Mitsubishi Evo 4 & 5 1996-1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Model Generation: IV & V Model Code Evo Iv: CN9A Model Code Evo V: CP9A Model Years Covered: 1996, 1997, 1998, 1999 👋 Introduction Market Position Market Segment: Performance Sedan / Rally Homologation Special Reputation: Iconic rally-bred performance car, celebrated for its sophisticated AWD system, powerful turbocharged engine, and handling prowess. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale. Key Features Signature Features: Advanced All-Wheel Drive, turbocharged intercooled engine, aggressive styling, homologation for WRC, driver-focused cockpit. Manual Value Target Audience: Mitsubishi Lancer Evolution owners, mechanics, performance tuners, enthusiasts. Utility For Owners: Enables DIY maintenance, repairs, and performance upgrades, saving costs and understanding vehicle systems. 📋 Manual Details Coverage Areas Regions Covered: Global (primary focus on JDM and European markets) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system, timing belt/chain, seals, gaskets, engine mounts. Engine Performance: Turbocharger system (TD05HR-16G for Evo IV, TD05HRA-15G for Evo V), intercooler, fuel injection system (MPI), ignition system, engine control unit (ECU) operation and diagnostics. Transmission: Manual Transmission (W5M33), transfer case, clutch system, shift linkages, transmission mounts, fluid specifications. Drivetrain: All-Wheel Drive (AWD) system, Active Center Differential (ACD) for Evo V, viscous coupling, rear differential, driveshafts, CV joints, wheel bearings. Suspension: Front and rear suspension systems (MacPherson struts front, multi-link rear), springs, shock absorbers, control arms, anti-roll bars, bushings, alignment specifications. Brakes: Front ventilated discs, rear solid discs, ABS system (Bosch), brake calipers, master cylinder, brake lines, parking brake, brake fluid specifications. Steering: Power assisted rack and pinion steering system, steering column, tie rods, steering knuckle, power steering fluid. Electrical: Wiring diagrams, battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, power windows, power locks, central locking. Body And Chassis: Body panel removal and installation, door mechanisms, hood, trunk, bumpers, interior trim, chassis structure, rust prevention, body sealing. HVAC: Heating, ventilation, and air conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant types, cabin filter. Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change. Repair: Engine rebuild procedures, head gasket replacement, turbocharger rebuild/replacement, transmission overhaul, clutch replacement, suspension component replacement, brake caliper rebuild, electrical component diagnosis and repair. Diagnostics: Troubleshooting guides, symptom-based diagnostics, error code interpretation (OBD-I/OBD-II relevant codes), electrical circuit testing, mechanical component testing. Special Tools: Identification and usage of specialized tools required for specific repairs and adjustments. Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures and specifications for all major systems. 📊 Manual Specifications File Format File Format: PDF Print Quality Scan Quality: High-resolution scans, clear text and images, searchable content. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Evo Iv: 4G63T Engine Code Evo V: 4G63T (revised) Engine Type: Inline-4, DOHC, 16-valve, turbocharged, intercooled Displacement: 1997cc (2.0 Liters) Performance Horsepower Evo Iv: 276 bhp @ 6250 rpm (JDM Spec) Torque Evo Iv: 350 Nm (258 lb-ft) @ 3000 rpm (JDM Spec) Horsepower Evo V: 276 bhp @ 6250 rpm (JDM Spec), increased torque Torque Evo V: 373 Nm (275 lb-ft) @ 3000 rpm (JDM Spec) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI), Electronic Fuel Control (EFC) Fuel Type: Unleaded gasoline (98 RON recommended) Ignition System: Distributorless Ignition System (DIS) with individual coil packs Turbocharger Turbocharger Evo Iv: Mitsubishi TD05HR-16G Turbocharger Evo V: Mitsubishi TD05HRA-15G (slightly smaller for improved response) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Code: W5M33 Optional Optional Transmission: None (Only Manual Available) Features Drivetrain Type: All-Wheel Drive (AWD) Acd Evo V: Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow) - Standard on Evo V Transfer Case: Mechanical transfer case with viscous coupling Clutch Type: Hydraulically operated, single dry plate clutch Fluid Specifications Transmission Fluid Type: GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85) Transfer Case Fluid Type: GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85) 📐 Dimensions Exterior Length Evo Iv: 4350 mm (171.3 in) Length Evo V: 4370 mm (172.0 in) Width: 1770 mm (69.7 in) Height Evo Iv: 1415 mm (55.7 in) Height Evo V: 1415 mm (55.7 in) Wheelbase: 2600 mm (102.4 in) Front Track Evo V: 1505 mm (59.3 in) Rear Track Evo V: 1505 mm (59.3 in) Weights Curb Weight Evo Iv: Approx. 1450 kg (3197 lbs) Curb Weight Evo V: Approx. 1460 kg (3219 lbs) Gross Vehicle Weight Rating: Approx. 1735 kg (3825 lbs) 🛡️ Safety Features Ratings Crash Test Results: No specific...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution

