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Mitsubishi Lancer Evo 4 & 5 1996-1999 Factory Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution Generation Codes: Evo IV (CN9A), Evo V (CP9A) Model Years Covered: 1996, 1997, 1998, 1999 👋 Introduction Market Position Segment: Performance...
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Mitsubishi Lancer Evo 4 & 5 1996-1999 Factory Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution
Generation Codes:
Evo IV (CN9A), Evo V (CP9A)
Model Years Covered:
1996, 1997, 1998, 1999
👋 Introduction
Market Position
Segment:
Performance Sedan / Rally homologation special
Reputation:
Legendary for its rally-bred performance, advanced all-wheel-drive systems, and potent turbocharged engines
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four
Key Features
Drivetrain Technology:
Advanced four-wheel-drive systems (AYC/ACD) for exceptional traction and handling
Engine Technology:
High-performance turbocharged and intercooled inline-4 engines
Aerodynamics:
Aggressive styling with functional aerodynamic aids like large rear spoilers and front splitters
Interior Features:
Driver-focused cockpit with performance-oriented seating and instrumentation
📋 Manual Details
Coverage Areas
Primary Focus:
Comprehensive service, repair, and maintenance
Target Audience:
Professional technicians and experienced DIY enthusiasts
Page Count
Estimated Pages:
Hundreds (exact count varies by specific version, typically 1000+ pages for complete factory manuals)
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine fuel system, engine cooling, engine lubrication, ignition system, emissions control, engine electrical (ECU, sensors)
Drivetrain:
Manual transmission, transfer case, front axle, rear axle, drive shafts, differentials (front, center, rear AYC/ACD)
Suspension Steering:
Front suspension, rear suspension, steering system, power steering
Brakes:
Front brakes (calipers, discs), rear brakes (calipers, discs), ABS system, parking brake
Electrical:
Battery, charging system, starting system, lighting, instruments, gauges, horn, wipers, washers, power windows, power locks, audio system, climate control, body control modules (BCM)
Body Chassis:
Body panels, doors, hoods, trunk, interior trim, chassis components, frame
HVAC:
Heating, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant system)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt inspections/replacement
Repair Rebuild:
Engine overhaul, transmission rebuild, differential service, suspension component replacement, brake caliper/rotor replacement, electrical component diagnosis and repair
Diagnostics:
Troubleshooting guides, symptom-based diagnosis, diagnostic trouble codes (DTCs), wiring diagrams, electrical schematics
Adjustments:
Valve clearance adjustment, ignition timing, clutch adjustment, brake adjustments
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical specifications
Technical Depth
Depth:
Complete factory-level repair and overhaul procedures, including detailed disassembly, assembly, and testing
Diagnostic Tools:
Information on using specialized diagnostic tools and scan tools for electronic systems
📊 Manual Specifications
File Format
Format:
Portable Document Format (PDF)
Searchability:
Likely text-searchable PDF for efficient information retrieval
Print Quality
Quality:
Designed for clear reproduction, including detailed diagrams and schematics
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Evo4:
4G63T (DOHC, 16-valve, Turbocharged Inline-4)
Engine Code Evo5:
4G63T (DOHC, 16-valve, Turbocharged Inline-4, often with larger turbo and improved intercooler over Evo IV)
Performance Evo4
Displacement Evo4:
1997 cc (2.0 Liters)
Horsepower Evo4 Jdm:
280 PS (276 hp) @ 6500 rpm (Often underestimated, real output higher)
Torque Evo4 Jdm:
352 Nm (260 lb-ft) @ 3000 rpm
Performance Evo5
Displacement Evo5:
1997 cc (2.0 Liters)
Horsepower Evo5 Jdm:
280 PS (276 hp) @ 6500 rpm (Often underestimated, real output higher)
Torque Evo5 Jdm:
373 Nm (275 lb-ft) @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Turbocharger:
Mitsubishi TD05HR-16G twin-scroll turbocharger with intercooler
Engine Management
ECU:
Electronic Control Unit (ECU) with specific tuning for performance
🔧 Transmission
Standard
Type:
