Mitsubishi Evo 4 & 5 1996-1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generations Covered: IV (Evo 4) and V (Evo 5) Model Years Covered: 1996, 1997, 1998, 1999 Codes Chassis Code Evo4: CN9A Chassis Code Evo5: CP9A Engine Code Common: 4G63T (DOHC Turbocharged) 👋 Introduction Market Position Market Position: The Lancer Evolution IV and V were benchmark performance sedans, celebrated for their rally-bred engineering, sophisticated all-wheel-drive systems, and potent turbocharged engines. They represented the pinnacle of affordable, high-performance motoring for their era. Competitive Analysis Competitors Era: Competed against rally homologation specials and performance variants from Subaru (Impreza WRX STi), Toyota (Celica GT-Four), and European performance marques. Key Features Key Features Evo4: Introduction of Active Yaw Control (AYC), revised engine internals, and a distinctive aerodynamic body kit. Marked a significant evolution in drivetrain technology. Key Features Evo5: Further refinement of the Evo IV, featuring wider bodywork, updated suspension geometry, improved intercooler, revised ECU, and a larger turbocharger for increased power and torque. Aimed at enhancing handling stability and outright performance. Manual Value Proposition Value Proposition: This factory service manual provides owners and technicians with the authoritative, in-depth information required to maintain, diagnose, and repair these iconic performance vehicles accurately, preserving their unique capabilities. 📋 Manual Details Coverage Areas Primary Market: Japan (JDM), and markets where these models were officially or unofficially supported. Page Count Estimated Page Count: Hundreds of pages (Exact count varies based on specific sections and models included, but indicates comprehensive coverage). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (likely translated from original Japanese, common for factory manuals). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete teardown, inspection, assembly, and specifications for the 4G63T engine, including turbocharger systems. Engine Management: ECU diagnostics, sensor functions, fuel injection control, ignition timing, and emissions control systems. Drivetrain: Manual and optional automatic transmissions, transfer case, Active Yaw Control (AYC) systems (specific to Evo IV/V), and limited-slip differentials. Suspension: Front and rear suspension components, geometry, alignment specifications, shock absorbers, springs, and bushings. Brakes: Hydraulic system, ABS operation, brake pad/rotor replacement, caliper overhaul, and bleeding procedures. Steering: Power steering system, steering rack, column, and related components. Electrical System: Wiring diagrams, component testing, fuse/relay identification, lighting, charging system, starting system, and battery. HVAC: Air conditioning system, heating, ventilation, blower motor, and controls. Body Exterior: Body panels, doors, windows, mirrors, bumpers, and trim. Body Interior: Seats, dashboard, trim panels, airbags, and interior accessories. Chassis And Frame: Frame construction, collision repair information, and underbody components. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, coolant checks, and belt inspections. Engine Repair: Head gasket replacement, piston/ring service, camshaft timing, and turbocharger rebuild. Transmission Service: Fluid changes, clutch replacement, gearbox disassembly, and rebuild procedures. Brake System Repair: Brake pad/rotor replacement, caliper service, hydraulic line repair, and ABS module diagnosis. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, component testing, and diagnostic codes. Suspension Alignment: Detailed procedures and specifications for wheel alignment (caster, camber, toe). Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon drivability issues. Body Repair: Panel replacement, dent repair techniques, and sealing procedures. Ayc System Service: Diagnosis and service of the Active Yaw Control system, including pump and actuator. Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic maintenance and fluid changes to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork repair. Diagnostic Information: Includes diagnostic trouble codes (DTCs), sensor data interpretation, and component testing procedures. Specifications And Tolerances: Detailed torque specifications, clearances, wear limits, and material specifications for all components. Wiring Diagrams: Complete, detailed electrical wiring diagrams for all vehicle systems. Illustrations And Diagrams: Abundant line drawings, exploded views, and diagrams to aid in component identification and assembly. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Searchability Searchability: Likely text-searchable PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler Engine Code: 4G63T Displacement: 1997 cc (2.0 Liters) Performance Horsepower Evo4: 280 PS (276 hp) @ 6500 rpm (Japanese market regulation limited) Torque Evo4: 330 Nm (243 lb-ft) @ 5000 rpm Horsepower Evo5: 280 PS (276 hp) @ 6500 rpm (Japanese market regulation limited), though often capable of more with revisions. Torque Evo5: 330 Nm (243 lb-ft) @ 5000 rpm (Standard models), some RS variants or later tuned models might have slightly higher figures. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection. Fuel Type: Premium Unleaded Gasoline (95 RON or higher recommended) Turbocharger Turbocharger Type: Mitsubishi Heavy Industries TD05H-16G (Evo IV), TD05HR-16G6-9.8T (Evo V) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Optional Optional Transmission Type: 4-Speed Automatic (less common, primarily in non-RS variants)...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Generations Covered:

