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Mitsubishi Evo 4 1996-1998 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV (Evo 4) Generation: Fourth Generation Production Years: 1996-1998 Codes Chassis Code: CN9A 👋 Introduction Market Position Segment: Performance Compact Sedan...
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Mitsubishi Evo 4 1996-1998 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV (Evo 4)
Generation:
Fourth Generation
Production Years:
1996-1998
Codes
Chassis Code:
CN9A
👋 Introduction
Market Position
Segment:
Performance Compact Sedan / Rally Homologation Special
Reputation:
Legendary, iconic status in rally racing and performance tuning communities
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione
Key Features
Driving Dynamics:
Exceptional handling, grip, and driver feedback thanks to AWD and advanced chassis design
Engine Technology:
Robust turbocharged inline-4 with advanced intercooling and engine management
Rally Heritage:
Directly derived from Mitsubishi's WRC program, offering a pure, unfiltered driving experience
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily Japanese Domestic Market, but applicable to worldwide variants)
Vehicle Variants:
All models and engines for Lancer Evolution IV
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, clutch, cooling system, exhaust system, fuel system, ignition system, lubrication system
Drivetrain:
All-Wheel Drive (AYC - Active Yaw Control), front differential, rear differential, driveshafts, transfer case
Chassis:
Suspension (front and rear), steering system, brakes (front and rear), wheels, tires
Electrical:
Battery, charging system, starting system, lighting, instrumentation, audio system, power accessories, wiring diagrams, ECU, sensors
Body:
Body structure, interior trim, exterior trim, doors, windows, seats, airbags
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections
Repair:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical system diagnosis and repair, body panel repair
Troubleshooting:
Diagnostic procedures, fault codes, common issues and solutions
Diagnostics:
Component testing, sensor readings, electrical circuit diagnosis
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, detailed electrical schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typically)
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T (MIVEC variant not yet introduced)
Configuration:
Turbocharged and Intercooled Inline-4 DOHC 16-valve
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower:
280 PS (276 hp; 206 kW) at 6,500 rpm (Japanese domestic market 'gentleman's agreement' limit)
Torque:
352 Nm (259 lb-ft) at 3,000 rpm
Fuel System
Induction:
Electronic Fuel Injection (EFI) with Twin-Scroll Turbocharger
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Cooling System
Type:
Water-cooled
Lubrication System
Type:
Forced lubrication with wet sump
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
N/A (Manual exclusively for Evo 4)
Features
Drivetrain:
All-Wheel Drive (Full-time)
Ayc:
Active Yaw Control (AYC) for enhanced cornering stability
Differentials:
Front Helical LSD, Rear Viscous LSD with AYC control
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,600 mm (102.4 in)
Track Width Front:
1,515 mm (59.6 in)
Track Width Rear:
1,505 mm (59.3 in)
Weights
Curb Weight:
1,450 kg (3,197 lb)
Gross Weight:
1,725 kg (3,803 lb)
Cargo
Trunk Volume:
Approx. 357 liters (12.6 cu ft)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not independently rated by agencies like NHTSA or Euro NCAP for this era, but built to high performance standards.
Active Features
ABS:
Standard Anti-lock Braking System
Ayc:
Active Yaw Control contributes to stability under hard cornering
Passive Features
Airbags:
Driver and Passenger Airbags (standard)
Seatbelts:
Three-point front and rear seatbelts
Body Structure:
Reinforced safety cell construction
💡 Technology Features
Infotainment
System:
Basic factory radio/cassette player with optional CD player. Limited by era.
Speakers:
Typically 4-6 speakers
Driver Assistance
System Focus:
Performance enhancement and stability control through AYC and AWD, not modern electronic aids.
Connectivity
Features:
N/A (Pre-modern connectivity era)
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months
Air Filter Replacement:
Every 15,000-30,000 km (9,000-18,000 miles)
Spark Plug Replacement:
Every 30,000-50,000 km (18,000-30,000 miles), depending on type
Timing Belt Replacement:
Every 90,000-100,000 km (56,000-62,000 miles) or 7 years
Fluid Specifications
Engine Oil:
API SG/SH or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature)
Coolant:
Mitsubishi Dia Queen Super Long Life Coolant (or equivalent ethylene glycol-based coolant with anti-corrosion additives)
Transmission Fluid:
GL-4 SAE 75W-85 or 75W-90 (specific Mitsubishi specification may apply)
Transfer Case Fluid:
GL-4 SAE 75W-85 or 75W-90 (specific Mitsubishi specification may apply)
Differential Fluid:
GL-5 SAE 80W-90 (or specific Mitsubishi specification)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine:
Cracked cylinder head (under extreme heat/abuse), turbocharger wear, piston ring wear with high mileage
Drivetrain:
AYC pump failure, differential wear (especially rear if abused), gearbox synchro wear
Chassis:
Rust in common areas (wheel arches, sills), worn suspension bushings, brake component wear
Electrical:
Sensor failures (e.g., crank angle sensor), wiring harness degradation over time
📚 Vehicle History
Brand Heritage
Rally Success:
Mitsubishi has a long and illustrious history in World Rally Championship (WRC), winning multiple manufacturer and driver titles.
Model Evolution
Predecessors:
Lancer Evolution I, II, and III
Successors:
Lancer Evolution V
Key Changes From Evo3:
Stiffer chassis, revised suspension geometry, larger intercooler, revised AYC system, wider track, updated aerodynamic components.
Production
Manufacturing Plant:
Mizushima Plant, Kurashiki, Okayama, Japan
Production Volume:
Estimated 6,000 units (exact figures vary)
🏆 Awards & Recognition
Recognitions
Rally Influence:
While the car itself wasn't awarded as a road car, its direct lineage to successful WRC cars grants it immense prestige.
Ratings
Enthusiast Ratings:
Consistently ranked as one of the best rally cars for the road and a highly desirable performance car by automotive journalists and enthusiasts.
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