5-speed manual transmission
Optional
Type:
No automatic transmission offered for these performance models
Features
Drivetrain Type:
All-Wheel Drive (AWD)
Active Center Differential:
Active Center Differential (ACD) - Evo V standard, Evo IV optional/later production
Ayc:
Active Yaw Control (AYC) - Standard on Evo V, optional on Evo IV
Gear Ratios
Gear Ratios:
Specific gear ratios for performance driving (details in manual)
📐 Dimensions
Exterior Evo4
Length Evo4:
4345 mm (171.1 in)
Width Evo4:
1770 mm (69.7 in)
Height Evo4:
1415 mm (55.7 in)
Exterior Evo5
Length Evo5:
4350 mm (171.3 in)
Width Evo5:
1770 mm (69.7 in)
Height Evo5:
1415 mm (55.7 in)
Weights
Curb Weight:
Approx. 1370-1400 kg (3020-3086 lbs) depending on trim and options
Wheelbase
Wheelbase:
2600 mm (102.4 in)
Track Width
Front Track Evo5:
1500 mm (59.1 in)
Rear Track Evo5:
1490 mm (58.7 in)
Wheels Tires
Wheel Size Evo4:
15-inch (standard), 16-inch (optional/GSR)
Wheel Size Evo5:
17-inch
Tire Size Evo5:
215/45R17
Bolt Pattern:
5x114.3 (5x4.5 inch)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific safety rating data publicly available for these homologation specials from that era, focus on structural integrity for motorsport.
Active Features
ABS:
Anti-lock Braking System (ABS) - Standard
AWD Traction Control:
Advanced AWD system with ACD and AYC for enhanced traction and stability
Passive Features
Airbags:
Driver and front passenger airbags (standard)
Seatbelts:
3-point front seatbelts with pre-tensioners, 3-point rear seatbelts
Chassis Structure:
Reinforced chassis and safety cage design for structural rigidity and occupant protection
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player with speakers (CD players became more common later)
Climate Control:
Manual or automatic climate control systems depending on trim level
Driver Assistance
Traction Control:
Not typically electronic traction control in the modern sense, but the AWD, AYC, and ACD systems are key electronic driver aids for performance.
Connectivity
Connectivity Options:
No modern connectivity features like Bluetooth or USB ports
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 km (4,660 miles) or 6 months, whichever comes first (severe driving conditions may require more frequent changes)
Air Filter:
Inspect every 15,000 km (9,320 miles), replace as needed or every 30,000 km (18,640 miles)
Spark Plugs:
Replace every 60,000 km (37,280 miles) (use recommended iridium or platinum plugs)
Coolant Flush:
Every 45,000 km (27,960 miles) or 2 years
Timing Belt:
Replace every 90,000 km (55,920 miles) or 5 years. Crucial for the 4G63 engine.
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended for high performance)
Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (manual transmission, specific Mitsubishi fluid recommended for ACD/AYC units)
Coolant:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent (Ethylene Glycol based with de-ionized water, 50/50 mix)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Wear:
Piston ring wear, connecting rod issues (especially with aggressive tuning or abuse), turbocharger wear, head gasket failures under high boost.
AWD System:
AYC/ACD pump failure, differential wear if fluid maintenance is neglected.
Suspect Area:
Radiator failure, exhaust system corrosion, front suspension bushings.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a rich heritage in rallying, with the Lancer Evolution series being a direct descendant of their WRC (World Rally Championship) efforts.
Model Evolution
Evolution Iv Introduction:
Introduced in August 1996, featuring a revised ECU, improved turbocharger, and a more advanced AYC system.
Evolution V Introduction:
Introduced in January 1998, with significant mechanical updates including wider track, larger brakes, new wheels, improved ACD, and a redesigned front bumper for better airflow.
Production
Production Period:
1996-1999
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rally Homologation:
Developed specifically to meet World Rally Championship (WRC) homologation requirements, earning it a legendary status.
Performance Acclaim:
Widely praised by automotive journalists and enthusiasts for its driving dynamics, acceleration, and handling capabilities.
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