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Mitsubishi Evo 5 1998 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution V (Evo V) Model Nickname: Evo V Year: 1998-1999 Codes Chassis Code: CP9A 👋 Introduction Market Position Market Position: The Mitsubishi...
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Mitsubishi Evo 5 1998 1999 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution V (Evo V)
Model Nickname:
Evo V
Year:
1998-1999
Codes
Chassis Code:
CP9A
👋 Introduction
Market Position
Market Position:
The Mitsubishi Lancer Evolution V (Evo V) was positioned as a high-performance, rally-bred homologation special. It represented the pinnacle of Mitsubishi's engineering prowess in the late 1990s, aimed at enthusiasts and motorsport participants. Its aggressive styling, advanced four-wheel-drive system, and turbocharged engine made it a formidable competitor in the performance sedan segment.
Competitive Analysis
Competitive Analysis:
Competed directly with other iconic performance sedans of the era such as the Subaru Impreza WRX STi, Ford Escort RS Cosworth, and Lancia Delta Integrale. The Evo V distinguished itself with its sophisticated Active Yaw Control (AYC) system and potent powerplant, solidifying its reputation as a driver's car.
Key Features
Key Features:
Aggressive aerodynamic enhancements (wider body, larger rear spoiler, revised front bumper), upgraded suspension components, potent turbocharged engine, advanced All-Wheel Drive (AWD) system with Active Yaw Control (AYC), high-performance Brembo brakes, sport-tuned interior.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Starting System, Charging System, Transmission (Manual & Automatic), Drivetrain (All-Wheel Drive, Differentials), Suspension (Front & Rear), Steering System, Braking System, ABS, Air Conditioning, Body Electrical, Body Hardware, Chassis Electrical, Interior Trim, Exterior Trim, Emission Control System, Diagnostic Procedures, Troubleshooting Charts, Wiring Diagrams, Torque Specifications, Maintenance Schedules, Fluid Capacities, Component Locations, Exploded Views, General Information, Specifications.
Page Count
Page Count:
Hundreds of pages (exact count varies based on printing preference)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, and reassembly procedures for engine components including cylinder head, block, pistons, connecting rods, crankshaft, camshafts, timing belt/chain, valves, oil pump, etc.
Engine Control:
Diagnosis and repair of the Engine Control Unit (ECU), sensors (MAP, TPS, O2, knock, crank, cam), actuators (injectors, ignition coils), and related wiring.
Fuel System:
Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel lines, evaporative emission (EVAP) system.
Ignition System
Ignition System:
Ignition coils, spark plugs, ignition timing, ignition control module, troubleshooting.
Exhaust System
Exhaust System:
Catalytic converter, mufflers, exhaust pipes, oxygen sensors, heat shields.
Cooling System
Cooling System:
Radiator, water pump, thermostat, cooling fans, coolant hoses, coolant specifications.
Lubrication System
Lubrication System:
Oil pan, oil pump, oil filter, oil passages, oil specifications, oil change intervals.
Starting Charging
Starting Charging:
Starter motor, alternator, battery, voltage regulator, troubleshooting.
Transmission Drivetrain
Transmission Drivetrain:
Manual transmission (Type 13), automatic transmission (optional), clutch system, driveshafts, front and rear differentials (including Active Yaw Control - AYC), viscous coupling, center differential.
Suspension Steering
Suspension Steering:
Front and rear suspension geometry, struts, shock absorbers, springs, control arms, bushings, power steering system, steering rack, wheel alignment specifications.
Braking System
Braking System:
Front and rear brake calipers (Brembo on many models), brake discs, brake pads, master cylinder, brake fluid specifications, ABS (Anti-lock Braking System) components and diagnosis.
Body Electrical
Body Electrical:
Lighting system (headlights, taillights, interior lights), power windows, power mirrors, central locking, wipers, horn, fuse box locations, relay functions, wiring diagrams for various circuits.
Body Hardware
Body Hardware:
Door panel removal, trunk lid, hood, bumpers, fenders, spoilers, glass replacement, sealants.
Interior Exterior Trim
Interior Exterior Trim:
Seat removal, dashboard assembly, center console, door panels, exterior trim pieces, badges, emblems.
Air Conditioning
Air Conditioning:
AC system components (compressor, condenser, evaporator, receiver/drier), refrigerant type, charging procedures, leak detection, diagnosis.
Procedures Included
Maintenance Procedures:
Detailed step-by-step instructions for routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad inspection and replacement, tire rotation, and drive belt inspection.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues across all vehicle systems.
Repair Procedures:
In-depth repair instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for virtually every part of the vehicle.
Wiring Diagrams:
Detailed, system-specific wiring schematics showing component connections, wire colors, and pinouts for electrical troubleshooting.
Diagnostic Troubleshooting:
Guidance on using diagnostic tools (e.g., scan tools), interpreting diagnostic trouble codes (DTCs), and performing electrical tests.
