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Mitsubishi Evolution VI 1999-2001 Factory Service Manual

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The Lancer Evolution VI, often referred to as the Evo VI or Evo 6, is a performance-oriented sedan produced from 1999 to 2001. Developed from the Lancer platform, it boasts...
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Mitsubishi Evolution VI 1999-2001 Factory Service ManualMitsubishi Evolution VI 1999-2001 Factory Service ManualMitsubishi Evolution VI 1999-2001 Factory Service ManualMitsubishi Evolution VI 1999-2001 Factory Service Manual
The Lancer Evolution VI, often referred to as the Evo VI or Evo 6, is a performance-oriented sedan produced from 1999 to 2001. Developed from the Lancer platform, it boasts a legendary status in motorsport, particularly in rallying, and is celebrated for its aggressive styling, powerful turbocharged engine, and advanced all-wheel-drive system. Key features include the iconic 4G63 engine, a robust chassis, and sophisticated traction and handling technologies like Active Centre Differential (ACD) and Active Yaw Control (AYC). This model represents a peak in rally homologation specials, offering exceptional performance capabilities and a direct connection to World Rally Championship heritage. This comprehensive factory service manual provides essential information for the maintenance, repair, and servicing of the Lancer Evolution VI (CP9A) for the years 1999, 2000, and 2001. It covers all major systems, including the powertrain, chassis, body, and electrical components, offering detailed procedures for routine maintenance, diagnostics, troubleshooting, and component overhauls. This manual is an indispensable resource for owners, technicians, and mechanics seeking to preserve the performance and reliability of this highly capable vehicle, ensuring its complex systems are maintained to factory specifications.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Model Nickname:
Evo VI
Codes
Chassis Code Prefix:
CP9A
Engine Code Prefix:
4G63
👋 Introduction
Market Position
Segment:
Rally homologation special, performance sedan
Reputation:
Legendary status in motorsport and enthusiast communities
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione
Key Features
Performance Focus:
Aggressive styling, turbocharged engine, advanced all-wheel-drive system
Rally Heritage:
Developed from the Lancer platform for World Rally Championship (WRC) success
📋 Manual Details
Coverage Areas
Applicable Years:
1999, 2000, 2001
Regions Covered:
Global (primarily Japan domestic market focus)
Page Count
Estimated Pages:
Hundreds (specific count not provided, but described as 'complete')
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English (implied by 'PDF Download' and common industry practice for exported manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine performance, fuel system, cooling system, lubrication system, ignition system, exhaust system, transmission (manual and automatic variants), drivetrain (front/rear differentials, transfer case, axles)
Chassis:
Suspension (front MacPherson strut, rear multi-link), steering, brakes (ABS, hydraulic components), wheels and tires, chassis electrical
Body And Interior:
Body construction, exterior panels, doors, windows, interior trim, seating, HVAC system, airbags
Electrical And Electronics:
Wiring diagrams, electrical troubleshooting, lighting system, audio system, ECU, sensors, actuators
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting, fault code interpretation
Repair And Rebuild:
Component removal and installation, overhaul procedures, torque specifications, assembly instructions
Special Procedures:
Alignment, wheel balancing, specialized tool usage
Technical Depth
Depth:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if OCR processed, enhancing usability
Print Quality
Printable:
Yes, designed for printing by the user
Resolution:
High quality, suitable for clear reproduction of diagrams and text
Binding Type
User Binding Options:
Printable allows for user binding (e.g., three-hole punch, spiral binding)
Paper Type
Recommended Paper:
Standard printer paper, with higher weight recommended for durability
⚙️ Engine Specifications
Primary Engine
Engine Family:
Mitsubishi Sirius / 4G6 (2.0L DOHC Turbo)
Engine Displacement:
1997 cc (2.0 Liters)
Engine Configuration:
Inline-4, turbocharged and intercooled
Performance
Horsepower Ps:
280 PS (276 hp; 206 kW) at 6500 rpm (JDM specification, often higher in reality)
Torque Nm:
