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Mitsubishi Evo 4 & 5 1996-1999 Repair Service Manual

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This manual covers the Mitsubishi Lancer Evolution IV (CN9A) and Evolution V (CP9A) models produced between 1996 and 1999. These vehicles are renowned performance rally homologation specials, characterized by their...
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Mitsubishi Evo 4 & 5 1996-1999 Repair Service ManualMitsubishi Evo 4 & 5 1996-1999 Repair Service ManualMitsubishi Evo 4 & 5 1996-1999 Repair Service ManualMitsubishi Evo 4 & 5 1996-1999 Repair Service Manual
This manual covers the Mitsubishi Lancer Evolution IV (CN9A) and Evolution V (CP9A) models produced between 1996 and 1999. These vehicles are renowned performance rally homologation specials, characterized by their potent 4G63 2.0L turbocharged engine, advanced all-wheel-drive systems with Active Yaw Control (AYC) on certain variants, and robust chassis dynamics optimized for rally performance. With aggressive aerodynamic styling and a heritage steeped in World Rally Championship success, these models represent a pinnacle of compact performance engineering from their era, offering an exhilarating driving experience. This comprehensive Factory Workshop Service Manual, provided in English, offers detailed guidance for owners, mechanics, and technicians. It encompasses a vast range of information, including in-depth maintenance procedures, diagnostic troubleshooting for engine, chassis, and electrical systems, detailed technical specifications, and essential safety guidelines. With over 1000 pages of technical data, this manual covers powertrain, chassis, electrical, and body systems, providing the necessary information for routine maintenance, complex repairs, and performance tuning to ensure the optimal operation and longevity of your Lancer Evolution IV or V.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV & V
Model Code Evo4:
CN9A
Model Code Evo5:
CP9A
Codes
Engine Codes:
4G63 (2.0L Turbocharged I4)
👋 Introduction
Market Position
Category:
Performance Rally Homologation Special / Sports Sedan
Segment:
Compact Performance
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Key Features
Drivetrain:
Advanced All-Wheel Drive (AWD) with Active Yaw Control (AYC) on some variants.
Engine Technology:
Legendary 4G63 2.0L DOHC turbocharged engine with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some later models.
Chassis Dynamics:
MacPherson strut front suspension, multi-link rear suspension, robust chassis design optimized for rally performance.
Aerodynamics:
Aggressive body kits, large rear spoilers, functional hood vents for improved downforce and cooling.
📋 Manual Details
Coverage Areas
Years Covered:
1996, 1997, 1998, 1999
Markets:
Global (primarily Japan domestic market)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine management, fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharger system, transmission (manual & automatic options), drivetrain (transfer case, differentials).
Chassis:
Suspension (front & rear), steering system, braking system (ABS included), wheels and tires.
Electrical:
Wiring diagrams, lighting, instruments, audio system, power windows, power locks, climate control, engine control unit (ECU), body control module (BCM).
Body:
Body exterior (panels, bumpers, glass), interior trim, seats, safety systems (airbags).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, electrical component repair, body panel repair and replacement.
Diagnostics:
Detailed diagnostic flowcharts, specifications for sensor readings, ECU pinouts, testing procedures for electronic components.
Technical Depth
Depth:
Comprehensive: Covers basic to advanced repair and diagnostic procedures. Includes disassembly, reassembly, specifications, tolerances, and torque values for all major components.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution scans suitable for detailed viewing of diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke Evo4:
85.0 mm x 88.0 mm
Bore X Stroke Evo5:
85.0 mm x 88.0 mm
Compression Ratio Evo4:
8.8:1
Compression Ratio Evo5:
8.8:1
Performance
Horsepower Evo4:
276 hp (206 kW) @ 6250 rpm (JDM spec - often underestimated)
Torque Evo4:
343 Nm (253 lb-ft) @ 3000 rpm (JDM spec - often underestimated)
Horsepower Evo5:
276 hp (206 kW) @ 6250 rpm (JDM spec - often underestimated)
Torque Evo5:
377 Nm (278 lb-ft) @ 3000 rpm (JDM spec - often underestimated)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Fuel Control (EFC)
Fuel Type:
Unleaded Premium (95 RON or higher recommended)
Turbocharger:
Mitsubishi TD05H-16G (Evo IV) / TD05HRA-15G (Evo V)
Intercooler:
Front-mounted air-to-air intercooler
🔧 Transmission
Standard
Type Evo4:
5-speed Manual (Type R/RS models often featured 6-speed manual)
Type Evo5:
5-speed Manual (RS/GSR models)
Optional
Type:
4-speed Automatic (less common for performance variants)
Features
Clutch:
Single dry plate, hydraulically operated diaphragm spring clutch
AWD System:
Full-time 4WD with viscous coupling center differential (AYC system on GSR models).
