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Mitsubishi Lancer Evo 6 1999-2001 Workshop Repair Service Ma

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This manual covers the Lancer Evolution VI, often referred to as the Evo 6, produced from 1999 to 2001. Known for its exceptional performance and rally-bred engineering, the Evo 6...
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SKU: 70460
Mitsubishi Lancer Evo 6 1999-2001 Workshop Repair Service MaMitsubishi Lancer Evo 6 1999-2001 Workshop Repair Service MaMitsubishi Lancer Evo 6 1999-2001 Workshop Repair Service MaMitsubishi Lancer Evo 6 1999-2001 Workshop Repair Service Ma
This manual covers the Lancer Evolution VI, often referred to as the Evo 6, produced from 1999 to 2001. Known for its exceptional performance and rally-bred engineering, the Evo 6 (chassis code CP9A) features a potent 4G63T turbocharged engine and a sophisticated all-wheel-drive system with Active Yaw Control (AYC). This model is celebrated for its aggressive styling, advanced aerodynamics, and a legacy rooted in World Rally Championship success, making it a highly sought-after performance compact sedan. It was offered in various trim levels, including the RS, GSR, and the special Tommi Makinen Edition. This comprehensive workshop repair service manual provides detailed guidance for owners, mechanics, and technicians. It covers a wide array of systems, including engine mechanical and performance, manual transmission, suspension, brakes, steering, and the electrical system. The manual includes routine maintenance procedures, diagnostic troubleshooting for common issues, major component rebuilds, and specific technical specifications such as torque settings. With its extensive coverage, this English-language manual aims to facilitate the proper maintenance, repair, and upkeep of your Lancer Evolution VI, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Model Nickname:
Evo 6
Years Covered By Manual:
1999, 2000, 2001
Codes
Chassis Code:
CP9A
Engine Code General:
4G63
👋 Introduction
Market Position
Market Segment:
Performance Compact Sedan / Rally Homologation Special
Competitors:
Subaru Impreza WRX STI, Ford Escort Cosworth, Lancia Delta Integrale, Audi S3.
Competitive Analysis
Key Differentiators:
Aggressive styling, advanced Active Yaw Control (AYC), potent 4G63 engine, legendary rally heritage, sophisticated four-wheel-drive system.
Key Features
Performance Focus:
Engineered for high-performance driving and motorsport applications.
Rally Homologation:
Produced to homologate the Lancer for the World Rally Championship (WRC).
Advanced Aero:
Distinctive aerodynamic enhancements including large rear wing, front splitter, and vented hood.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily focused on JDM and European specifications)
Trim Levels Covered:
All Trim Levels (RS, GSR, Tommi Makinen Edition)
Page Count
Estimated Page Count:
Approx. 1500-2000+ pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing belt/chain, valve train.
Engine Performance:
Fuel injection system (MPI), ignition system, turbocharger system, exhaust system, emission control system, engine control unit (ECU).
Transmission Manual:
Clutch system, gearbox (including 5-speed W5M51 or 6-speed options if applicable), drive shafts, differentials (front, rear, and Active Yaw Control - AYC).
Transmission Automatic:
Not applicable for standard Evo 6 models.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, sway bars, bushings, alignment specifications.
Brakes:
Brake system components (discs, calipers, pads), ABS system, parking brake, brake fluid specifications, bleeding procedures.
Steering:
Power steering system, steering rack, steering column, wheel alignment.
Electrical System:
Battery, alternator, starter motor, lighting system, wiring diagrams, fuses, relays, ignition switch, power windows, central locking.
Body And Interior:
Body panels, doors, hood, trunk, bumpers, seats, dashboard, trim panels, weatherstripping, glass replacement.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.
Driver Assistance Features:
Active Yaw Control (AYC) system diagnostics and calibration.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flush, brake checks, tire rotation.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common faults and symptoms across all major systems, including OBD-II fault code interpretation.
Major Component Rebuild:
Complete engine rebuild procedures, gearbox overhaul, differential rebuild.
Component Replacement:
Detailed instructions for replacing individual parts like water pump, alternator, starter, fuel pump, radiators, brake calipers, etc.
Suspension Alignment:
Front and rear wheel alignment procedures and specifications.
Electrical Component Testing:
Testing and diagnosis of sensors, actuators, and electrical modules.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
Specifications Torque Settings:
Detailed torque specifications for all fasteners and critical components.
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission overhauls and advanced diagnostics.
Diagnostics Level:
Advanced: Includes methods for diagnosing complex electronic and mechanical issues.
Rebuild Procedures:
Full rebuild procedures for engine, transmission, and differentials.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (typically, depending on the original scan quality)
Printability:
Printable (allows users to print specific sections or the entire manual)
Print Quality
Image Resolution:
High-resolution scans of original factory manuals, ensuring clarity of diagrams and text.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, turbocharged, intercooled.