Model Generation:

IV & V

Model Code Evo Iv:

Model Code Evo V:

Model Years Covered:

1996, 1997, 1998, 1999

👋 Introduction

Market Position

Market Segment:

Performance Sedan / Rally Homologation Special

Reputation:

Iconic rally-bred performance car, celebrated for its sophisticated AWD system, powerful turbocharged engine, and handling prowess.

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.

Key Features

Signature Features:

Advanced All-Wheel Drive, turbocharged intercooled engine, aggressive styling, homologation for WRC, driver-focused cockpit.

Manual Value

Target Audience:

Mitsubishi Lancer Evolution owners, mechanics, performance tuners, enthusiasts.

Utility For Owners:

Enables DIY maintenance, repairs, and performance upgrades, saving costs and understanding vehicle systems.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primary focus on JDM and European markets)

Page Count

Estimated Page Count:

1000+

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full coverage: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system, timing belt/chain, seals, gaskets, engine mounts.

Engine Performance:

Turbocharger system (TD05HR-16G for Evo IV, TD05HRA-15G for Evo V), intercooler, fuel injection system (MPI), ignition system, engine control unit (ECU) operation and diagnostics.

Transmission:

Manual Transmission (W5M33), transfer case, clutch system, shift linkages, transmission mounts, fluid specifications.

Drivetrain:

All-Wheel Drive (AWD) system, Active Center Differential (ACD) for Evo V, viscous coupling, rear differential, driveshafts, CV joints, wheel bearings.

Suspension:

Front and rear suspension systems (MacPherson struts front, multi-link rear), springs, shock absorbers, control arms, anti-roll bars, bushings, alignment specifications.

Brakes:

Front ventilated discs, rear solid discs, ABS system (Bosch), brake calipers, master cylinder, brake lines, parking brake, brake fluid specifications.

Steering:

Power assisted rack and pinion steering system, steering column, tie rods, steering knuckle, power steering fluid.

Electrical:

Wiring diagrams, battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, power windows, power locks, central locking.

Body And Chassis:

Body panel removal and installation, door mechanisms, hood, trunk, bumpers, interior trim, chassis structure, rust prevention, body sealing.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant types, cabin filter.

Procedures Included

Maintenance:

Routine maintenance schedules, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change.

Repair:

Engine rebuild procedures, head gasket replacement, turbocharger rebuild/replacement, transmission overhaul, clutch replacement, suspension component replacement, brake caliper rebuild, electrical component diagnosis and repair.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, error code interpretation (OBD-I/OBD-II relevant codes), electrical circuit testing, mechanical component testing.

Special Tools:

Identification and usage of specialized tools required for specific repairs and adjustments.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures and specifications for all major systems.

📊 Manual Specifications

File Format

File Format:

Print Quality

Scan Quality:

High-resolution scans, clear text and images, searchable content.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code Evo Iv:

4G63T

Engine Code Evo V:

4G63T (revised)

Engine Type:

Inline-4, DOHC, 16-valve, turbocharged, intercooled

Displacement:

1997cc (2.0 Liters)

Performance

Horsepower Evo Iv:

276 bhp @ 6250 rpm (JDM Spec)

Torque Evo Iv:

350 Nm (258 lb-ft) @ 3000 rpm (JDM Spec)

Horsepower Evo V:

276 bhp @ 6250 rpm (JDM Spec), increased torque

Torque Evo V:

373 Nm (275 lb-ft) @ 3000 rpm (JDM Spec)

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI), Electronic Fuel Control (EFC)

Fuel Type:

Unleaded gasoline (98 RON recommended)

Ignition System:

Distributorless Ignition System (DIS) with individual coil packs

Turbocharger

Turbocharger Evo Iv:

Mitsubishi TD05HR-16G

Turbocharger Evo V:

