Mitsubishi Evolution IV & V 1996-1999 Repair Service Manual

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Welcome to the comprehensive service manual for the Mitsubishi Lancer Evolution IV and V, produced between 1996 and 1999. These iconic performance sedans, based on the CP9A chassis, are renowned...

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Taper: Car

Distributeur:

UGS: 70464

Mots clés: 1996 1997 1998 1999 Car Cars Evolution IV Evolution V Misc Mitsubishi

Variantes de produits

Description

Welcome to the comprehensive service manual for the Mitsubishi Lancer Evolution IV and V, produced between 1996 and 1999. These iconic performance sedans, based on the CP9A chassis, are renowned for their direct lineage from Mitsubishi's World Rally Championship success, offering a driver-focused experience with exceptional handling and acceleration. Key features include a potent 2.0L 4G63T turbocharged engine, advanced full-time four-wheel drive with Active Yaw Control (AYC) for superior cornering, and a robust, rally-bred construction. Both the Evolution IV and V represent significant advancements in performance engineering, delivering exhilarating driving dynamics that have cemented their status among automotive enthusiasts. This workshop repair service manual provides in-depth coverage for all aspects of the Mitsubishi Lancer Evolution IV and V, primarily focusing on Japanese domestic market (JDM) specifications with common global variations. Spanning over 1000 pages, it details everything from routine maintenance procedures like oil changes and filter replacements to complex component repairs and engine rebuilds. You will find extensive information on the powertrain, drivetrain including the Getrag 5-speed transmission and AYC system, chassis, electrical systems, and bodywork. Diagnostic troubleshooting guides, technical specifications, and safety information are also included, making this manual an indispensable resource for owners and technicians seeking to maintain and repair these high-performance vehicles.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV & V

Model Code:

CP9A (Evo IV), CP9A (Evo V)

Production Years Covered:

1996-1999

👋 Introduction

Market Position

Segment:

Compact performance sedan, rallying icon

Reputation:

Renowned for its potent turbocharged engine, advanced all-wheel-drive system, and rally-bred performance capabilities.

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Ford Escort Cosworth, Toyota Celica GT-Four

Key Features

Performance Focus:

High-performance, driver-focused vehicle engineered for extreme handling and acceleration.

Advanced AWD:

Features Mitsubishi's sophisticated Active Yaw Control (AYC) system for enhanced cornering stability and grip.

Rally Heritage:

Direct lineage from Mitsubishi's successful World Rally Championship (WRC) program.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, maintenance, and repair for Mitsubishi Lancer Evolution IV and V

Region Of Origin:

Primarily Japanese domestic market (JDM) specifications, with common global variations

Page Count

Estimated Page Count:

Approximately 1000+ pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English (with potential for Japanese diagrams/terminology)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, lubrication system, cooling system, fuel system, ignition system, exhaust system, turbocharger system

Drivetrain:

Manual transmission (Getrag 5-speed), Active Yaw Control (AYC) system, front differential, rear differential

Chassis:

Suspension (front MacPherson strut, rear multi-link), steering system, braking system (ABS specifications)

Electrical:

Engine control unit (ECU) and wiring diagrams, lighting systems, instrumentation, audio system, power accessories, starter and charging system

Body:

Body exterior and interior components, body sealing, structural repairs, collision repair information

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, belt inspections

Component Repair:

Engine rebuild procedures, transmission overhaul, brake caliper and rotor replacement, shock absorber and strut replacement, turbocharger servicing

Diagnostics Troubleshooting:

DTC (Diagnostic Trouble Code) retrieval and interpretation, symptom-based troubleshooting guides, electrical diagnostic flowcharts

Technical Data Specs:

Torque specifications for all fasteners, fluid capacities and types, electrical component specifications, alignment specifications

Technical Depth

Depth:

Extensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures for electronic systems.

