Mitsubishi Evolution VI 1999-2001 Repair Service Manual

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This manual covers the Lancer Evolution VI, a performance-oriented 4-door sedan produced from 1999 to 2001. Known by its chassis code CP9A, this iconic vehicle is powered by a 4G63T...

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Taper: Car

Distributeur:

UGS: 70459

Mots clés: 1999 2000 2001 Car Cars Evolution VI Misc Mitsubishi

Variantes de produits

Description

This manual covers the Lancer Evolution VI, a performance-oriented 4-door sedan produced from 1999 to 2001. Known by its chassis code CP9A, this iconic vehicle is powered by a 4G63T turbocharged engine and features a legendary all-wheel-drive system with advanced Active Yaw Control (AYC). The Lancer Evolution VI was developed with rally homologation in mind, offering exceptional grip, acceleration, and handling capabilities, making it a highly acclaimed performance car. Its engineering quality, reliability, and unique driving dynamics stem from extensive motorsport heritage, particularly success in the World Rally Championship. This comprehensive workshop repair service manual provides detailed guidance for the maintenance, servicing, and repair of the Lancer Evolution VI. It covers all major systems and components, including the engine and drivetrain, chassis and suspension, electrical systems, and body and interior. Within its extensive pages, users will find routine maintenance procedures, diagnostic troubleshooting guides, detailed repair procedures, and special procedures specific to the model, such as AYC system calibration. This manual is an essential resource for owners, mechanics, and technicians seeking to preserve the performance and longevity of their Lancer Evolution VI.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution VI

Model Designation:

Evo VI / Evo 6

Body Style:

4-door Sedan

Production Years:

1999-2001

Codes

Chassis Code:

Engine Code Primary:

4G63T

Engine Code Variants:

4G63 (non-turbo variants exist in standard Lancer range, but not relevant to Evo VI)

Transmission Codes:

F5M51 (5-speed manual), V5M31 (4-speed automatic - rare for Evo VI)

👋 Introduction

Market Position

Market Segment:

Performance Compact Sedan / Rally Homologation Special

Competitive Analysis

Key Competitors:

Subaru Impreza WRX STI, Ford Focus RS, Peugeot 206 WRC (in rallying context), but direct road competitors include performance variants of other compact sedans.

Key Features

Driving Dynamics:

Legendary all-wheel-drive system (4WD), advanced Active Yaw Control (AYC) system, powerful turbocharged engine, focused suspension tuning for rallying.

Performance Focus:

Designed with rally homologation in mind, offering exceptional grip, acceleration, and handling capabilities.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive service, maintenance, and troubleshooting for all major systems and components.

Page Count

Page Count:

Est. 1500+ pages (typical for full factory service manuals)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine And Drivetrain:

Engine mechanical, cylinder head, valvetrain, lubrication, cooling, fuel, ignition, emissions control, turbocharging, exhaust, clutch, manual transmission (all-wheel drive system - AYC/ACD).

Chassis And Suspension:

Front suspension, rear suspension, steering system, braking system (ABS), wheel alignment, chassis components.

Electrical And Electronics:

Engine Control Unit (ECU), powertrain control module (PCM), body control module (BCM), wiring diagrams, lighting, instrumentation, audio system, power windows/locks, charging system, starting system.

Body And Interior:

Body exterior panels, doors, hood, trunk, bumpers, interior trim, seats, HVAC system, safety systems (airbags).

Procedures Included

Maintenance Procedures:

Routine maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacement.

Diagnostic Procedures:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system testing.

Repair Procedures:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, body panel repair, electrical component diagnosis and replacement.

Special Procedures:

Active Yaw Control (AYC) system calibration and service, timing belt replacement, turbocharger service, clutch replacement, differential service.

Technical Depth

Depth:

Detailed torque specifications, tolerances, component testing procedures, wiring schematics, diagnostic flowcharts, component removal and installation sequences, exploded views.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or sections.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchability:

Likely text-searchable if scanned from original factory manual.

