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Mitsubishi Evolution IV 1996-1998 Factory Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Chassis Code: CN9A Production Years Covered: 1996, 1997, 1998 Codes Engine Code Primary: 4G63T Engine Code Variant: 4G63 (DOHC Turbocharged...
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Mitsubishi Evolution IV 1996-1998 Factory Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV
Chassis Code:
CN9A
Production Years Covered:
1996, 1997, 1998
Codes
Engine Code Primary:
4G63T
Engine Code Variant:
4G63 (DOHC Turbocharged Intercooler)
👋 Introduction
Market Position
Positioning:
Performance homologation special for World Rally Championship (WRC), iconic JDM sports sedan.
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Toyota Celica GT-Four, Ford Escort RS Cosworth (in relevant markets).
Key Features
Driving Dynamics:
Advanced All-Wheel Drive (AWD) with Active Yaw Control (AYC), sharp handling, powerful turbocharged engine.
Rally Heritage:
Directly derived from Mitsubishi's successful rally cars, enhancing its performance credibility.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual (FSM)
Language:
English
Format:
PDF Download
Completeness:
Complete Official Factory Service Repair Manual
Page Count
Estimated Page Count:
Hundreds of pages (indicative of a comprehensive FSM)
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine overhaul, diagnostics, specifications, timing belt, oil pump, cooling system, lubrication, emissions control.
Fuel System:
Fuel injection system, fuel pump, injectors, fuel pressure regulator, EVAP system, fuel tank and lines.
Turbocharger System:
Turbocharger inspection, repair, oil and coolant lines, wastegate operation, boost control.
Transmission System:
Manual transmission (W5M51-2-RCNN) removal, installation, internal components, fluid specifications, shift linkage, clutch system.
Drivetrain System:
All-Wheel Drive (AWD) system, Active Yaw Control (AYC), center differential, front and rear differentials, drive shafts, CV joints.
Suspension System:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications, AYC system components.
Braking System:
Front and rear brake assembly, ABS system, brake fluid specifications, hydraulic lines, master cylinder, calipers, rotors.
Steering System:
Power steering system, steering rack, tie rods, steering column, fluid specifications.
Electrical System:
Wiring diagrams, charging system (alternator, battery), starting system, ignition system, lighting, sensors, ECUs, fuses and relays.
HVAC System:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant, compressor, evaporator, condenser.
Body And Trim:
Exterior body panels, interior trim, doors, hood, trunk, bumpers, glass, seals, trim removal and installation.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and changes, belt inspection and replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams for fault finding.
Repair:
Step-by-step repair procedures for all major systems, component replacement, and adjustments.
Overhaul:
Complete engine and transmission overhaul procedures with detailed component disassembly and reassembly instructions.
Specifications And Tolerances:
Torque specifications, clearances, alignment angles, fluid capacities, and other critical technical data.
Installation:
Procedures for installing new or replacement parts and accessories.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and drivetrain rebuilds, advanced diagnostics).
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typical for factory PDF downloads)
Print Quality
Printability:
Printable (allows users to print specific sections or the entire manual)
Binding Type
Binding Type For Printed Copy:
N/A (PDF Download)
Paper Type
Paper Type For Printed Copy:
N/A (PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T (Inline-4, DOHC, 16-valve, turbocharged, intercooled)
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Performance
Horsepower Ps:
280 PS (276 bhp) @ 6500 rpm (Japanese domestic market 'gentlemen's agreement')
Torque Nm:
352 Nm (260 lb-ft) @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Turbo Injection
Turbocharger Model:
Mitsubishi TD05H-16G
Compression Ratio:
8.8:1
Engine Management
ECU Type:
ECU controlled ignition and fuel injection
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (W5M51-2-RCNN)
Optional
Type:
None offered for Evolution IV
Features
Drive System:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Center Differential:
Viscous coupling type
Ayc System:
Hydraulically actuated rear differential controlling torque distribution between rear wheels.
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2625 mm (103.3 in)
Front Track:
1500 mm (59.1 in)
Rear Track:
1495 mm (58.9 in)
Weights
Curb Weight:
Approx. 1400 kg (3086 lbs)
Gross Vehicle Weight Rating:
N/A (typically not specified for performance models in this era)
Towing Capacity:
Not Recommended
🛡️ Safety Features
Ratings
Federal Motor Vehicle Safety Standards:
Not officially rated by NHTSA in modern terms for this period and market.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) enhances stability and cornering.
Passive Features
Airbags:
Driver's side airbag (standard); Passenger airbag not universally standard for all markets.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners.
Body Construction:
Reinforced chassis with impact-absorbing crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory radio/cassette or CD player, typically with 4-6 speakers. Limited by era.
Driver Assistance
Stability Control:
Active Yaw Control (AYC) is a primary dynamic stability and traction aid.
Connectivity
Connectivity Features:
Basic, primarily focused on vehicle performance and diagnostics. No modern infotainment or smartphone integration.
Gauges And Displays
Instrument Cluster:
Comprehensive gauge cluster including boost gauge, oil pressure, oil temperature, and voltmeter.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first (severe driving conditions may warrant more frequent changes).
Timing Belt Replacement:
Every 90,000-100,000 km (56,000-62,000 miles) or 5 years.
Spark Plugs:
Inspect at 40,000 km (25,000 miles), replace as needed based on condition. High-performance plugs may have different intervals.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 (synthetic recommended for performance).
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based, low silicate coolant) with distilled water.
Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 (manual transmission). Check manual for specific AYC fluid.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine:
Head gasket failures (especially if poorly maintained or modified), turbocharger wear, connecting rod bearing issues in high-stress applications.
Drivetrain:
AYC pump failure, differential wear, transmission synchro wear.
Electrical:
Corrosion on connectors, crank angle sensor issues, ECU capacitor degradation (common in older Japanese ECUs).
Suspension:
Worn bushings, front strut tower mushrooming (due to harsh driving).
📚 Vehicle History
Brand Heritage
Motorsport Connection:
Mitsubishi's extensive rallying experience, especially with the Lancer platform in WRC, heavily influenced the Evolution series.
Model Evolution
Previous Generation:
Mitsubishi Lancer Evolution III (CE9A).
Next Generation:
Mitsubishi Lancer Evolution V (CP9A).
Production
Production Location:
Japan
Production Volume:
Limited production run, highly sought after.
🏆 Awards & Recognition
Recognitions
Rally Success:
Foundation for its performance reputation; while the Evo IV itself wasn't a direct rally homologation, the Evo lineage secured numerous WRC titles.
Enthusiast Acclaim:
Widely regarded as a classic JDM performance car, highly praised for its driving dynamics and accessible performance.
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