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Mitsubishi Lancer Evo 6 1999-2001 Factory Service Manual

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This manual covers the Mitsubishi Lancer Evolution VI, commonly known as the Evo 6 or Evo VI, produced between 1999 and 2001. Available in GSR and RS variants, this iconic...
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Mitsubishi Lancer Evo 6 1999-2001 Factory Service ManualMitsubishi Lancer Evo 6 1999-2001 Factory Service ManualMitsubishi Lancer Evo 6 1999-2001 Factory Service Manual
This manual covers the Mitsubishi Lancer Evolution VI, commonly known as the Evo 6 or Evo VI, produced between 1999 and 2001. Available in GSR and RS variants, this iconic rally homologation special, chassis code CP9A, is renowned for its high-performance engineering, drawing directly from World Rally Championship heritage. Key features include an advanced All-Wheel Drive system with Active Yaw Control (AYC) and Active Center Differential (ACD), powered by a potent 4G63T turbocharged engine. Its driver-focused design and exceptional handling make it a celebrated sports sedan. This comprehensive factory service repair manual provides detailed information essential for the maintenance, diagnosis, troubleshooting, and repair of the Lancer Evolution VI. It covers all major systems, including the powertrain (engine, transmission, drivetrain), chassis (suspension, steering, brakes), electrical systems, body, and HVAC. The manual offers factory-level detail with diagrams, specifications, and repair procedures, making it an indispensable resource for owners, mechanics, and technicians seeking to preserve the optimal performance and longevity of this specialized vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Model Variant:
GSR, RS
Common Name:
Evo 6, Evo VI
Codes
Chassis Code:
CP9A
Engine Code:
4G63T
👋 Introduction
Market Position
Positioning:
Iconic rally homologation special, positioned as a high-performance, driver-focused sports sedan.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale (previous generations).
Key Features
Performance Features:
Advanced All-Wheel Drive (AYC/ACD), potent turbocharged engine, aggressive aerodynamic styling.
Manual Utility:
Essential tool for owners and enthusiasts to maintain and repair this specialized performance vehicle, ensuring optimal performance and longevity.
Significance
Rally Heritage:
Developed directly from Mitsubishi's highly successful World Rally Championship (WRC) program.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Factory Service Repair
Additional Coverage:
Maintenance, Diagnosis, Troubleshooting, Repair, Specifications
Page Count
Estimated Pages:
Hundreds of pages (specific count not provided, typical for factory manuals)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63T), Turbocharger, Cooling System, Fuel System, Exhaust System, Transmission (Manual, Optional Automatic), Drivetrain (All-Wheel Drive, AYC, ACD)
Chassis:
Suspension (Front McPherson Strut, Rear Multi-Link), Steering System, Brake System (ABS), Wheel Hubs & Bearings
Electrical:
Engine Control Unit (ECU), Ignition System, Lighting, Instrumentation, Audio System, Power Accessories, Wiring Diagrams
Body:
Body Exterior & Interior Panels, Doors, Hood, Trunk, Bumpers, Glass, Seats, Trim
HVAC:
Heating, Ventilation, Air Conditioning System
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Top-offs, Tune-ups
Repair:
Engine Overhaul, Turbocharger Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis & Replacement
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting, Fault Code Interpretation (OBD-II)
Specifications:
Torque Specifications, Tolerances, Lubricant Requirements, Electrical Data
Calibration:
Alignment Procedures, AYC/ACD System Calibration
Technical Depth
Depth:
Comprehensive factory-level detail, suitable for professional technicians and experienced enthusiasts.
Detail Level:
Includes detailed diagrams, exploded views, service data, diagnostic procedures, and repair instructions.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text for easy information retrieval.
Print Quality
Printability:
Designed for printing, allowing users to create a physical copy.
Binding Type
Binding:
Not applicable for PDF download; refers to potential printed output binding (e.g., comb, spiral).