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Engine Code:

4G63T

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Ps:

280 PS (JDM) / 276 HP (Export markets, often rated lower for tax purposes)

Torque Nm:

330 Nm (JDM) / 335 Nm (Export)

Fuel System

Fuel Delivery:

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

Fuel Type:

Unleaded Premium Gasoline (95 RON or higher recommended)

Turbocharging

Turbocharger Type:

Mitsubishi TD05HR-16G6-10.5T (Twin-Scroll)

Engine Management

ECU Type:

Engine Control Unit (ECU) with advanced ignition and fuel mapping.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual

Transmission Code Standard:

F5M51

Optional

Transmission Type Optional:

4-speed Automatic (Rare for Evo VI models, typically found in standard Lancers or specific markets).

Transmission Code Optional:

V5M31

Features

Drivetrain:

All-Wheel Drive (4WD) with Active Yaw Control (AYC)

Differentials:

Front: Limited Slip Differential (LSD) - Helical. Rear: Active Yaw Control (AYC) unit with Electronic Control Unit.

📐 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 Width Front:

1515 mm (59.6 in)

Track Width Rear:

1505 mm (59.3 in)

Weights

Curb Weight Kg:

Approx. 1360 kg (2998 lbs)

Gross Vehicle Weight Rating Kg:

Approx. 1700 kg (3748 lbs)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Limited official ratings for this era and homologation model; focus was on performance and structural integrity for rallying. Refer to specific country safety standards of the time.

Active Features

Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD).

Active Yaw Control (AYC) system for enhanced stability and cornering grip.

Passive Features

Airbags:

Driver and passenger front airbags (standard on most models).

Seatbelts:

3-point inertia reel seatbelts with pre-tensioners.

Body Construction:

Reinforced safety cell, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD or Cassette player. Aftermarket upgrades are common.

Instrumentation:

Performance-oriented gauges including boost gauge, oil pressure gauge, tachometer, speedometer.

Driver Assistance

Traction Control:

No explicit electronic traction control beyond the AWD system and AYC.

Connectivity

Connectivity Options:

Limited to factory-installed options like power windows/locks. No modern Bluetooth or USB connectivity from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 km (4,500 miles) or 6 months, whichever comes first. More frequent under severe driving conditions.

Timing Belt Replacement:

Every 96,000 km (60,000 miles) or 4 years, whichever comes first. Crucial due to interference engine design.

Fluid Specifications

Engine Oil:

API SG/SH/SJ or ACEA A2/A3; Viscosity SAE 10W-30 or 10W-40 recommended (refer to manual for specific oil type and capacity).

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Capacity: Approx. 7.5 Liters.

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90. Capacity: Approx. 2.3 Liters.

Differential Fluid Rear:

API GL-5, SAE 75W-90. Capacity: Approx. 1.3 Liters (AYC unit).

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Engine Issues:

Cracked cylinder heads (especially in earlier models or heavily modified cars), turbocharger wear, oil consumption, piston ring wear.

Drivetrain Issues:

AYC pump failure, clutch wear, transmission synchro issues (especially with hard driving).

Body And Chassis Issues:

Rust (especially around wheel arches, sills), suspension bushing wear.

📚 Vehicle History

Brand Heritage

Motorsport Legacy:

Mitsubishi's extensive involvement in World Rally Championship (WRC) with Tommi Mäkinen winning multiple titles.

Model Evolution

Evo Vi Development:

Evolved from Lancer platform, focusing on aerodynamic improvements (e.g., larger front bumper openings, revised rear spoiler), enhanced cooling, stronger engine internals, and refined AYC system.

Special Editions:

Wider availability of RS models (homologation specials) and the highly sought-after Tommi Mäkinen Edition (TME) with unique styling and mechanical enhancements.

Production

Production Location:

Japan

Production Volume:

Relatively limited compared to standard Lancer models, especially for RS and TME variants.

🏆 Awards & Recognition

Recognitions

Rally Dominance:

The Evo VI's engineering and platform were the basis for Mitsubishi's dominant Lancer WRC cars, contributing to multiple manufacturer and driver championships.

Enthusiast Acclaim:

Consistently ranked as one of the greatest performance cars of its era by automotive publications and enthusiasts worldwide.