Engine Mechanical:
Engine assembly, disassembly, inspection, repair (4G63 MIVEC)
Engine Electrical:
Ignition system, fuel injection system, emission control system, starter, alternator, sensors
Fuel System:
Fuel pump, injectors, fuel lines, EVAP system
Cooling System:
Radiator, water pump, thermostat, cooling fan operation
Lubrication System:
Oil pump, oil passages, oil filter replacement
Transmission Manual:
6-speed manual transmission (Type-MR), clutch system, flywheel
Transmission Automatic:
Not applicable to standard Evo 9 models covered by this manual
Drivetrain Awc:
Active Center Differential (ACD), Super Active Yaw Control (S-AYC), propeller shaft, driveshafts, differentials
Suspension Front:
MacPherson struts, control arms, anti-roll bar, wheel bearings
Suspension Rear:
Multi-link independent suspension, shock absorbers, springs, anti-roll bar
Steering:
Power steering system, steering rack, steering column
Brakes Front:
Brembo 4-piston calipers, ventilated discs, ABS system
Brakes Rear:
Brembo 2-piston calipers, ventilated discs, ABS system
Body Exterior:
Body panels, doors, hood, trunk, bumpers, fenders, aerodynamic components
Body Interior:
Seats, dashboard, trim panels, airbags, interior lighting
Electrical Body:
Lighting system (headlights, taillights, interior), power windows, central locking, mirrors, wipers, horn
HVAC:
Air conditioning system, heater, climate control
Safety Systems:
Airbags (driver, passenger, side), seat belts, SRS system
Diagnostics:
OBD-II troubleshooting, diagnostic trouble codes (DTCs), sensor data interpretation
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, timing belt/chain inspection
Engine Repair:
Head gasket replacement, piston ring replacement, valve stem seals, turbocharger inspection and repair
Transmission Repair:
Gearbox overhaul, synchronizer replacement, clutch replacement, differential servicing
Brake Service:
Brake pad and rotor replacement, caliper service, brake fluid bleeding, ABS component testing
Suspension Repair:
Shock absorber replacement, spring replacement, bushing replacement, wheel alignment specifications
Electrical Diagnostics:
Wiring diagrams, component testing, fuse and relay identification, ECU diagnostics
Bodywork Repair:
Panel alignment, dent repair, rust prevention, glass replacement
HVAC Service:
Refrigerant handling, component replacement (compressor, condenser), leak detection
Troubleshooting:
Symptom-based diagnostic flowcharts for various issues
Torque Specifications:
Detailed torque values for all critical fasteners
Depth:
Comprehensive; suitable for DIY mechanics and professional technicians. Covers everything from routine maintenance to major component overhauls.
Diagnostics Level:
Advanced diagnostics, including electronic system troubleshooting and component testing procedures.
Rebuild Procedures:
Detailed procedures for complete engine and transmission rebuilds.
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, especially under spirited driving conditions.
Engine 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 (standard or platinum/iridium).
Timing Belt Chain Inspection:
The 4G63 uses a timing belt. Inspection and replacement typically recommended around 60,000-90,000 miles (96,000-144,000 km). Manual will specify.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for precise specification)
Power Steering Fluid:
Dexron III ATF or equivalent power steering fluid (verify with manual)
Head Gasket:
While improved over earlier Evos, high-performance use can stress head gaskets. Regular coolant level checks are vital.
Rear Differential:
S-AYC pump and related components can require maintenance or rebuilding over time.
Turbocharger:
Proper warm-up and cool-down procedures are critical to turbo longevity. Check for oil leaks and boost leaks.
Clutch:
Wear is dependent on driving style. Regular inspection for slipping and proper engagement is advised.