📊 Manual Specifications

File Format

Format:

Searchable PDF

Print Quality:

High-resolution scans, suitable for printing individual pages or the entire manual

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

2.0L DOHC 16-valve turbocharged inline-4

Engine Variant Evoiv:

MIVEC (Mitsubishi Innovative Valve timing Electronic Control) equipped, twin-scroll turbocharger

Engine Variant Evov:

Revised turbocharger, higher compression ratio, improved MIVEC tuning

Performance

Horsepower Evoiv:

280 PS (approx. 276 bhp) @ 6500 rpm (Gorman regulated)

Torque Evoiv:

350 Nm (approx. 258 lb-ft) @ 3000 rpm (Gorman regulated)

Horsepower Evov:

280 PS (approx. 276 bhp) @ 6500 rpm (Gorman regulated, minor internal improvements)

Torque Evov:

357 Nm (approx. 263 lb-ft) @ 3000 rpm (Gorman regulated, minor internal improvements)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (Octane Rating: 98 RON recommended)

Ignition System:

Distributorless Ignition System (DIS) with individual ignition coils

🔧 Transmission

Standard

Type:

Getrag 5-speed manual transmission

Optional

Type:

Not applicable for these performance-oriented models

Features

AWD System:

Full-time 4-wheel drive with Active Yaw Control (AYC) for rear differential torque vectoring

Ayc Control Evoiv:

Hydraulic control of rear differential lockup for improved cornering.

Ayc Control Evov:

Electronically controlled hydraulic AYC, offering finer adjustments.

📐 Dimensions

Exterior

Length Evoiv:

4350 mm (171.3 in)

Width Evoiv:

1770 mm (69.7 in)

Height Evoiv:

1415 mm (55.7 in)

Wheelbase Evoiv:

2600 mm (102.4 in)

Length Evov:

4360 mm (171.7 in)

Width Evov:

1770 mm (69.7 in)

Height Evov:

1415 mm (55.7 in)

Wheelbase Evov:

2600 mm (102.4 in)

Weights

Curb Weight Evoiv:

Approx. 1360 kg (2998 lbs)

Curb Weight Evov:

Approx. 1380 kg (3042 lbs)

🛡️ Safety Features

Ratings

Crash Test Information:

No official NHTSA/Euro NCAP ratings for this era, but construction focused on rigidity.

Active Features

Standard Anti-lock Braking System (ABS)

Active Yaw Control (AYC) for enhanced stability and traction control

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners

Chassis Construction:

Reinforced chassis for improved rigidity and crash protection.

💡 Technology Features

Infotainment

Audio System:

Factory radio with cassette player and CD compatibility (optional) and 4-6 speakers.

Instrumentation:

Comprehensive digital and analog gauges including boost gauge, oil pressure, and water temperature.

Driver Assistance

Traction Control:

Standard AYC system actively manages torque distribution for enhanced traction and stability.

Connectivity

Oem Connectivity:

Limited by era; primarily focused on vehicle performance systems. No integrated Bluetooth or USB.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 km (3,000-5,000 miles) or 6 months, whichever comes first, depending on driving conditions.

Air Filter Replacement:

Every 15,000-20,000 km (9,000-12,000 miles)

Spark Plug Replacement:

Every 40,000-50,000 km (25,000-30,000 miles), depending on plug type.

Fluid Specifications

Engine Oil:

API SG or SH, SAE 10W-30 or 10W-40 recommended. Check manual for specific viscosity and grade.

Coolant:

Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.

Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 synthetic gear oil.

Differentials Fluid:

API GL-5, SAE 75W-90 synthetic gear oil. Specific AYC fluid type may be required for the rear differential.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Dexron III ATF or equivalent power steering fluid.

Known Issues

Engine:

Head gasket failure, turbocharger wear, piston ring wear (especially on modified engines)

Drivetrain:

AYC system pump failure, clutch wear, transmission synchromesh wear

Chassis:

Subframe rust, suspension bushing wear, brake component wear

Electrical:

Corrosion on connectors, ECU failure on heavily modified cars, AYC sensor issues

📚 Vehicle History

Brand Heritage

Rally Success:

Mitsubishi's long and successful history in the World Rally Championship (WRC) directly influenced the development of the Lancer Evolution series.

Model Evolution

Evoiv Introduction:

Introduced in August 1996, significant upgrades over the Evo III, including a new engine variant and AYC.

Evov Introduction:

Introduced in January 1998, further refinement of the chassis and drivetrain, including improved AYC.

Chassis Code:

Both generations utilize the CP9A chassis, derived from the Mitsubishi Lancer.

Production

Manufacturing Location:

Japan

Special Editions:

Limited editions like the GSR, RS, Evolution GSR RS (rare) were produced.

🏆 Awards & Recognition

Recognitions

Motorsport Accolades:

Numerous victories and championships in the World Rally Championship (WRC) during the 1990s, cementing its status as a rally legend.

Ratings

Enthusiast Popularity:

Consistently ranks high among automotive enthusiasts for its performance, handling, and tuning potential.