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Mitsubishi Lancer Evolution 6 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Common Nickname: Evo VI Generation Generation Code: CP9A Production Years: 1999-2001 Codes Chassis Code: CP9A Engine Code Primary: 4G63 👋 Introduction Market Position Market Position: High-performance rally homologation special, iconic JDM sports sedan. Competitive Analysis Key Competitors: Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale. Key Features Vehicle Type: All-wheel drive, turbocharged, compact sports sedan. Performance Focus: Gravel and tarmac rally performance, dynamic handling, robust powertrain. Manual Utility: Essential for owners seeking to maintain, repair, or restore their Evo VI to peak performance. 📋 Manual Details Coverage Areas Covered Model Years: 1999-2001 Covered Regions: Global (with variations noted for specific markets) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, timing system, lubrication, cooling. Engine Performance: Fuel injection system, ignition system, turbocharger system, exhaust system diagnostics. Transmission: Manual (5-speed) and optional Automatics (if applicable to specific models), clutch, drivetrain components. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, geometry. Brakes: Hydraulic system, ABS, brake pads, rotors, calipers, bleeding procedures, parking brake. Steering: Power steering system, steering rack, tie rods, alignment. Electrical: Complete wiring diagrams, component testing, fuses, relays, battery, charging system, starting system. Body And Interior: Body panels, doors, trim, seats, interior components, HVAC system, audio system. Chassis And Frame: Frame construction, underbody, rust prevention, chassis components. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement. Diagnostic Procedures: Troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs), electrical testing. Repair Procedures: Step-by-step instructions for component removal, installation, and repair. Rebuilding Procedures: Detailed instructions for engine and transmission rebuilds. Calibration And Adjustment: Alignment, idle speed, sensor calibration (where applicable). Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality Suitability: High-resolution images and diagrams suitable for printing specific pages. Binding Type Binding Type For Print: Digital (printable) Paper Type Paper Type For Print: Standard printer paper recommended ⚙️ Engine Specifications Primary Engine Engine Name: 4G63T (Evo VI RS/GSR variants) Engine Name Engine Type: Inline-4, DOHC, 16-valve, turbocharged and intercooled. Displacement Displacement: 1997 cc (2.0 Liters) Bore Stroke Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio Compression Ratio: 8.8:1 Performance Gsr Horsepower Gsr: 276 hp (206 kW) @ 6250 rpm (JDM/EU spec, often higher in reality due to underrating) Torque Gsr: 275 lb-ft (373 Nm) @ 3000 rpm (JDM/EU spec, often higher in reality) Performance Rs Horsepower Rs: 276 hp (206 kW) @ 6250 rpm Torque Rs: 275 lb-ft (373 Nm) @ 3000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection. Turbocharger: Mitsubishi TD05H-16G twin-scroll turbocharger with intercooler. Cooling System Cooling Type: Water-cooled Lubrication System Oil Capacity: 4.5 Liters (4.8 US Quarts) with filter Recommended Oil Engine Oil Specification: API SG or higher, SAE 10W-30 or 10W-40 recommended for most conditions (check manual for specific temperature ranges). 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (Type-R, F5M33-2-RWBAB) Optional Optional Transmission: 4-speed Automatic Transmission (less common, usually on non-performance variants of Lancer) Features AWD System: Active Front-Differential (Helical LSD), electronically controlled Multi-Stage System (4WD/Front-bias AWD), Active Rear Differential (Mechanical LSD on RS, electronic ACD on GSR). Transmission Fluid Spec: Manual Transmission: SAE 75W-90 GL-4 or GL-5 gear oil. (Specific Mitsubishi part number recommended in manual). 📐 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) Front Track: 1515 mm (59.6 in) Rear Track: 1510 mm (59.4 in) Weights Curb Weight Gsr: Approx. 1370 kg (3020 lbs) Curb Weight Rs: Approx. 1300 kg (2866 lbs) Gross Vehicle Weight: Varies by market and specification Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheels Tires Standard Wheel Size: 17 x 7.0 inches (GSR), 16 x 7.0 inches (RS - early models) Standard Tire Size Gsr: 215/40R17 Standard Tire Size Rs: 205/50R16 (early), 215/40R17 (later) 🛡️ Safety Features Ratings NHTSA Ratings: Not directly tested by NHTSA under its modern rating system. Icam Ratings: Varies by market; generally considered safe for its era. Active Features Active Safety Features: Anti-lock Braking System (ABS), Active Center Differential (ACD) on GSR, mechanical LSD on RS, advanced AWD system. Passive Features Passive Safety Features: Driver and passenger front airbags, reinforced chassis, three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Infotainment System: Basic audio system with AM/FM radio and CD player (optional). Limited integration by modern standards. Driver Assistance Driver Assistance Features: ABS, ACD (GSR). Connectivity Connectivity Options: None beyond basic audio connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every...