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Performance
Horsepower Ps:
276 PS (206 kW) at 6,500 rpm (JDM spec, often underestimated)
Torque Nm:
373 Nm (275 lb-ft) at 3,000 rpm (JDM spec)
Compression Ratio:
8.5:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI) with Denso injectors.
Fuel Type:
Unleaded premium gasoline (RON 95 or higher recommended)
Turbocharger
Turbocharger Model:
Mitsubishi TD05H-16G (common for Evo 6 GSR)
Boost Pressure:
Approx. 1.0 bar (14.5 psi) regulated by wastegate and ECU.
Cooling System
Cooling Capacity:
Approx. 7.5 liters
Lubrication System
Oil Capacity:
Approx. 4.5 liters (with filter)
Recommended Oil Viscosity:
10W-30 or 10W-40 (API SG or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed manual (W5M51 for GSR, various for RS)
Optional
Optional Transmission:
Some markets may have offered 6-speed manual options or specific RS variants.
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) or front mechanical LSD / rear mechanical LSD depending on trim.
Ayc System:
Active Yaw Control electronically controls torque distribution to rear wheels for enhanced cornering.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 SAE 75W-90 (check manual for specific recommendations)
Fluid Capacity
Manual Transmission Capacity:
Approx. 2.4 liters
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,405 mm (55.3 in)
Wheelbase:
2,600 mm (102.4 in)
Track Width Front:
1,510 mm (59.4 in)
Track Width Rear:
1,505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1,360 kg (2,998 lbs) for GSR
Gross Vehicle Weight Rating:
Varies by market and trim
Towing Capacity:
Not recommended or specified
Wheels Tires
Wheel Size:
17 x 7.5 inches (standard GSR)
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Tire Size Standard:
215/45R17 (e.g., Bridgestone Potenza S02A for TME)
🛡️ Safety Features
Ratings
Crash Test Ratings:
NHTSA and IIHS ratings vary by model year and market; often not independently tested extensively due to homologation nature.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on GSR, typically with Brembo braking system.
Ayc:
Active Yaw Control (AYC) enhances stability and cornering grip.
AWD:
Advanced electronically controlled All-Wheel Drive system (Super All-Wheel Control - S-AWC variant for some later models, though AYC is key for Evo 6).
Passive Features
Airbags:
Driver and passenger airbags standard.
Seatbelts:
Three-point seatbelts with pretensioners.
Body Construction:
Reinforced chassis for rally performance.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player or cassette deck, typically 4 or 6 speakers. Aftermarket upgrades common.
Navigation:
Optional factory navigation system on some high-spec models, rare and often outdated.
Driver Assistance
Traction Control:
While AYC and AWD provide significant traction control, a dedicated electronic traction control system (TCS) was not standard on all Evo 6 models. Manual will detail systems present.
Connectivity
Bluetooth:
Not available from factory. Aftermarket integration is standard.
Engine Management
ECU Type:
Mitsubishi ECU, programmable for tuning (e.g., aftermarket ECUs or remapping services are common).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (severe duty driving recommended).
Air Filter Replacement:
Every 15,000 km (9,000 miles) or as needed based on driving conditions.
Spark Plug Replacement:
Every 30,000 km (18,000 miles) for standard plugs, longer for platinum/iridium (refer to manual for exact type).
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 5-7 years. Critical for 4G63T engine to prevent catastrophic failure.
Fluid Specifications
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol based coolant with correct color).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation)
Known Issues
Engine Sludge:
Potential for oil sludge buildup in the 4G63 engine if maintenance is neglected. Regular oil changes are crucial.
Ayc Pump Failure:
The AYC hydraulic pump can fail over time due to age and wear. Manual will detail diagnosis and potential replacement procedures.
Turbocharger Wear:
Turbocharger seals and bearings can wear, leading to oil consumption or loss of boost. Manual covers inspection and overhaul.
Clutch Wear:
High-performance clutch can wear out with aggressive driving. Manual provides replacement procedures.
Rust:
Common in older performance cars, especially in areas with salted roads. Check wheel arches, sills, and subframes.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's rich history in the World Rally Championship (WRC) with multiple driver and manufacturer titles.
Model Evolution
Predecessors:
Evolution I (1992), Evolution II (1994), Evolution III (1995), Evolution IV (1996), Evolution V (1998).
Evolution Vi Introduction:
Introduced in January 1999, building upon the Evo V.
Tommi Makinen Edition:
Special edition released in 2000 to celebrate Tommi Mäkinen's fourth consecutive WRC drivers' championship, featuring unique styling and mechanical upgrades.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
Production Volume:
Limited production numbers, highly sought after by enthusiasts.
🏆 Awards & Recognition
Recognitions
Rally Dominance:
The Evo platform, particularly the Mk1 (CP9A) generation, was the backbone of Mitsubishi's immense WRC success.
Performance Reviews:
Consistently lauded by automotive press for its handling, performance, and value as a pure sports sedan.
Enthusiast Status:
Considered a modern classic and a highly desirable enthusiast car globally.
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