Technical Depth
Technical Depth:
Full factory-level technical information suitable for professional technicians and advanced DIY enthusiasts. Covers basic maintenance through complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhauls.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution, enabling clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital PDF - Printable)
Paper Type
Paper Type:
N/A (Digital PDF - Printable)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Intercooled Turbocharged DOHC Inline-4
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1
Performance
Horsepower:
280 PS (276 hp / 206 kW) @ 6500 rpm (JDM Spec)
Torque:
352 Nm (260 lb-ft) @ 3000 rpm (JDM Spec)
Fuel System
Fuel System Type:
Electronic Fuel Injection (EFI) with Sequential Port Injection
Fuel Type:
Unleaded Premium Gasoline (RON 95 or higher recommended)
Turbocharger
Turbocharger Details:
Mitsubishi TD05H-16G (or similar variant) twin-scroll turbocharger
Engine Management
Engine Management System:
ECU controlled engine management
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (F5M51)
Optional
Optional Transmission:
N/A for Evo V (Only Manual Transmission Offered)
Features
Drivetrain System:
Mitsubishi's advanced All-Wheel Drive (AWD) system with Active Yaw Control (AYC) and Helical Limited-Slip Front Differential.
Ayc System:
Active Yaw Control system electronically manages torque distribution between rear wheels for enhanced cornering stability and traction.
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 (or manufacturer specified equivalent)
Transfer Case Fluid Type:
API GL-4, SAE 75W-90 (or manufacturer specified equivalent)
Rear Differential Fluid Type:
API GL-5, SAE 80W-90 (or manufacturer specified equivalent)
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Front Track:
1500 mm (59.1 in)
Rear Track:
1505 mm (59.3 in)
Weights
Curb Weight:
Approx. 1340 kg (2954 lbs)
Gross Vehicle Weight:
Not specified in product data, typically around 1700 kg.
Wheels Tires
Wheel Size:
17 inches
Tire Size:
225/45R17
Bolt Pattern:
5x114.3 mm
🛡️ Safety Features
Ratings
Safety Ratings:
Specific official crash test ratings for the 1998-1999 Evo V in major global markets are not readily available or were not standardized as they are today. However, the vehicle features robust chassis construction typical of homologation specials.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Active Yaw Control (AYC), sophisticated All-Wheel Drive (AWD) system.
Passive Features
Passive Safety Features:
Front airbags (driver and passenger), 3-point seat belts with pre-tensioners, reinforced chassis structure, impact-absorbing steering column.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/Cassette/CD player with standard speaker system. No advanced digital displays or integrated navigation typical of modern vehicles.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily focused on mechanical aids like AWD and AYC for enhanced traction and handling.
Connectivity
Connectivity:
No Bluetooth or USB connectivity; features are mechanical and analog.
Engine Management
Engine Management Technology:
ECU-controlled fuel injection and ignition timing, knock sensor for detonation control, MAP sensor for boost pressure monitoring.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (severe driving conditions may require more frequent changes).
Air Filter Replacement:
Every 20,000 km (12,000 miles) or as needed based on driving environment.
Spark Plug Replacement:
Every 40,000 km (24,000 miles) for standard plugs, or as recommended for performance plugs.
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 5 years, whichever comes first. Critical component for the 4G63T engine.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, Viscosity: 10W-30 or 10W-40 (check manual for specific temperature ranges and manufacturer recommendations).
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Mitsubishi Genuine Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for precise specification).
Power Steering Fluid Type:
Mitsubishi Genuine Power Steering Fluid or Dexron III ATF.
Known Issues
Common Issues:
Timing belt failure (if not replaced on schedule), turbocharger wear and oil leaks, clutch wear, worn suspension bushings, potential for rear differential and AYC system issues due to aggressive use, starter motor failure, and electrical gremlins if not maintained.
Performance Part Wear:
Due to their performance-oriented nature, components like brake pads, discs, and tires will wear faster than on standard vehicles. Regular inspection and replacement are crucial.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long and successful history in motorsport, particularly in the World Rally Championship (WRC). The Lancer Evolution series was born out of this rally heritage, designed to homologate technology and performance for competition.
Model Evolution
Model Evolution:
The Evo V marked a significant evolution from the Evo IV. It featured a wider track, revised suspension geometry, larger front brakes (Brembo), an upgraded engine with a larger turbocharger and intercooler, and distinct bodywork with a larger rear spoiler and aggressive front bumper. These enhancements were direct responses to evolving rally regulations and competition.
Production
Production Years:
1998 - 1999
Manufacturing Location:
Japan
Market Availability:
Primarily for the Japanese Domestic Market (JDM), with limited availability in other select markets. Later generations and specific RS/GSR variants became more widely exported.
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the Evo V model itself are scarce, the Lancer Evolution line is widely recognized for its success in the World Rally Championship, cementing its reputation as one of the greatest rally cars of all time. The Evo V was a key player in this legacy.
Ratings
Performance Ratings:
Consistently praised by automotive journalists and enthusiasts for its exceptional handling, grip, and driver engagement. Often cited as a benchmark for AWD performance cars.
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