IV (Evo 4) and V (Evo 5)

Model Years Covered:

1996, 1997, 1998, 1999

Codes

Chassis Code Evo4:

Chassis Code Evo5:

Engine Code Common:

4G63T (DOHC Turbocharged)

👋 Introduction

Market Position

Market Position:

The Lancer Evolution IV and V were benchmark performance sedans, celebrated for their rally-bred engineering, sophisticated all-wheel-drive systems, and potent turbocharged engines. They represented the pinnacle of affordable, high-performance motoring for their era.

Competitive Analysis

Competitors Era:

Competed against rally homologation specials and performance variants from Subaru (Impreza WRX STi), Toyota (Celica GT-Four), and European performance marques.

Key Features

Key Features Evo4:

Introduction of Active Yaw Control (AYC), revised engine internals, and a distinctive aerodynamic body kit. Marked a significant evolution in drivetrain technology.

Key Features Evo5:

Further refinement of the Evo IV, featuring wider bodywork, updated suspension geometry, improved intercooler, revised ECU, and a larger turbocharger for increased power and torque. Aimed at enhancing handling stability and outright performance.

Manual Value Proposition

Value Proposition:

This factory service manual provides owners and technicians with the authoritative, in-depth information required to maintain, diagnose, and repair these iconic performance vehicles accurately, preserving their unique capabilities.

📋 Manual Details

Coverage Areas

Primary Market:

Japan (JDM), and markets where these models were officially or unofficially supported.

Page Count

Estimated Page Count:

Hundreds of pages (Exact count varies based on specific sections and models included, but indicates comprehensive coverage).

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English (likely translated from original Japanese, common for factory manuals).

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete teardown, inspection, assembly, and specifications for the 4G63T engine, including turbocharger systems.

Engine Management:

ECU diagnostics, sensor functions, fuel injection control, ignition timing, and emissions control systems.

Drivetrain:

Manual and optional automatic transmissions, transfer case, Active Yaw Control (AYC) systems (specific to Evo IV/V), and limited-slip differentials.

Suspension:

Front and rear suspension components, geometry, alignment specifications, shock absorbers, springs, and bushings.

Brakes:

Hydraulic system, ABS operation, brake pad/rotor replacement, caliper overhaul, and bleeding procedures.

Steering:

Power steering system, steering rack, column, and related components.

Electrical System:

Wiring diagrams, component testing, fuse/relay identification, lighting, charging system, starting system, and battery.

HVAC:

Air conditioning system, heating, ventilation, blower motor, and controls.

Body Exterior:

Body panels, doors, windows, mirrors, bumpers, and trim.

Body Interior:

Seats, dashboard, trim panels, airbags, and interior accessories.

Chassis And Frame:

Frame construction, collision repair information, and underbody components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, coolant checks, and belt inspections.

Engine Repair:

Head gasket replacement, piston/ring service, camshaft timing, and turbocharger rebuild.

Transmission Service:

Fluid changes, clutch replacement, gearbox disassembly, and rebuild procedures.