Mitsubishi TD05HRA-15G (slightly smaller for improved response)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Transmission Code:

W5M33

Optional

Optional Transmission:

None (Only Manual Available)

Features

Drivetrain Type:

All-Wheel Drive (AWD)

Acd Evo V:

Active Center Differential (ACD) with driver-selectable modes (Tarmac, Gravel, Snow) - Standard on Evo V

Transfer Case:

Mechanical transfer case with viscous coupling

Clutch Type:

Hydraulically operated, single dry plate clutch

Fluid Specifications

Transmission Fluid Type:

GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85)

Transfer Case Fluid Type:

GL-4 Gear Oil (e.g., Mitsubishi Diaqueen LSD Gear Oil 75W-85)

📐 Dimensions

Exterior

Length Evo Iv:

4350 mm (171.3 in)

Length Evo V:

4370 mm (172.0 in)

Width:

1770 mm (69.7 in)

Height Evo Iv:

1415 mm (55.7 in)

Height Evo V:

1415 mm (55.7 in)

Wheelbase:

2600 mm (102.4 in)

Front Track Evo V:

1505 mm (59.3 in)

Rear Track Evo V:

1505 mm (59.3 in)

Weights

Curb Weight Evo Iv:

Approx. 1450 kg (3197 lbs)

Curb Weight Evo V:

Approx. 1460 kg (3219 lbs)

Gross Vehicle Weight Rating:

Approx. 1735 kg (3825 lbs)

🛡️ Safety Features

Ratings

Crash Test Results:

No specific official crash test ratings widely published for these JDM-homologated models from the era, but engineered to strict rally safety standards.

Active Features

Active Features:

Anti-lock Braking System (ABS), Active Center Differential (ACD) on Evo V.

Passive Features

Passive Features:

Frontal airbags (driver and passenger), three-point seatbelts with pre-tensioners, reinforced chassis structure, impact-absorbing crumple zones.

Chassis Design

Chassis Type:

Monocoque chassis based on Lancer platform, significantly reinforced for rally use.

💡 Technology Features

Infotainment

Infotainment System:

Basic JDM radio/cassette player, optional CD player. Focus is on performance, not advanced infotainment.

Driver Assistance

Driver Assistance Features:

ABS, AYC (Evo IV), ACD (Evo V) - primarily focused on enhancing driving dynamics and control.

Connectivity

Connectivity:

N/A (No integrated Bluetooth, USB, or advanced connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first (severe use recommended).

Air Filter Replacement:

Every 10,000 km (6,000 miles) or 12 months.

Spark Plug Replacement:

Every 30,000 km (18,000 miles).

Timing Belt Replacement:

Every 100,000 km (60,000 miles) or 5 years.

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended for performance).

Engine Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter change.

Coolant Type:

Ethylene glycol-based coolant (Mitsubishi Super Long Life Coolant recommended), 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Common Problems:

Head gasket failure (especially if modified or poorly maintained), turbocharger wear, clutch wear, AYC/ACD system issues, rust in wheel arches and sills, differential wear.

Performance Tuning Considerations:

Requires careful tuning to avoid engine damage, particularly concerning air-fuel ratios and detonation under boost.

📚 Vehicle History

Brand Heritage

Brand History:

Mitsubishi Motors, a Japanese multinational automotive manufacturer with a strong heritage in motorsports, particularly rallying.

Model Evolution

Evolution Iv Introduction:

Introduced in August 1996, featuring a redesigned chassis, improved aerodynamics, and the introduction of the Active Yaw Control (AYC) system.

Evolution V Introduction:

Introduced in January 1998, significant updates included wider bodywork, larger wheels (17-inch), revised suspension geometry, and the introduction of the Active Center Differential (ACD) replacing AYC on some models.

Production

Production Location:

Japan (Mizushima Plant)

Production Years Overall:

1996-1999 (for Evo IV and V models)

Motorsport Connection

Wrc Homologation:

Developed as a homologation special for the World Rally Championship (WRC), featuring performance enhancements derived from rally racing technology.

🏆 Awards & Recognition

Recognitions

Motorsport Achievements:

The Lancer Evolution platform is a multiple-time World Rally Champion (driver and manufacturer titles achieved with subsequent models, but the DNA starts here).

Enthusiast Recognition

Reputation Among Enthusiasts:

Highly regarded as a future classic and one of the most iconic performance cars of the 1990s.