 7.5 Liters. Transmission Oil: API GL-4 or GL-5, SAE 75W-90 (Manual Transmission). Capacity approx. 2.3 Liters. Differential Oil Front: API GL-5, SAE 75W-90 (Front Helical LSD). Capacity approx. 1.1 Liters. Differential Oil Rear: API GL-5, SAE 75W-90 (Active Yaw Control). Capacity approx. 1.3 Liters. Known Issues Engine Reliability: The 4G63T is generally robust, but common issues include turbocharger wear, clutch wear due to aggressive driving, and potential valve stem seal issues leading to oil consumption. Ayc System: The Active Yaw Control (AYC) system's pump and differential can be prone to wear or failure, leading to a loss of its characteristic handling benefit. Rust Corrosion: As with many performance cars of its era, rust can be...
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Mitsubushi LANCER EVO 6 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI (Evo 6)
Codes
Chassis Code:
CP9A
Engine Code Primary:
4G63T
👋 Introduction
Market Position
Vehicle Segment:
Performance Sedan / Rally Homologation Special
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale
Key Features
Manual Value Proposition:
Provides detailed, year-specific repair information for a high-performance vehicle, crucial for enthusiasts and professional mechanics.
Vehicle Description:
Renowned for its rally racing pedigree, advanced all-wheel-drive system, and potent turbocharged engine.
📋 Manual Details
Coverage Areas
General Repair:
All Workshop Repair Procedures
Electrical:
Electrical Diagrams Included
Service Procedures:
Comprehensive Service Procedures
Page Count
Estimated Page Count:
Varies (Estimate based on comprehensive coverage: 800-1200 pages)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
Delivery
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Engine Removal/Installation, Cylinder Head/Valve, Cylinder/Piston, Crankcase, Crankshaft/Primary shaft, Lubrication, Fuel System
Transmission:
Clutch, Gearshift Linkage, Sub transmission, Transmission, Crankshaft/Primary shaft (related to gearbox)
Suspension Steering:
Front Wheel/Suspension, Rear Wheel/Suspension
Brakes:
Hydraulic Brake
Electrical Charging:
Battery/Charging System, Ignition System, Electric Starter, Switches
General Maintenance:
Inspection and Adjustment, Lubrication, Fluid Capacities
Body Chassis:
Implied through comprehensive repair procedures
Procedures Included
Maintenance:
Routine Service, Fluid Changes, Filter Replacements, Adjustments
Repair Rebuild:
Engine Rebuilding, Component Overhauls, Drivetrain Repairs, Brake System Repairs
Diagnostics:
Troubleshooting Sections, Diagnostic Flowcharts (implied)
Wiring:
Re-wiring Procedures, Electrical Diagrams
Technical Depth
Depth:
Comprehensive Workshop Level (from basic maintenance to complete engine and drivetrain rebuilds)
📊 Manual Specifications
File Format
Compatibility:
PC/MAC Compatible
Interactivity:
Zoom In/Out Functionality
Searchability:
PDF format typically allows for text search of keywords within the manual.
Print Quality
Print Option:
Print Specific Pages or Entire Manual
Binding Type
Binding:
Digital (PDF - no physical binding)
Paper Type
Paper Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, DOHC, 16-Valve, Turbocharged and Intercooled
Engine Code:
4G63T (MIVEC system absent in this generation)
Performance
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Horsepower Ps:
280 PS (206 kW) @ 6500 rpm (JDM spec)
Torque Nm:
350 Nm (258 lb-ft) @ 3000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) with Electronic Fuel Control (ECU)
Fuel Type:
Unleaded Premium Gasoline (Octane Rating: 98 RON recommended)
Cooling System
Cooling Type:
Water-Cooled, Pressurized System with Thermostatic Control
🔧 Transmission
Standard
Type:
5-Speed Manual (MLP-310F)
Optional
Type:
N/A (Manual transmission standard for performance focus)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) Type II and Front Helical LSD
Transfer Case:
Mechanical Transfer Case with Center Differential
📐 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)
Weights
Curb Weight:
Approx. 1360 kg (2998 lbs)
Gross Vehicle Weight Rating:
Not Specified (typically above curb weight)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Vehicle not subjected to extensive modern crash testing standards of the time)
Active Features
Braking:
Front: Ventilated Discs (e.g., Brembo 4-piston calipers on RS model), Rear: Ventilated Discs (e.g., Brembo 2-piston calipers on RS model)
Traction Control:
Active Yaw Control (AYC) Type II, All-Wheel Drive (AWD)
Passive Features
Airbags:
Driver and Passenger Airbags (Standard)
Seatbelts:
3-point Inertia Reel Seatbelts with Pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM/CD player with speaker system.
Driver Assistance
Handling Systems:
Active Yaw Control (AYC) Type II, Limited Slip Differentials (Front Helical), MacPherson Strut Front Suspension, Multi-link Rear Suspension.
Connectivity
Exterior Features:
Large rear wing, front fog lights, iconic wide body kit, aluminum hood with vent.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe use: 2,500 km / 3 months)
Air Filter:
Inspect every 10,000 km (6,200 miles), replace as needed or at 20,000 km (12,400 miles)
Spark Plugs:
Replace every 20,000 km (12,400 miles) for standard plugs, potentially longer for iridium plugs (check manual for specifics).
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature)
Coolant:
Ethylene Glycol based antifreeze coolant (50% mix with distilled water). Capacity approx. 7.5 Liters.
Transmission Oil:
API GL-4 or GL-5, SAE 75W-90 (Manual Transmission). Capacity approx. 2.3 Liters.
Differential Oil Front:
API GL-5, SAE 75W-90 (Front Helical LSD). Capacity approx. 1.1 Liters.
Differential Oil Rear:
API GL-5, SAE 75W-90 (Active Yaw Control). Capacity approx. 1.3 Liters.
Known Issues
Engine Reliability:
The 4G63T is generally robust, but common issues include turbocharger wear, clutch wear due to aggressive driving, and potential valve stem seal issues leading to oil consumption.
Ayc System:
The Active Yaw Control (AYC) system's pump and differential can be prone to wear or failure, leading to a loss of its characteristic handling benefit.
Rust Corrosion:
As with many performance cars of its era, rust can be an issue, particularly in the wheel arches, sills, and around the rear differential mountings, depending on the climate and maintenance history.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi Motors has a strong heritage in motorsport, particularly in rallying.
Model Evolution
Evo Lineage:
The Lancer Evolution series was created to homologate the Lancer for World Rally Championship (WRC) competition.
Evo 6 Development:
The Evo VI featured improved engine internals, a larger turbocharger, revised suspension geometry, and more aggressive aerodynamics compared to the Evo V. It also introduced the GSR 'Tommi Mäkinen Edition' with further enhancements.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution VI, particularly the Tommi Mäkinen Edition, achieved significant success in the World Rally Championship, contributing to Mitsubishi's strong performance image.
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