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

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Distributeur:

UGS: 69859

Mots clés: 1996 1997 1998 1999 Car Cars Lancer Evo 4 Lancer Evo 5 Misc Mitsubishi

Variantes de produits

Description

The Mitsubishi Lancer Evolution, specifically covering the Evo IV (CN9A) and Evo V (CP9A) generations produced from 1996 to 1999, stands as a legendary performance sedan renowned for its rally-bred engineering and advanced all-wheel-drive systems. These models are distinguished by their potent turbocharged inline-4 engines, aggressive aerodynamic enhancements, and driver-focused interiors. The Lancer Evolution's reputation is built on its exceptional handling and traction, largely due to its sophisticated Active Center Differential (ACD) and Active Yaw Control (AYC) systems, making it a formidable machine both on the road and in motorsport contexts. This comprehensive factory service manual provides detailed information for the professional technician and experienced DIY enthusiast. It covers all essential aspects of vehicle maintenance, repair, and diagnostics, including in-depth procedures for the powertrain, drivetrain, suspension, steering, brakes, electrical systems, HVAC, and body/chassis components. With extensive coverage of scheduled maintenance, repair and rebuild procedures, troubleshooting guides, and technical specifications, this manual is an indispensable resource for ensuring the optimal performance and longevity of your Lancer Evolution.

🏷️ 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

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

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

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.