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

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This manual covers the Mitsubishi Lancer Evolution IV and Evolution V, produced between 1996 and 1999. These iconic performance sedans, also known by their common names Evo 4 and Evo...

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Taper: Car

Distributeur:

UGS: 70467

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

Variantes de produits

Description

This manual covers the Mitsubishi Lancer Evolution IV and Evolution V, produced between 1996 and 1999. These iconic performance sedans, also known by their common names Evo 4 and Evo 5, are renowned for their World Rally Championship (WRC) heritage and advanced Super All-Wheel Control (S-AWC) system, including Active Yaw Control (AYC). Powered by the legendary 4G63 turbocharged engine, these vehicles offer exceptional performance and handling, making them highly sought after by enthusiasts. The Lancer Evolution IV (chassis code CN9A) and Evolution V (chassis code CP9A) represent significant engineering achievements in their respective generations, built for rally homologation and spirited driving. This comprehensive workshop repair service manual provides in-depth information for owners, mechanics, and technicians. It details maintenance procedures, diagnostics, and repair for all major systems, including the 4G63 engine, 5-speed manual transmission, drivetrain components, AYC system, suspension, brakes, and electrical systems. The manual includes troubleshooting guides, engine overhaul instructions, turbocharger service, transmission rebuild procedures, and detailed wiring diagrams. With an estimated 1500-2500 pages, this English-language resource offers extensive coverage, enabling users to effectively maintain, diagnose, and repair their Lancer Evolution IV or V.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution IV / Evolution V

Common Name:

Lancer Evo 4, Evo 5, Evo IV, Evo V

Codes

Chassis Codes Evo Iv:

Chassis Codes Evo V:

Generation

Generation Evo Iv:

Fourth Generation

Generation Evo V:

Fifth Generation

👋 Introduction

Market Position

Market Segment:

Performance Rally Homologation Special / Sports Sedan

Competitive Analysis

Key Competitors:

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

Key Features

Rally Heritage:

Directly derived from Mitsubishi's World Rally Championship (WRC) lineage.

AWD System:

Advanced Super All-Wheel Control (S-AWC) evolution, including Active Yaw Control (AYC).

Engine Technology:

Legendary 4G63 engine with robust internals and significant tuning potential.

Target Audience

Target Audience:

Enthusiast owners, mechanics, and tuners seeking in-depth knowledge for maintenance, repair, and modification.

📋 Manual Details

Coverage Areas

Coverage Years:

1996, 1997, 1998, 1999

Page Count

Estimated Page Count:

~1500-2500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain Engine:

4G63 (2.0L DOHC Turbocharged I4) engine diagnostics, overhaul, performance tuning, cooling system, lubrication system, fuel injection, ignition system, emissions control.

Powertrain Transmission:

5-speed manual transmission (Type R/RS/GSR variants), clutch system, drivetrain components (front/rear differentials, transfer case, driveshafts), AYC (Active Yaw Control) system.

Chassis Suspension:

Front MacPherson struts, multi-link rear suspension, spring rates, damper specifications, alignment procedures, bush and ball joint replacement.

Chassis Brakes:

Front Brembo opposed-piston calipers, rear single-piston calipers, ABS (Anti-lock Braking System) diagnostics, brake fluid specifications, rotor and pad replacement, hydraulic system bleeding.

Electrical System:

Wiring diagrams, ECU (Engine Control Unit) pinouts, sensor diagnostics (MAP, TPS, Crankshaft Position, Knock), starter, alternator, battery, lighting system, horn, wipers, power windows.

Body And Interior:

Body panel removal and installation, interior trim, seats, dashboard, HVAC (Heating, Ventilation, and Air Conditioning) system, door mechanisms, exterior lighting.

Diagnostics And Troubleshooting:

Fault code retrieval, diagnostic procedures for engine, transmission, AYC, and ABS systems, common issues and their resolutions.

Procedures Included

Engine Overhaul:

Complete engine rebuild procedures, including cylinder head disassembly/assembly, piston and connecting rod installation, crankshaft bearing replacement, camshaft timing.

Turbocharger Service:

Turbocharger inspection, installation, and diagnosis. Oil and coolant line routing.

Suspension And Steering:

Strut and shock absorber replacement, control arm bushing replacement, wheel bearing replacement, power steering system diagnosis and repair.

Transmission Rebuild:

Detailed steps for disassembling, inspecting, and reassembling the 5-speed manual transmission. Gear selection and synchro ring replacement.

Brake System Maintenance:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, bleeding procedures, master cylinder and booster testing.

Electrical Troubleshooting:

Using wiring diagrams to diagnose electrical faults, sensor testing, actuator testing, ECU troubleshooting.

Technical Depth

Depth Of Coverage:

Comprehensive (from routine maintenance and adjustments to complete engine/transmission rebuilds and advanced diagnostics).

