Mitsubishi Evolution IV 1996-1998 Factory Service Manual

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Distributeur:

UGS: 69810

Mots clés: 1996 1997 1998 Car Cars Evolution IV Misc Mitsubishi

Variantes de produits

Description

The Mitsubishi Lancer Evolution IV, chassis code CN9A, produced from 1996 to 1998, stands as an iconic JDM sports sedan, engineered as a performance homologation special for World Rally Championship (WRC) competition. Building on Mitsubishi's extensive rallying heritage, this model is renowned for its advanced All-Wheel Drive (AWD) system featuring Active Yaw Control (AYC), delivering exceptional handling and driver engagement. Powered by the legendary 4G63T DOHC turbocharged intercooled engine, the Lancer Evolution IV offers potent performance, making it a highly sought-after vehicle for enthusiasts and performance driving. This comprehensive Factory Service Manual (FSM) provides detailed guidance for the maintenance, diagnosis, and repair of the Mitsubishi Lancer Evolution IV. Covering all major systems including the engine, fuel, turbocharger, transmission, drivetrain, suspension, braking, steering, and electrical systems, this manual offers step-by-step procedures for everything from routine maintenance and fluid changes to complete engine and transmission overhauls. It includes essential technical specifications, troubleshooting guides, and diagnostic information, ensuring owners, mechanics, and technicians can effectively maintain and preserve the performance and reliability of this celebrated vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV

Chassis Code:

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:

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

Standard Anti-lock Braking System (ABS)

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.