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Mitsubishi Lancer Evolution 6 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Common Nickname:
Evo VI
Generation
Generation Code:
CP9A
Production Years:
1999-2001
Codes
Chassis Code:
CP9A
Engine Code Primary:
4G63
👋 Introduction
Market Position
Market Position:
High-performance rally homologation special, iconic JDM sports sedan.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale.
Key Features
Vehicle Type:
All-wheel drive, turbocharged, compact sports sedan.
Performance Focus:
Gravel and tarmac rally performance, dynamic handling, robust powertrain.
Manual Utility:
Essential for owners seeking to maintain, repair, or restore their Evo VI to peak performance.
📋 Manual Details
Coverage Areas
Covered Model Years:
1999-2001
Covered Regions:
Global (with variations noted for specific markets)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, internal components, timing system, lubrication, cooling.
Engine Performance:
Fuel injection system, ignition system, turbocharger system, exhaust system diagnostics.
Transmission:
Manual (5-speed) and optional Automatics (if applicable to specific models), clutch, drivetrain components.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, geometry.
Brakes:
Hydraulic system, ABS, brake pads, rotors, calipers, bleeding procedures, parking brake.
Steering:
Power steering system, steering rack, tie rods, alignment.
Electrical:
Complete wiring diagrams, component testing, fuses, relays, battery, charging system, starting system.
Body And Interior:
Body panels, doors, trim, seats, interior components, HVAC system, audio system.
Chassis And Frame:
Frame construction, underbody, rust prevention, chassis components.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement.
Diagnostic Procedures:
Troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs), electrical testing.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Rebuilding Procedures:
Detailed instructions for engine and transmission rebuilds.
Calibration And Adjustment:
Alignment, idle speed, sensor calibration (where applicable).
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repair.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality Suitability:
High-resolution images and diagrams suitable for printing specific pages.
Binding Type
Binding Type For Print:
Digital (printable)
Paper Type
Paper Type For Print:
Standard printer paper recommended
⚙️ Engine Specifications
Primary Engine
Engine Name:
4G63T (Evo VI RS/GSR variants)
Engine Name
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled.
Displacement
Displacement:
1997 cc (2.0 Liters)
Bore Stroke
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio
Compression Ratio:
8.8:1
Performance Gsr
Horsepower Gsr:
276 hp (206 kW) @ 6250 rpm (JDM/EU spec, often higher in reality due to underrating)
Torque Gsr:
275 lb-ft (373 Nm) @ 3000 rpm (JDM/EU spec, often higher in reality)
Performance Rs
Horsepower Rs:
276 hp (206 kW) @ 6250 rpm
Torque Rs:
275 lb-ft (373 Nm) @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injection.
Turbocharger:
Mitsubishi TD05H-16G twin-scroll turbocharger with intercooler.
Cooling System
Cooling Type:
Water-cooled
Lubrication System
Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter
Recommended Oil
Engine Oil Specification:
API SG or higher, SAE 10W-30 or 10W-40 recommended for most conditions (check manual for specific temperature ranges).
