Mitsubishi Lancer Evo 5 1998 1999 Factory Service Manual

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Welcome to the service manual for the Mitsubishi Lancer Evolution V (Evo 5), produced between 1998 and 1999 under chassis code CP9A. This iconic performance sedan, a direct descendant of...

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Taper: Car

Distributeur:

UGS: 69861

Mots clés: 1998 1999 Car Cars Lancer Evo 5 Misc Mitsubishi

Variantes de produits

Description

Welcome to the service manual for the Mitsubishi Lancer Evolution V (Evo 5), produced between 1998 and 1999 under chassis code CP9A. This iconic performance sedan, a direct descendant of Mitsubishi's World Rally Championship (WRC) lineage, is renowned for its sophisticated all-wheel-drive system, potent turbocharged 4G63T engine delivering 280 PS, and rally-bred handling. The Evo 5 distinguished itself with significant chassis and aerodynamic enhancements, including a wider track and distinctive front bumper design, making it a sought-after vehicle for enthusiasts and performance car aficionados. Its engineering quality and reliability, when properly maintained, have cemented its status as a legendary sport compact. This comprehensive Factory Service Manual (FSM) provides over 800 pages of detailed information essential for the maintenance, diagnosis, and repair of your Lancer Evolution V. It covers all critical systems, including the mechanical and electrical aspects of the 4G63T engine, the F5M51 5-speed manual transmission, the advanced all-wheel-drive and Active Yaw Control (AYC) systems, suspension, steering, and brakes. The manual includes step-by-step procedures for routine maintenance, troubleshooting common issues, detailed component rebuilds, and crucial technical specifications, such as torque values. This resource is an indispensable tool for owners, mechanics, and technicians aiming to preserve the performance and integrity of this legendary vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution V (Evo 5)

Production Years:

1998-1999

Chassis Codes:

Codes

Engine Code Primary:

4G63T

Transmission Code Primary:

F5M51 (5-speed manual)

👋 Introduction

Market Position

Segment:

Performance Rally Homologation Special / Sport Compact

Target Audience:

Enthusiasts, tuners, professional mechanics, collectors

Competitive Analysis

Key Rivals:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four

Key Features

Vehicle Focus:

All-wheel drive, turbocharged performance, rally-bred handling, aggressive aerodynamics.

Manual Value:

Essential resource for maintaining and repairing one of the most iconic performance sedans.

📋 Manual Details

Coverage Areas

Primary Focus:

Mechanical, Electrical, Bodywork, Maintenance, Repair

Included Systems:

Engine, Fuel System, Cooling System, Exhaust System, Clutch, Transmission, Drivetrain (Front/Rear Differentials, Transfer Case), Suspension (Front/Rear), Steering, Brakes, Electrical System, HVAC, Body Panels, Interior Trim, Audio System, Security System

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, and assembly of 4G63T engine components including block, crankshaft, connecting rods, pistons, cylinder head, camshafts, valvetrain.

Engine Management:

Wiring diagrams, sensor locations and specifications, ECU diagnosis, ignition system, fuel injection system troubleshooting.

Transmission Drivetrain:

F5M51 manual transmission overhaul, clutch system service, transfer case and rear differential inspection and repair, AWD system diagnostics.

Suspension Steering:

Front and rear suspension component replacement and alignment procedures, steering rack and power steering system service.

Braking System:

Brake component replacement (discs, pads, calipers), ABS system diagnosis and repair, brake fluid specifications and bleeding procedures.

Electrical System:

Comprehensive wiring diagrams, fuse and relay locations, starter, alternator, lighting system troubleshooting, power windows, mirrors, and central locking service.

HVAC System:

Air conditioning system diagnosis, refrigerant handling (where applicable by year), heater core and blower motor service.

Body Exterior:

Panel removal and installation, door, hood, trunk, and bumper service, glass replacement procedures.

Body Interior:

Dashboard, seats, door panels, and trim component removal and installation.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug service, coolant flushes, brake pad/disc replacement, timing belt replacement (critical for 4G63T).

Troubleshooting:

Diagnostic flowcharts for common and specific issues across all major systems, error code interpretation.

Repair Rebuild:

Detailed step-by-step instructions for engine, transmission, differential, turbocharger, and other major component overhauls.

Diagnostics:

On-board diagnostics (OBD-I/II where applicable), specific sensor testing, electrical continuity and resistance checks.

Specifications Torque:

All critical torque specifications for engine, chassis, and drivetrain fasteners.

Adjustments:

Engine idle speed, clutch pedal free play, parking brake adjustment.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine and drivetrain rebuilds.

Diagnostic Detail:

Advanced diagnostic procedures, including electrical testing with multimeter and oscilloscope references.

Component Diagrams:

Detailed exploded views and part diagrams for most components.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely (dependent on OCR quality of original scan)

Print Quality

Quality:

Good to Excellent (typical for factory scans)

Printable:

Yes, designed for printing by sections or in full.

