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Mitsubishi Evolution IV 1996-1998 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV Model Code: CN9A Generation Generation: Fourth Generation Codes Chassis Code: CN9A 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution...
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Mitsubishi Evolution IV 1996-1998 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV
Model Code:
CN9A
Generation
Generation:
Fourth Generation
Codes
Chassis Code:
CN9A
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution IV (Evo IV) was a high-performance homologation special, designed for rallying and street use, known for its advanced all-wheel-drive system and potent turbocharged engine.
Competitive Analysis
Competitors:
Primary competitors included the Subaru Impreza WRX STi, Ford Escort RS Cosworth, and Lancia Delta Integrale during its era.
Key Features
Features:
4G63T engine, AYC system, advanced suspension geometry, aerodynamic enhancements, potent braking system, rally-bred chassis.
📋 Manual Details
Coverage Areas
Coverage:
All markets/variants of the Mitsubishi Lancer Evolution IV (1996-1998)
Page Count
Page Count:
Estimated 1000+ pages (typical for a comprehensive factory service manual)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management (ECU), forced induction (turbocharger).
Transmission:
Manual transmission (W5M33), driveline, clutch, transfer case, Active Yaw Control (AYC) system.
Brakes:
Hydraulic brake system, ABS, parking brake, brake component diagnosis and repair.
Suspension Steering:
Front and rear suspension components, steering system, power steering, wheel alignment.
Electrical:
Complete electrical system, wiring diagrams, starter, alternator, battery, lighting, instruments, power accessories, body electronics.
Body Chassis:
Body structure, exterior panels, interior trim, doors, glass, HVAC system, chassis components, collision repair information.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Systematic diagnostic procedures, symptom-based troubleshooting, fault code interpretation.
Repair:
Detailed step-by-step repair procedures for all major vehicle components, including engine rebuilds, transmission overhauls, suspension replacement, brake service, electrical repairs.
Diagnostics:
On-Board Diagnostics (OBD-I/II) information, diagnostic tool usage, sensor testing, actuator testing.
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical component specifications.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and tuning information.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Typically fully searchable text for quick information retrieval.
Print Quality
Quality:
High-resolution scans of original factory manuals, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve
Engine Code:
4G63T
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower:
280 PS (206 kW; 276 hp) (JDM & European markets, often under-reported in some markets)
Torque:
352 Nm (259 lb-ft) at 3000 RPM (JDM & European markets)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point fuel injection
Fuel Type:
Unleaded premium gasoline (95-98 RON)
Forced Induction
Turbocharger:
Mitsubishi TD05HR-16G twin-scroll turbocharger with intercooler
🔧 Transmission
Standard
Type:
5-speed manual transmission
Transmission Code:
W5M33-2-PPSP
Optional
Type:
N/A (Manual transmission only)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Differentials:
Helical limited-slip front differential, mechanical limited-slip rear differential, AYC rear differential.
📐 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)
Track Front:
1470 mm (57.9 in)
Track Rear:
1475 mm (58.1 in)
Weights
Curb Weight:
Approx. 1360 kg (2998 lbs) depending on specification
Gross Weight:
Not specified
🛡️ Safety Features
Ratings
Crash Test Ratings:
No standardized global crash test ratings available for this era of homologation specials; designed to FIA safety standards for rallying.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Standard Active Yaw Control (AYC) system for enhanced handling and traction.
Passive Features
Airbags:
Driver's airbag, optional passenger airbag
Seatbelts:
3-point ELR seatbelts with pretensioners
Body Structure:
Reinforced chassis and safety cell design for structural integrity.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player.
Driver Assistance
Handling Systems:
Active Yaw Control (AYC), viscous coupling center differential, limited-slip front and rear differentials.
Connectivity
Electronics:
Basic automotive electronics for the era; focus on performance and mechanical systems rather than advanced electronic aids.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6 months, depending on driving conditions.
Air Filter:
Inspect every 10,000 km, replace as needed or every 20,000 - 30,000 km.
Spark Plugs:
Replace every 40,000 - 60,000 km, depending on plug type (platinum/iridium recommended).
Timing Belt:
Replace every 80,000 - 100,000 km or 5-7 years. Crucial for 4G63T engine to prevent catastrophic failure.
Fluid Specifications
Engine Oil:
API SG/SH or higher, Viscosity 10W-30 or 10W-40 recommended. Synthetic oil highly recommended for performance driving.
Coolant:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent, a 50/50 mix of ethylene glycol and distilled water.
Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 gear oil. DIA-QUEEN MSA52067 (for AYC differential).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Problems:
Ringland failure (especially with increased boost/tuning), turbocharger wear/failure, AYC pump failure, clutch wear, cam seal leaks, exhaust manifold cracking.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi has a strong rally heritage, with the Lancer platform being the basis for their World Rally Championship (WRC) efforts. The Evolution series directly translated rally technology to production cars.
Model Evolution
Evolution:
The Evo IV was a significant step forward from the Evo III, introducing the AYC system, revised aerodynamics, and an updated chassis. It was the first Evolution model to feature a 280 PS engine output in Japan, a gentleman's agreement among Japanese manufacturers.
Production
Production Years:
1996-1998
Manufacturing Location:
Japan
Variants:
GSR (standard AWD with AYC), RS (lighter, homologation special with mechanical diffs).
🏆 Awards & Recognition
Recognitions
Rally Success:
While the Evo IV itself wasn't homologated for long, its design and technologies were heavily influenced by Mitsubishi's WRC success with earlier Lancer Evolutions and paved the way for later championship-winning models.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its exceptional handling, acceleration, and driver engagement. Often cited as a benchmark for performance sedans.
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