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (Type-R, F5M33-2-RWBAB)
Optional
Optional Transmission:
4-speed Automatic Transmission (less common, usually on non-performance variants of Lancer)
Features
AWD System:
Active Front-Differential (Helical LSD), electronically controlled Multi-Stage System (4WD/Front-bias AWD), Active Rear Differential (Mechanical LSD on RS, electronic ACD on GSR).
Transmission Fluid Spec:
Manual Transmission: SAE 75W-90 GL-4 or GL-5 gear oil. (Specific Mitsubishi part number recommended in manual).
📐 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)
Front Track:
1515 mm (59.6 in)
Rear Track:
1510 mm (59.4 in)
Weights
Curb Weight Gsr:
Approx. 1370 kg (3020 lbs)
Curb Weight Rs:
Approx. 1300 kg (2866 lbs)
Gross Vehicle Weight:
Varies by market and specification
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheels Tires
Standard Wheel Size:
17 x 7.0 inches (GSR), 16 x 7.0 inches (RS - early models)
Standard Tire Size Gsr:
215/40R17
Standard Tire Size Rs:
205/50R16 (early), 215/40R17 (later)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not directly tested by NHTSA under its modern rating system.
Icam Ratings:
Varies by market; generally considered safe for its era.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Active Center Differential (ACD) on GSR, mechanical LSD on RS, advanced AWD system.
Passive Features
Passive Safety Features:
Driver and passenger front airbags, reinforced chassis, three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Infotainment System:
Basic audio system with AM/FM radio and CD player (optional). Limited integration by modern standards.
Driver Assistance
Driver Assistance Features:
ABS, ACD (GSR).
Connectivity
Connectivity Options:
None beyond basic audio connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (severe use may require shorter intervals).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type (iridium recommended for longevity).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years, whichever comes first. Crucial due to interference engine design.
Fluid Specifications
Coolant Specification:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with correct pH and silicate/nitrite/amine free formulation. Capacity approx. 6.8 Liters.
Brake Fluid Specification:
DOT 3 or DOT 4 (check manual for exact specification and replacement interval). Capacity approx. 1 Liter.
Power Steering Fluid Specification:
ATF Dexron II or III equivalent (check manual for precise type).
Known Issues
Known Issues Engine:
Potential for cracked pistons or head gasket failure under extreme abuse or poor maintenance. Camshaft wear. Turbocharger oil feed issues.
Known Issues Suspension:
Worn suspension bushings, especially control arm bushings. Rusted subframes.
Known Issues Electrical:
Corroded wiring connectors, failing idle air control valve (IACV), fuel pump issues.
Known Issues Body:
Rust, particularly around wheel arches, sills, and rear subframe mounts. Damaged body kits/aero components.
📚 Vehicle History
Brand Heritage
Brand Heritage Motorsport:
Mitsubishi has a long and successful history in motorsport, particularly in the World Rally Championship (WRC).
Model Evolution
Evolution Series Origin:
The Lancer Evolution series was created specifically to homologate the Lancer for Group A rallying regulations.
Evo Vi Development:
The Evo VI built upon the Evo IV and V, featuring significant aerodynamic and mechanical enhancements for improved rally performance and cooling.
Tommi Makinen Edition:
Special edition (Evo VI T.M. Edition) released in honor of rally driver Tommi Mäkinen's fourth consecutive WRC title, featuring unique styling, engine tuning, and suspension components.
Production
Production Location:
Japan (Mizushima Plant)
Production Volume:
Approximately 6,000 units of Evo VI GSR and 2,600 units of Evo VI RS (including T.M. Editions) were produced.
🏆 Awards & Recognition
Recognitions
Motorsport Awards:
Dominant force in WRC during the late 1990s and early 2000s, contributing to numerous manufacturer and driver championships.
Ratings
Performance Ratings:
Consistently ranked among the top performance cars of its era by automotive journalists worldwide for handling and acceleration.
Certifications
Homologation Status:
Group A homologation for WRC competition.
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