Differential Rear:
Mechanical Limited-Slip Differential (LSD) (Helical LSD on RS models, Viscous LSD on GSR).
📐 Dimensions
Exterior
Length Evo4:
4350 mm (171.3 in)
Width Evo4:
1770 mm (69.7 in)
Height Evo4:
1415 mm (55.7 in)
Wheelbase Evo4:
2600 mm (102.4 in)
Length Evo5:
4360 mm (171.7 in)
Width Evo5:
1770 mm (69.7 in)
Height Evo5:
1415 mm (55.7 in)
Wheelbase Evo5:
2600 mm (102.4 in)
Weights
Curb Weight Evo4 Gsr:
1450 kg (3197 lbs)
Curb Weight Evo4 Rs:
1400 kg (3086 lbs)
Curb Weight Evo5 Gsr:
1450 kg (3197 lbs)
Curb Weight Evo5 Rs:
1400 kg (3086 lbs)
Cargo
Cargo Volume:
Not prominently advertised, sedan configuration.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not independently tested by major agencies like NHTSA/Euro NCAP during its original production era.
Active Features
ABS:
Standard on GSR, optional on RS. Advanced ABS system.
Ayc:
Active Yaw Control (AYC) system on GSR models, electronically controlling torque distribution to rear wheels.
Passive Features
Airbags:
Driver and passenger airbags standard on GSR, optional/absent on RS.
Seatbelts:
Pretensioner and force-limiting seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo cassette player with optional CD player, 4-6 speakers.
Driver Assistance
Traction Control:
Not typically equipped with electronic traction control; relies on AWD and AYC for grip.
Connectivity
Bluetooth:
Not available on factory systems.
ECU Tuning:
ECU is highly programmable for performance tuning, a common modification.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, depending on driving conditions.
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles)
Spark Plug Replacement:
Every 40,000 - 60,000 km (24,000 - 36,000 miles), depending on plug type.
Timing Belt Replacement:
Every 100,000 km (60,000 miles) or 5 years.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3, Viscosity 10W-30, 10W-40, or 5W-30 (check manual for specific climate recommendations).
Coolant:
Mitsubishi Genuine Long Life Antifreeze/Coolant (Green) or equivalent ethylene glycol-based coolant.
Transmission Fluid Manual:
API GL-4 or GL-5 Gear Oil, Viscosity 75W-90.
Differential Fluid Rear:
API GL-5 Gear Oil, Viscosity 75W-90 (for mechanical LSD).
Transfer Case Fluid:
API GL-4 Gear Oil, Viscosity 75W-90.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Wear:
Piston ring wear, bearing failures, especially if poorly maintained or driven hard without proper warm-up.
Turbocharger:
Oil leaks, bearing failure, exhaust housing cracks due to high temperatures and stress.
Ayc System:
Failure of the AYC pump or sensors, fluid leaks.
Clutch Wear:
Wear and tear on clutch components due to aggressive driving.
Suspension:
Wear in bushings, ball joints, and shock absorbers due to performance driving and chassis loads.
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi has a long and successful history in the World Rally Championship (WRC), with the Lancer Evolution series being its flagship performance vehicle.
Model Evolution
Evo1 To Evo3:
Evolutions I to III established the Evo's reputation for rally-bred performance and AWD technology.
Evo4 Introduction:
The Evo IV (CN9A), launched in August 1996, featured a completely new chassis, significant engine upgrades, and the introduction of AYC.
Evo5 Introduction:
The Evo V (CP9A), launched in January 1998, was a facelift and enhancement of the Evo IV. It featured wider track, larger front bumper openings, upgraded turbocharger, larger intercooler, Brembo brakes, and a revised AYC system.
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Period Evo4:
August 1996 – August 1997
Production Period Evo5:
January 1998 – January 1999
🏆 Awards & Recognition
Recognitions
Rally Pedigree:
Renowned for its direct lineage to WRC-winning vehicles, making it a highly sought-after performance car.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its handling, acceleration, and raw performance.
Certifications
Homologation:
Built to homologate Mitsubishi for Group A and World Rally Championship competition.
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