Vehicle Segment:
Compact performance sedan (rally homologation special).
Usp Key Selling Point:
All-wheel drive, turbocharged 4G63T engine, advanced AYC system, racing pedigree.
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Model Significance:
Marked a significant evolution with a wider body, improved suspension geometry, and the introduction of the AYC system.
Covered Model Years:
1996, 1997, 1998
Primary Markets:
Japan (JDM), but covers mechanicals applicable globally.
Estimated Pages:
Hundreds (as stated, typical factory manuals are extensive, often 1000+ pages when printed).
Type:
Factory Service Repair Manual
Language:
English (assumed from product description context, though original factory may be Japanese. This PDF is likely a translated or professionally compiled English version).
Engine Mechanical:
Detailed disassembly, inspection, assembly, and testing of the 4G63T engine, including cylinder head, block, pistons, crankshaft, camshafts, timing belt, oil pump, and cooling system.
Engine Management And Ignition:
ECU operation, sensor diagnostics (MAP, TPS, O2, knock), fuel injection system, ignition timing, emissions control systems.
Transmission Drivetrain:
Manual transmission (Getrag 5-speed for Evo IV), clutch system, transfer case, driveshafts, differentials (front, rear, AYC - Active Yaw Control).
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, control arms, steering gearbox, power steering system.
Brakes:
Brake system operation, hydraulic lines, calipers, master cylinder, ABS (Anti-lock Braking System) components, parking brake.
Electrical System:
Wiring diagrams for all circuits, starter, alternator, battery, lighting, gauges, power windows, mirrors, central locking.
Body And Interior:
Body panel removal and installation, door mechanisms, seat adjustments, dashboard trim, HVAC system.
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and tensioning.
Troubleshooting:
Diagnostic flowcharts and symptom-based guides for common and uncommon problems across all vehicle systems.
Repair And Rebuild:
Step-by-step instructions for component removal, repair, and reinstallation, including engine rebuilds, transmission overhauls, and suspension component replacement.
Diagnostics:
Detailed explanations of diagnostic trouble codes (DTCs), sensor data interpretation, and use of specialized diagnostic tools (if applicable to the era).
Specifications And Tolerances:
Precise torque values, clearance measurements, and critical tolerances for all mechanical components.
Depth Of Information:
Comprehensive. Covers everything from basic fluid services to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.
Target Audience:
Professional mechanics, experienced DIY enthusiasts, and motorsport technicians.
Searchability:
Likely text-searchable if a properly OCR'd PDF.
Printability:
Designed to be printable. Users can print specific sections or the entire manual.
Binding For Printed Copy:
N/A (Digital PDF, but implies users can bind printed versions).
Recommended Paper For Printing:
N/A (Digital PDF, but typical manuals would be printed on durable, matte paper).
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 L)
Bore X Stroke:
85.0 mm x 88.0 mm
Horsepower Ps:
280 PS (approx. 276 hp) at 6,500 rpm (JDM spec)
Torque Kgm:
35.0 kgm (approx. 253 lb-ft) at 3,000 rpm (JDM spec)
Fuel Delivery:
Electronic Fuel Injection (MPI - Multi-Point Injection)
Fuel Type:
Unleaded premium gasoline (RON 98 recommended)
Turbocharger:
Mitsubishi TD05HR-16G (twin-scroll) with intercooler
Engine Oil Change:
Every 5,000 km (3,100 miles) or 6 months, whichever comes first (severe use).
Transmission Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Transfer Case Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Rear Differential Fluid Change:
Every 30,000 km (18,600 miles) or 24 months, whichever comes first.
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 5 years.
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific grade based on climate).
Transmission Fluid:
GL-4 SAE 75W-90 (manual transmission)
Transfer Case Fluid:
GL-4 SAE 75W-90
Rear Differential Fluid:
GL-5 SAE 80W-90 (for standard differential), specific LSD or AYC fluid may be required by manual.
Coolant:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Common Problems:
Eccentric cam/pulley wear, turbocharger seal failure (leading to oil burning), clutch wear, AYC pump failure, cracked exhaust manifold, piston ring land failure (due to detonation/abuse).
Critical Maintenance Points:
Strict adherence to timing belt replacement schedule, regular oil changes with quality oil, avoiding detonation, proper AYC fluid maintenance.
Motorsport Link:
Mitsubishi's extensive rallying heritage, particularly in the World Rally Championship (WRC).
Predecessor:
Mitsubishi Lancer Evolution III (Evo 3)
Successor:
Mitsubishi Lancer Evolution V (Evo 5)
Evolutionary Step:
Significant chassis rigidity improvements, wider track, revised suspension geometry, and introduction of AYC.
Production Years:
August 1996 – January 1998
Production Volume:
Approximately 6,000 units produced.
Manufacturing Location:
Japan
