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Mitsubishi Lancer EVO 6 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Common Name: Evo VI Chassis Code: CP9A Codes Engine Code: 4G63T 👋 Introduction Market Position Positioning: The Mitsubishi Lancer Evolution...
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Mitsubishi Lancer EVO 6 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Common Name:
Evo VI
Chassis Code:
CP9A
Codes
Engine Code:
4G63T
👋 Introduction
Market Position
Positioning:
The Mitsubishi Lancer Evolution VI (Evo VI) was a highly acclaimed performance sedan, celebrated for its rally-bred engineering, sophisticated all-wheel-drive system (AYC), and potent turbocharged engine, making it a benchmark in its class.
Competitive Analysis
Competitors:
Primary competitors included the Subaru Impreza WRX STI, Ford Focus RS, and other high-performance compact sedans of its era. The Evo VI distinguished itself with its advanced Active Yaw Control (AYC) system.
Key Features
Features:
Iconic 4G63T engine, advanced AYC system, robust chassis, aggressive aerodynamic styling, Recaro seats, WRC heritage.
📋 Manual Details
Coverage Areas
Covered Models:
All Mitsubishi Lancer Evolution VI models, including GSR, RS, Tommi Makinen Edition.
Regions Covered:
Global specifications and procedures generally applicable to all markets where the Evo VI was officially sold.
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, lubrication system, cooling system, exhaust system, turbocharger system.
Drivetrain:
Transmission (manual, AYC), transfer case, differentials (front, rear AYC), driveshafts, axles.
Suspension:
Front suspension (MacPherson strut), rear suspension (Multi-link), shock absorbers, springs, anti-roll bars, bushings.
Steering:
Power steering system, steering rack, column, linkages.
Brakes:
Brake system (front and rear discs), ABS, brake hydraulics, calipers, pads, rotors, lines.
Electrical:
Battery, charging system, starter motor, lighting, wipers, horn, dashboard instruments, ECUs, sensors, wiring diagrams.
Body:
Exterior body panels, interior trim, doors, windows, seats, bumpers, chassis structure, corrosion protection.
Climate Control:
HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting, fault code interpretation, electrical diagnostics.
Repair:
Engine overhaul, transmission rebuild, brake system overhaul, suspension component replacement, body panel repair, electrical component repair.
Installation:
Component installation, accessory installation, engine and transmission removal/installation, suspension upgrades.
Specifications:
Torque specifications, clearances, measurements, tolerances, diagnostic parameters.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and calibration procedures.
📊 Manual Specifications
File Format
Compatibility:
Viewable on any device with a PDF reader (PC, Mac, tablet, smartphone).
Print Quality
Quality:
High-resolution scans ensuring crisp text and clear diagrams for easy reading and printing.
Binding Type
Type:
N/A (Digital PDF format)
Paper Type
Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Description:
2.0L Inline-4 DOHC 16-valve turbocharged and intercooled engine.
Engine Code:
4G63T
Performance
Horsepower:
276 hp (206 kW) at 6,500 rpm (Japanese domestic market, often conservatively rated; actual output could be higher).
Torque:
275 lb-ft (373 Nm) at 3,000 rpm (Japanese domestic market).
Fuel System
System:
Electronic Fuel Injection (EFI) with multi-point injection.
Turbocharger:
Mitsubishi TD05H-16G turbocharger with intercooler.
Cooling System
Capacity:
Approx. 8.0 Liters (with specific coolant type required).
Lubrication System
Oil Capacity:
Approx. 4.5 Liters (with oil filter change, specific oil viscosity recommended).
Engine Management
ECU:
Engine Control Unit (ECU) with diagnostic capabilities, often tunable for performance gains.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
N/A (Manual transmission was standard across all Evo VI variants)
Features
Active Yaw Control:
Standard on most models, the AYC system actively controls torque distribution to the rear wheels for enhanced cornering stability and traction.
All Wheel Drive:
Full-time Four-Wheel Drive (4WD) system with mechanical limited-slip center differential and Active Yaw Control (AYC) at the rear.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific API GL-4 or GL-5 rated gear oil, e.g., Mitsubishi Genuine Gear Oil MN188061 or equivalent.
Ayc Fluid:
Specific AYC unit fluid, e.g., Mitsubishi Genuine AYC Fluid MZ313374 or equivalent.
📐 Dimensions
Exterior
Length:
Approx. 4,350 mm (171.3 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,415 mm (55.7 in)
Wheelbase:
Approx. 2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,360 - 1,400 kg (2,998 - 3,086 lbs), depending on trim.
🛡️ Safety Features
Ratings
Crash Test Data:
Official crash test ratings for the Evo VI era are not as standardized as modern tests. However, its robust chassis and structural design were praised.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) with electronic brake-force distribution (EBD).
Ayc:
Active Yaw Control (AYC) significantly enhances cornering stability and traction.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners.
Chassis Design:
Reinforced safety cell and crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory fitted audio systems typically included CD player and radio. Aftermarket upgrades are common.
Driver Assistance
Traction Control:
While not a traditional 'traction control' system in the modern sense, the AYC and 4WD system provide exceptional traction management.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB were standard. This is a pre-smartphone era vehicle.
Instrumentation
Gauges:
Comprehensive dashboard instrumentation including boost gauge, oil pressure, oil temperature (on some variants), and voltmeter.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions. Enthusiast driving may necessitate more frequent changes.
Spark Plugs:
Every 30,000 - 45,000 miles (48,000 - 72,000 km), depending on type (e.g., iridium recommended).
Timing Belt:
Every 60,000 miles (96,000 km) or 5 years. Crucial due to interference engine design.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3, SAE 10W-30 or 10W-40 recommended. For high-performance use, synthetic oils are highly advised.
Coolant:
Ethylene glycol-based antifreeze coolant (e.g., Mitsubishi DIAQUEEN SUPER LONG LIFE COOLANT or equivalent) mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine:
Cracked cylinder heads (especially if overheated or modified), turbocharger wear, piston ring wear, valve stem seal issues leading to oil consumption.
Drivetrain:
AYC pump failure, differential wear (especially under hard use), clutch wear, gearbox synchro wear.
Suspension:
Worn bushings, worn shock absorbers, strut top bearing failure.
Electrical:
Corroded grounds, failing sensors (e.g., crank/cam sensors), AYC pump failure.
Parts Availability
Comment:
While some parts are becoming rare, many performance-oriented aftermarket parts are readily available, and specialist suppliers cater to Evo owners.
📚 Vehicle History
Brand Heritage
Motorsport Connection:
The Lancer Evolution lineage is deeply rooted in rallying, with the Evo VI being a direct descendant of Mitsubishi's highly successful World Rally Championship (WRC) cars.
Model Evolution
Evo Vi Introduction:
Introduced in January 1999, the Evo VI was an evolution of the Evo V, featuring revised styling, improved cooling, and mechanical enhancements.
Tommi Makinen Edition:
A special edition released in late 1999 to celebrate Tommi Makinen's fourth consecutive WRC drivers' title. Featured a quicker steering rack, updated turbo, different intercooler, specific suspension tuning, and unique styling cues.
Production
Production Years:
1999 - 2001
Key Markets:
Japan, Europe, Australia.
🏆 Awards & Recognition
Recognitions
Motorsport Titles:
The Evo VI platform underpinned Tommi Mäkinen's fourth consecutive World Rally Championship (WRC) Drivers' title in 2001, solidifying its legendary status.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its incredible handling, acceleration, and driver engagement, often outperforming more expensive machinery.
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