Binding Type

Recommendation:

Spiral binding recommended for workshop use.

Paper Type

Recommendation:

Heavy-duty paper for workshop durability.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline-4, DOHC, 16-valve, Turbocharged and Intercooled

Displacement:

1997 cc (2.0 Liters)

Performance

Horsepower Ps:

280 PS (at 6,500 rpm, JDM spec)

Torque Nm:

330 Nm (at 3,000 rpm, JDM spec)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

8.5:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Injection

Fuel Type:

Unleaded Gasoline (Octane rating typically 95 RON or higher recommended)

Turbocharger

Type:

Mitsubishi TD05H-16G (or similar variant)

Intercooler

Type:

Front-mounted Air-to-Air Intercooler

🔧 Transmission

Standard

Type:

5-speed Manual (F5M51)

Optional

Type:

None (Manual transmission was standard)

Features

Drivetrain:

All-Wheel Drive (AWD) with Active Yaw Control (AYC)

Gear Ratios Primary:

Specific ratios detailed in the manual, typically close-ratio for performance.

Transmission Fluid Spec:

Refer to manual for specific gear oil type and viscosity (e.g., API GL-4/GL-5).

📐 Dimensions

Exterior

Length:

Approx. 4,350 mm

Width:

Approx. 1,770 mm

Height:

Approx. 1,415 mm

Wheelbase:

Approx. 2,635 mm

Track Width Front:

Approx. 1,500 mm

Track Width Rear:

Approx. 1,505 mm

Weights

Curb Weight Kg:

Approx. 1,360 kg

Gross Vehicle Weight Kg:

Refer to manual or vehicle placard

Wheels Tires

Wheel Size:

17 inches (standard)

Tire Size Standard:

225/45R17

Bolt Pattern:

5x114.3 mm (5x4.5 inches)

🛡️ Safety Features

Ratings

Crash Test Results:

NHTSA/IIHS ratings for this specific era may be limited; focus is on structural integrity and driver control.

Active Features

AWD System:

Advanced All-Wheel Drive with Driver-Selectable Modes (Tarmac, Gravel, Snow)

Ayc System:

Active Yaw Control for enhanced cornering stability and torque vectoring.

Anti-lock Braking System

Passive Features

Airbags:

Driver and Front Passenger Airbags

Seatbelts:

3-point Inertia Reel Seatbelts with Pre-tensioners

Body Structure:

Reinforced unibody construction for chassis rigidity and occupant protection.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette/CD player, speakers. Many owners upgrade.

Instrumentation:

Comprehensive gauge cluster including boost gauge, tachometer, speedometer, fuel, coolant temp, oil pressure.

Driver Assistance

Traction Control:

No dedicated electronic traction control system beyond the AWD and AYC differentials.

Connectivity

Original Connectivity:

Basic; no integrated Bluetooth or navigation from factory.

🔧 Maintenance

Service Intervals

Oil Change:

Typically 5,000-7,500 km or 3-6 months (dependent on driving conditions; refer to manual for exact recommendation).

Timing Belt Replacement:

Critical: Recommended every 80,000 - 100,000 km or 5-7 years. Failure can cause catastrophic engine damage.

Coolant Flush:

Every 2 years or 40,000 km.

Spark Plugs:

Refer to manual for specific type and interval (e.g., platinum or iridium plugs).

Fluid Specifications

Engine Oil Type:

Refer to manual for viscosity (e.g., 10W-30, 10W-40, 20W-50 depending on climate and use). High-performance synthetic recommended.

Coolant Type:

Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for confirmation).

Power Steering Fluid:

Refer to manual for specification (often ATF or specific power steering fluid).

Known Issues

Engine:

Connecting rod bearing failure (especially on modified engines), turbocharger wear, rear main seal leaks, head gasket issues (less common than later models but possible).

Ayc System:

AYC pump failure, accumulator leaks, electrical issues with the AYC controller.

Rust:

Common areas include strut towers, rear quarter panels, rocker panels, and floor pans.

Electrical:

Corrosion on grounds, aging wiring harness components, intermittent issues with power windows or door locks.

Turbocharger:

Seal failure leading to oil consumption or smoke, wastegate actuator issues.

📚 Vehicle History

Brand Heritage

Motorsport Connection:

Developed from Mitsubishi's successful WRC Lancer Evolution lineage.

Model Evolution

Evo V Significance:

Marked significant chassis and aerodynamic improvements, wider track, and larger wheels over Evo IV. Featured unique front bumper with larger air intakes and fog lights.

Production

Manufacturing Location:

Japan

Production Volume:

Limited; exact numbers vary but are considered relatively scarce compared to mainstream vehicles.

🏆 Awards & Recognition

Recognitions

Motorsport Achievements:

Directly linked to Mitsubishi's WRC success, a halo vehicle for performance.

Enthusiast Recognition:

Widely regarded as one of the most significant and desirable 'modern' rally homologation cars.