Paper Type
Paper Type:
Not applicable for PDF download; refers to potential printed output paper quality.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T Inline 4-Cylinder DOHC 16-Valve Turbocharged
Displacement:
1997 cc
Performance
Horsepower Ps:
276 PS (272 hp) @ 6500 rpm (JDM/European spec)
Torque Nm:
373 Nm (275 lb-ft) @ 3000 rpm (JDM/European spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Twin-Scroll Turbocharger
Engine Management
ECU:
ECI-Multi (Electronic Controlled Ignition)
Cooling System
Cooling Type:
Water-cooled, Pressurized
Lubrication System
Oil Capacity Liters:
Approximately 4.5 L (with filter)
🔧 Transmission
Standard
Type:
5-speed Manual Transaxle (MLSL)
Optional
Type:
4-speed Automatic (Rare, primarily for specific markets)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) and Active Center Differential (ACD)
Fluid Specifications
Manual Transmission Fluid:
API GL-4/GL-5, SAE 75W-90 (Specific Mitsubishi recommendation in manual)
Transfer Case Fluid:
Refer to manual (often same as transmission fluid)
Ayc Pump Fluid:
Refer to manual (specific hydraulic fluid)
📐 Dimensions
Exterior
Length Mm:
4345
Width Mm:
1770
Height Mm:
1415
Wheelbase Mm:
2600
Weights
Curb Weight Kg Approx:
1400 - 1470 (depending on trim and options)
Gross Vehicle Weight Rating Kg:
Refer to manual
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not extensively tested by modern standards, but designed with rally safety features.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) for enhanced cornering stability
Acd:
Active Center Differential (ACD) for variable torque distribution
Passive Features
Airbags:
Driver and passenger airbags (standard on GSR, optional/market dependent on RS)
Seatbelts:
Three-point inertia-reel seatbelts
Chassis Construction:
Reinforced body structure for rigidity and crash protection.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo with CD Player (market dependent), potential for aftermarket upgrades.
Display:
Basic instrument cluster, no central infotainment screen.
Driver Assistance
Stability Control:
Not equipped with electronic stability control (ESC) in the modern sense; AYC/ACD systems provide dynamic stability enhancement.
Connectivity
Connectivity Features:
Limited by era; primarily focuses on vehicle performance and control systems. No Bluetooth or advanced connectivity as standard.
🔧 Maintenance
Service Intervals
Oil Change Km:
Typically every 5,000 - 10,000 km or 6 months (refer to manual for exact specification based on driving conditions)
Air Filter Replacement Km:
Refer to manual (typically 20,000 - 40,000 km)
Spark Plug Replacement Km:
Refer to manual (e.g., Iridium plugs often rated for 100,000 km)
Fluid Specifications
Engine Oil Type:
Synthetic 5W-40 or 10W-40 (refer to manual for exact viscosity and API rating)
Coolant Type:
Ethylene Glycol based coolant, Mitsubishi Super Long Life Coolant (or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine:
Head gasket failure (especially on modified engines), turbocharger failure, piston ring wear. Regular maintenance is crucial.
Drivetrain:
AYC pump failure, ACD issues, worn clutch components.
Suspension:
Worn bushings, strut wear.
Torque Specs
Cylinder Head Torque:
Refer to manual (critical for engine integrity, typically a multi-stage tightening sequence)
Wheel Lug Nuts:
Refer to manual (typically around 103 Nm or 76 lb-ft)
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi has a strong lineage in motorsport, particularly in the World Rally Championship, with the Lancer Evolution series being its flagship performance model.
Model Evolution
Evolution Sequence:
The Evo VI represented a significant evolution over the Evo V, featuring engine upgrades, revised suspension, and distinctive styling elements like the iconic large rear wing.
Special Editions:
Tommi Mäkinen Edition (Evo VI T.M.E.) released to celebrate rally success, featuring unique styling and mechanical enhancements.
Production
Production Years:
1999 - 2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Evo VI, particularly the Tommi Mäkinen Edition, is celebrated for its significant success in the World Rally Championship, solidifying its legendary status.
Ratings
Enthusiast Appreciation:
Consistently rated highly by automotive journalists and enthusiasts for its driving dynamics, handling, and performance.
Certifications
Homologation:
Rally homologation model, requiring adherence to specific performance and design criteria for WRC eligibility.
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