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, clear text and diagrams suitable for printing.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Searchability

Searchability:

Likely text-searchable PDF for quick access to specific topics.

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, Intercooled Turbocharged

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Evo Iv:

280 PS (276 hp; 206 kW) @ 6500 rpm (JDM Spec)

Torque Evo Iv:

352 Nm (259 lb-ft) @ 3000 rpm (JDM Spec)

Horsepower Evo V:

280 PS (276 hp; 206 kW) @ 6500 rpm (JDM Spec)

Torque Evo V:

373 Nm (275 lb-ft) @ 3000 rpm (JDM Spec)

Fuel System

Fuel Induction:

Multi-point Fuel Injection (MPI) with Electronic Fuel Pump

Fuel Type:

Unleaded Gasoline (Premium Unleaded Recommended)

Engine Management

ECU Type:

Proprietary Mitsubishi ECU

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Optional

Optional Transmission:

None (Manual transmission was standard for performance variants)

Features

Transmission Features:

Close-ratio gearsets, stout construction for high-torque applications.

Drivetrain

Drivetrain Layout:

All-Wheel Drive (AWD)

AWD System Details:

Symmetrical AWD with Active Yaw Control (AYC) – electronically controlled hydraulic unit for torque vectoring to rear wheels (Evo IV/V variants differ slightly).

📐 Dimensions

Exterior

Length Evo Iv:

4350 mm (171.3 in)

Width Evo Iv:

1770 mm (69.7 in)

Height Evo Iv:

1415 mm (55.7 in)

Wheelbase Evo Iv:

2600 mm (102.4 in)

Length Evo V:

4350 mm (171.3 in)

Width Evo V:

1770 mm (69.7 in)

Height Evo V:

1415 mm (55.7 in)

Wheelbase Evo V:

2600 mm (102.4 in)

Weights

Curb Weight Evo Iv:

~1400 kg (3086 lb)

Curb Weight Evo V:

~1450 kg (3197 lb)

🛡️ Safety Features

Ratings

Safety Ratings:

Primarily Japanese domestic market (JDM) homologation standards; specific international ratings may vary or be limited.

Active Features

Active Safety:

ABS (Anti-lock Braking System), AYC (Active Yaw Control), powerful Brembo braking system.

Passive Features

Passive Safety:

Reinforced chassis, driver and passenger airbags (standard on most models), three-point seat belts.

💡 Technology Features

Infotainment

Infotainment System:

Basic factory stereo systems with CD/Cassette player; limited advanced features by modern standards.

Driver Assistance

Driver Assistance Features:

ABS, AYC (Active Yaw Control).

Connectivity

Connectivity:

None by modern standards (no Bluetooth, USB, or smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-7,500 km (3,000-5,000 miles) or 6 months, depending on driving conditions (severe use may require more frequent changes).

Timing Belt Replacement:

Recommended every 80,000-100,000 km (50,000-60,000 miles) or 5-7 years, crucial due to interference engine design.

Fluid Specifications

Engine Oil Specification:

10W-30 or 5W-30 API SG/SH/SJ rated synthetic or semi-synthetic oil.

Coolant Specification:

Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with proper corrosion inhibitors, 50/50 mix with distilled water.

Transmission Fluid:

API GL-4 SAE 75W-90 or 75W-85 gear oil for the manual transmission. AYC/transfer case may require specific fluids; consult manual for exact specifications.

Brake Fluid:

DOT 3 or DOT 4 high-temperature brake fluid.

Known Issues

Known Issues Engine:

Cracked cylinder head (especially on modified engines), turbo seal failure (leading to smoking), connecting rod bearing wear at high mileage/power levels.

Known Issues Ayc:

Failure of AYC pump, sensor faults, leaks in the hydraulic system.

Known Issues Corrosion:

Rusting in common areas like wheel arches, sills, and around the battery tray, especially in regions with salt exposure.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mitsubishi Motors has a long and storied history in motorsport, particularly in rallying with the Lancer platform.

Model Evolution

Evolution Iv Introduction:

Launched in August 1996, featuring a significant redesign with a new body and enhanced AYC system.

Evolution V Introduction:

Launched in January 1998, a facelift and performance upgrade over the Evo IV, featuring wider track, larger wheels, improved aerodynamics, and a torque-enhanced engine.

Production

Production Period:

Evo IV: 1996-1998; Evo V: 1998-1999

Key Variants:

GSR (Grand Sport Racing) - luxury sport trim, RS (Rally Sport) - stripped-down, lightweight, homologation special.

🏆 Awards & Recognition

Recognitions

Motorsport Success:

Multiple WRC manufacturer and driver championships during the era, validating the performance and engineering of the platform.

Enthusiast Acclaim

Cult Status:

Widely regarded as one of the greatest rally cars for the road, commanding a strong enthusiast following and collector's item status.