Brake System Repair:

Brake pad/rotor replacement, caliper service, hydraulic line repair, and ABS module diagnosis.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, component testing, and diagnostic codes.

Suspension Alignment:

Detailed procedures and specifications for wheel alignment (caster, camber, toe).

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon drivability issues.

Body Repair:

Panel replacement, dent repair techniques, and sealing procedures.

Ayc System Service:

Diagnosis and service of the Active Yaw Control system, including pump and actuator.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance and fluid changes to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork repair.

Diagnostic Information:

Includes diagnostic trouble codes (DTCs), sensor data interpretation, and component testing procedures.

Specifications And Tolerances:

Detailed torque specifications, clearances, wear limits, and material specifications for all components.

Wiring Diagrams:

Complete, detailed electrical wiring diagrams for all vehicle systems.

Illustrations And Diagrams:

Abundant line drawings, exploded views, and diagrams to aid in component identification and assembly.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

Searchability

Searchability:

Likely text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-Cylinder, DOHC, 16-Valve, Turbocharged with Intercooler

Engine Code:

4G63T

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Evo4:

280 PS (276 hp) @ 6500 rpm (Japanese market regulation limited)

Torque Evo4:

330 Nm (243 lb-ft) @ 5000 rpm

Horsepower Evo5:

280 PS (276 hp) @ 6500 rpm (Japanese market regulation limited), though often capable of more with revisions.

Torque Evo5:

330 Nm (243 lb-ft) @ 5000 rpm (Standard models), some RS variants or later tuned models might have slightly higher figures.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection.

Fuel Type:

Premium Unleaded Gasoline (95 RON or higher recommended)

Turbocharger

Turbocharger Type:

Mitsubishi Heavy Industries TD05H-16G (Evo IV), TD05HR-16G6-9.8T (Evo V)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual

Optional

Optional Transmission Type:

4-Speed Automatic (less common, primarily in non-RS variants)

Features

Drivetrain Layout:

All-Wheel Drive (AWD) with Active Yaw Control (AYC) and viscous coupling center differential.

Ayc System:

Hydraulic system that controls torque distribution to rear wheels based on steering angle, yaw rate, and throttle input.

Clutch Type:

Single Dry Plate Clutch (Hydraulically Actuated)

📐 Dimensions

Exterior

Length Mm Evo4:

Width Mm Evo4:

Height Mm Evo4:

Wheelbase Mm Evo4:

Length Mm Evo5:

Width Mm Evo5:

Height Mm Evo5:

Wheelbase Mm Evo5:

Weights

Curb Weight Kg Evo4:

~1400-1450 (depending on trim)

Curb Weight Kg Evo5:

~1400-1450 (depending on trim)

Gross Vehicle Weight Rating Kg:

Approx. 1700-1750 (Consult specific vehicle VIN for exact GVWR)

Towing Capacity Kg:

Not Recommended/Designed For Towing

🛡️ Safety Features

Ratings

Crash Test Ratings Era:

While formal crash test ratings from agencies like NHTSA/Euro NCAP were less standardized or publicly available for JDM homologation specials of this era, factory safety features were incorporated.

Active Features

Active Safety Features:

All-Wheel Drive (AWD) with AYC, Anti-lock Braking System (ABS), Limited-Slip Differentials (front and rear optional/standard depending on spec).

Passive Features

Passive Safety Features:

Driver and front passenger airbags, reinforced chassis, three-point seatbelts with pre-tensioners, crumple zones.

Rollover Protection:

Reinforced A and B pillars, and roof structure.

💡 Technology Features

Infotainment

Infotainment System:

Basic radio/cassette player or CD player. Speaker configurations varied by trim. Digital displays for climate control and other functions were common.

Driver Assistance

Driver Assistance Features:

ABS, AYC (Active Yaw Control) is the primary advanced dynamic driver assistance system.

Connectivity

Connectivity Features:

Limited by era; typically featured power windows, central locking, and optional power mirrors. No modern connectivity like Bluetooth or USB ports.

