Powertrain:
Engine overhaul, fuel system, ignition system, cooling system, lubrication system, exhaust system, turbocharger and intercooler systems.
Drivetrain:
Manual Transmission (5-speed/6-speed on Evo V RS), Automatic Transmission (less common for performance variants), Transfer Case, Front Differential, Rear Differential (Active Yaw Control on applicable models), Drive Shafts, Axles.
Suspension And Steering:
Front and Rear Suspension (MacPherson Strut, Multi-link), Shock Absorbers, Springs, Bushings, Steering Gearbox, Power Steering System.
Brakes:
Front and Rear Disc Brakes (Brembo calipers on performance variants), ABS System, Brake Booster, Master Cylinder, Parking Brake.
Electrical:
Battery, Alternator, Starter Motor, Engine Control Unit (ECU), Ignition System, Lighting System, Instrumentation, Wiring Diagrams, Fuses and Relays, Audio System, Power Windows/Locks (if equipped).
Bodywork And Chassis:
Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Chassis Structure, Corrosion Prevention.
HVAC And Comfort:
Air Conditioning System, Heater Core, Ventilation System, Radiator Fan Control.
Safety Systems:
Airbag System (if equipped), Seatbelt Mechanisms.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Diagnostics And Troubleshooting:
Fault code interpretation, common problems and their solutions, diagnostic procedures for all major systems, electrical system troubleshooting guides.
Engine Repair:
Complete engine rebuild procedures, cylinder head service, piston and ring replacement, crankshaft and connecting rod service, camshaft and timing belt/chain replacement.
Transmission Repair:
Transmission disassembly, inspection, repair, and reassembly. Clutch replacement procedures, flywheel service.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, bleeding procedures, ABS component diagnosis and replacement.
Suspension And Steering Repair:
Component replacement (shocks, springs, control arms, ball joints), alignment procedures, steering rack repair/replacement.
Electrical System Repair:
Component testing and replacement (alternator, starter, sensors), wiring harness repair, troubleshooting of electronic modules.
Bodywork And Interior Repair:
Panel replacement, door and window regulator repair, interior trim panel removal and installation, glass replacement.
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic flowcharts.
Diagnostic Capability:
Advanced diagnostic procedures, including symptom-based troubleshooting and wiring diagrams for electrical systems.
Special Tools:
Lists required special tools for specific procedures, aiding in professional repairs.
Oil Change Interval Km:
5,000-7,500 km (depending on driving conditions, more frequently for spirited driving)
Timing Belt Replacement Km:
100,000 km or 5 years (critical replacement interval for the 4G63 engine)
Engine Oil Type:
API SG/SH/SJ or higher, ACEA A3/B3 or equivalent. Viscosity typically 10W-30 or 10W-40 (synthetic recommended).
Engine Oil Capacity Liters:
4.5 (without filter), 4.8 (with filter)
Coolant Type:
Ethylene Glycol based antifreeze (Mitsubishi Super Long Life Coolant or equivalent)
Transmission Fluid Type Manual:
API GL-4 or GL-5, SAE 75W-90 (Hypoid gear oil)
Differential Fluid Type Rear:
API GL-5, SAE 75W-90 (or specific AYC fluid if applicable, check manual)
Brake Fluid Type:
DOT 3 or DOT 4
Engine Reliability:
Generally robust 4G63 engine, but prone to head gasket failure if overheated or poorly maintained. Timing belt integrity is paramount.
Ayc System:
AYC pump and solenoids can fail over time, leading to warning lights and loss of active yaw control function. Fluid needs regular checking/changing.
Turbocharger:
Turbocharger can suffer from oil starvation if the engine is run hard and then shut off immediately without a cool-down period. Regular oil changes and proper maintenance are key.
Rust And Corrosion:
As with many cars of this era, particularly those used in challenging climates, rust can be an issue in wheel arches, sills, and suspension mounting points.
Motorsport Roots:
Mitsubishi's extensive rally heritage, particularly from the World Rally Championship (WRC), heavily influenced the development of the Lancer Evolution series.
Evo4 Introduction:
Introduced a new chassis and significant aerodynamic improvements. The AYC system was a major technological advancement for this generation.
Evo5 Enhancements:
Featured a slightly larger turbocharger, larger intercooler, revised ECU, stiffer suspension, and bodywork tweaks for improved aerodynamics and cooling. Introduced the 6-speed manual option on the RS model.
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Limited Editions:
Evolution V RS ('Rally Sport') model was a more stripped-down, performance-oriented version often used for motorsport homologation.