373 Nm (275 lb-ft) at 3000 rpm (JDM specification)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.8:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injectors
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Engine Internals
Block Material:
Cast Iron (known for strength)
Head Material:
Aluminum Alloy
Turbocharger
Turbo Model:
Mitsubishi TD05HR-16G (twin-scroll)
Engine Management
ECU Type:
Electronic Control Unit (ECU) with engine management system
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Getrag-based, often referred to as RS gearbox)
Optional
Type:
4-speed Automatic Transmission (available on some markets, less common for performance variants)
Features
Awc System:
Active Centre Differential (ACD) and Active Yaw Control (AYC) or Super AYC on some models, integrated with transmission and drivetrain
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 or GL-5, viscosity typically 75W-90
Automatic Transmission Fluid Type:
Dexron III or equivalent (if applicable)
📐 Dimensions
Exterior
Length:
4340 mm (170.9 in)
Width:
1770 mm (69.7 in)
Height:
1405 mm (55.3 in)
Wheelbase:
2600 mm (102.4 in)
Track Front:
1510 mm (59.4 in)
Track Rear:
1505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1360 kg (2998 lbs) for GSR model
Gross Vehicle Weight Rating:
Not specified, but typically around 1800-1900 kg
Wheels And Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
215/40R17
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
Crash Test Results:
No official NHTSA/Euro NCAP ratings for this specific model year due to its homologation-based nature and target market. However, built to meet rigorous WRC safety standards.
Active Features
Braking System:
Front: Ventilated discs, Rear: Ventilated discs. Brembo calipers standard on GSR. ABS standard.
Traction Control:
Advanced electronically controlled All-Wheel Control (AWC) system including ACD and AYC/Super AYC.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Body Structure:
Reinforced chassis and safety cage for rally-derived strength.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player and speakers. Aftermarket upgrades are common.
Driver Assistance
Advanced AWD:
The defining technology: ACD (Active Centre Differential) and AYC/Super AYC (Active Yaw Control) for superior traction and handling.
Connectivity
Original Connectivity:
Basic for its era, focused on vehicle performance rather than extensive connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under hard driving conditions.
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on driving environment.
Spark Plug Replacement:
Platinum or Iridium plugs typically last 80,000-100,000 km (50,000-60,000 miles).
Fluid Specifications
Engine Oil Type:
Synthetic 5W-40 or 5W-50 recommended, meeting API SJ/SL or ACEA A3/B3/B4 standards.
Engine Oil Capacity:
Approximately 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene glycol based coolant, typically 50/50 mix with distilled water. (e.g., Mitsubishi Super Long Life Coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4 (check specific manual for exact spec)
Known Issues
Engine Wear:
Piston ring land failures and connecting rod bending can occur with aggressive tuning or detonation. Regular maintenance and correct fueling are critical.
Ayc Pump:
AYC pump failure or leaks can occur over time, affecting rear-wheel steering performance.
Clutch:
Performance clutches may have shorter lifespans than standard clutches, especially under heavy use.
Maintenance Documentation Value
Importance For Evos:
Crucial for maintaining the complex AWD system, engine performance, and longevity of these highly tuned vehicles.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a strong history in rallying, with the Lancer Evolution series being a dominant force.
Model Evolution
Evolution Series:
The Evolution VI (Evo VI) succeeded the Evo V and introduced styling and mechanical revisions, including a more aggressive front bumper and the introduction of the TME (Tommi Mäkinen Edition) variant.
Sub Variants:
RS (Ralliart Sport - lightweight, homologation special) and GSR (Grand Sport Rally - more luxury-oriented, but still performance-focused). TME (Tommi Mäkinen Edition) celebrated WRC driver's championships.
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Dominance:
Multiple WRC Manufacturer's and Driver's Championships for Mitsubishi and Tommi Mäkinen.
Ratings
Enthusiast Appreciation:
Universally acclaimed as one of the greatest rally cars for the road ever produced.
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