Performance Tech

Performance Monitoring:

Gauges included a tachometer, speedometer, oil pressure, oil temperature, and boost gauge (on some trims).

🔧 Maintenance

Service Intervals

Engine Oil Change Interval Km:

5,000 - 7,500 km (or 3-6 months, depending on driving conditions; more frequent recommended for spirited driving).

Engine Oil Filter Replacement:

Replace with every oil change.

Spark Plug Replacement Km:

20,000 - 40,000 km (depending on plug type; Platinum/Iridium may last longer).

Timing Belt Replacement Km:

100,000 km or 7 years (whichever comes first).

Coolant Flush Interval Km:

40,000 - 80,000 km or 2-4 years.

Transmission Fluid Change Km:

40,000 - 60,000 km (Manual Transmission).

Transfer Case Fluid Change Km:

40,000 - 60,000 km.

Rear Differential Fluid Change Km:

40,000 - 60,000 km.

Fluid Specifications

Engine Oil Type:

API SG/SH or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature).

Engine Oil Capacity Liters:

Approx. 4.5 Liters (with filter change).

Coolant Type:

Ethylene Glycol based, for aluminum engines (e.g., Mitsubishi DiaQueen Super Long Life Coolant).

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 Synthetic Gear Oil (for 5-speed manual transmission).

Transfer Case Fluid Type:

API GL-4, SAE 75W-90 Synthetic Gear Oil.

Rear Differential Fluid Type:

API GL-5, SAE 80W-90 or 75W-90 Synthetic Hypoid Gear Oil (Check for LSD-specific oil if equipped).

Brake Fluid Type:

DOT 3 or DOT 4 (High-temperature DOT 4 recommended for spirited use).

Power Steering Fluid Type:

ATF Dexron II or equivalent.

Known Issues

Engine Common Failures:

Head gasket failure (especially if overheated or poorly maintained), turbocharger wear (oil leaks, smoking), connecting rod bearing failures (at high RPM/boost if not properly tuned/maintained).

Ayc System Issues:

AYC pump failure, sensor faults, or fluid leaks can lead to the AYC warning light illuminating.

Suspension Wear:

Worn control arm bushings, ball joints, and shock absorbers due to spirited driving and age.

Clutch Wear:

Clutch wear and tear is accelerated with aggressive driving and frequent launches.

Rust Corrosion:

Vulnerable areas include wheel arches, rocker panels, and the underbody, especially in regions with road salt.

📚 Vehicle History

Brand Heritage

Brand Heritage Motorsport:

Mitsubishi's extensive history in the World Rally Championship (WRC) directly influenced the development and engineering of the Lancer Evolution series, establishing its legendary status.

Model Evolution

Evo4 Development:

Introduced in August 1996, the Evo IV marked a significant departure with a completely new chassis and the pioneering introduction of the Active Yaw Control (AYC) system, enhancing cornering agility. The engine received internal upgrades for improved durability.

Evo5 Development:

Launched in January 1998, the Evo V was an evolution, not a revolution. It featured a wider body kit for improved aerodynamics and tire fitment, suspension geometry tweaks for better stability, and mechanical improvements to the engine and turbocharger, including a larger intercooler and revised ECU. The AYC system was also refined.

Production

Production Period:

Evo IV: August 1996 - August 1998. Evo V: January 1998 - January 1999.

Production Location:

Japan

Variants Evo4:

GSR (standard, AYC), RS (homologation special, AYC delete, closer ratios, lighter interior).

Variants Evo5:

GSR (standard, AYC), RS (homologation special, AYC delete, closer ratios, lighter interior).

🏆 Awards & Recognition

Recognitions

Motorsport Accolades:

The Mitsubishi Lancer Evolution platform achieved numerous victories and championships in the WRC, solidifying its reputation as a dominant force in motorsport.

Automotive Journalism Reviews:

Consistently praised by automotive media for its exceptional handling, braking, and acceleration, earning accolades as one of the greatest performance cars of its era.