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Mitsubishi Lancer Evolution 4 1996-1998 Full Service Repair Manual

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The Mitsubishi Lancer Evolution IV (Evo IV), chassis code CN9A, is a high-performance sedan produced from 1996 to 1998. Built as a homologation special for World Rally Championship (WRC) racing,...
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Type: Car
Vendor:
Mitsubishi
Sku: 83913
Tags: 1996 1997 1998 Car Cars Lancer Evolution 4 Misc Mitsubishi
Mitsubishi Lancer Evolution 4 1996-1998 Full Service Repair Manual
The Mitsubishi Lancer Evolution IV (Evo IV), chassis code CN9A, is a high-performance sedan produced from 1996 to 1998. Built as a homologation special for World Rally Championship (WRC) racing, it embodies Mitsubishi's rich motorsport heritage. The Evo IV is distinguished by its aggressive styling, a potent 2.0L 4G63T DOHC turbocharged engine producing 280 PS, and an advanced all-wheel-drive system featuring Active Yaw Control (AYC) for exceptional handling and cornering stability. This driver-focused vehicle, known for its engineering quality and reliability when properly maintained, competed against esteemed models like the Subaru Impreza WRX STi. This comprehensive service and repair manual, presented in English, covers the Mitsubishi Lancer Evolution IV models from 1996 to 1998. It provides detailed instructions for a wide range of maintenance and repair procedures, encompassing engine mechanicals, electronic engine management, manual and AWD transmissions (including AYC system diagnosis), drivetrain, suspension, steering, brakes, and the complete electrical system. The manual also includes information on body and chassis, climate control, scheduled maintenance, troubleshooting guides, diagnostic procedures, and essential wiring diagrams, offering over 1000 pages of technical expertise to assist owners and technicians in keeping the vehicle in optimal condition.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV (Evo IV)
Generation Code:
CN9A
Codes
Chassis Code:
CN9A
Engine Code:
4G63T (DOHC Turbocharged)
👋 Introduction
Market Position
Positioning:
A homologation special built for rally racing, offering exceptional performance and handling in a road-legal package. Known as a driver's car.
Competitive Analysis
Competitors:
Subaru Impreza WRX STi, Ford Escort RS Cosworth, Lancia Delta Integrale Evoluzione
Key Features
Performance Enhancements:
Aggressive styling, powerful turbocharged engine, advanced all-wheel-drive system with Active Yaw Control (AYC), upgraded suspension and brakes
📋 Manual Details
Coverage Areas
Model Years Covered:
1996, 1997, 1998
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, searchable)
File Format:
Likely PDF, optimized for digital viewing and printing
Searchability:
Typically features searchable text for quick access to information
Print Quality:
High-resolution for clear diagrams and text
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component testing, timing belt replacement, turbocharger service, cooling system, lubrication system
Engine Management Electronic:
ECU diagnosis, sensor testing (MAP, TPS, IAT, Knock, O2), fuel injection system, ignition system, emissions control
Transmission Manual:
Clutch system, gearbox overhaul, gear shift mechanism, lubrication, flywheel replacement
Transmission AWD:
Active Yaw Control (AYC) system diagnosis and calibration, transfer case, center differential, rear differential
Drivetrain:
Driveshafts, CV joints, wheel hubs, axle components
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, strut tower braces
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Front and rear brake systems, ABS operation and diagnosis, brake fluid, caliper service, rotor replacement, brake lines
Electrical System:
Battery, charging system, starter, lighting, horn, wipers, power windows, mirrors, fuses, relays, wiring diagrams
Body And Chassis:
Body panel alignment, door mechanisms, interior trim, chassis components, rust prevention, body repair techniques
Climate Control:
HVAC system diagnosis, refrigerant, compressor, heater core, A/C system service
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake inspections, tire rotation
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides for all major systems
Repair Procedures:
Step-by-step instructions for engine, transmission, suspension, brake, electrical, and body component repair and replacement
Diagnostics:
Detailed diagnostic procedures for electronic control units (ECUs), sensors, actuators, and mechanical systems
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including complex electronic diagnostics and AYC system calibration
⚙️ Engine Specifications
Primary Engine
Engine Type:
2.0L Inline-4 DOHC 16-valve Turbocharged (4G63T)
Performance
Horsepower:
280 PS (276 hp; 206 kW) at 6,500 rpm (JDM Spec)
Torque:
350 Nm (258 lb-ft) at 3,000 rpm (JDM Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injection
Turbocharger:
Mitsubishi TD05HR-16G twin-scroll turbocharger with intercooler
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant, or equivalent)
Lubrication System
Oil Type:
SAE 10W-30 or 10W-40 API SG or higher (e.g., Mitsubishi DiaQueen ECO-Action SAE 10W-30)
Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter
Engine Management
Ignition System:
Distributorless ignition system (DIS) with individual ignition coils
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (F5M51)
Optional
Type:
N/A (Manual transmission was standard for Evo IV)
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC)
Ayc System:
Hydraulically controlled differential for torque vectoring to the rear wheels
Lubrication
Gearbox Oil Type:
API GL-4 or GL-5, SAE 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil 75W-90)
Transfer Case Oil Type:
API GL-4 or GL-5, SAE 75W-90 (e.g., Mitsubishi DiaQueen LSD Gear Oil 75W-90)
Ayc Oil Type:
Special AYC fluid, consult manual for specific type (often a high-viscosity hydraulic fluid)
📐 Dimensions
Exterior
Length:
4,350 mm (171.3 in)
Width:
1,770 mm (69.7 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1,450 kg (3,197 lbs)
Gross Vehicle Weight:
N/A (Not typically specified in manuals of this era)
Wheels And Tires
Standard Tire Size:
205/50R16
Wheel Bolt Pattern:
5x114.3 (5x4.5 inches)
Standard Wheel Size:
16x7.0 inches
🛡️ Safety Features
Ratings
NHTSA Rating:
N/A (Vehicle not designed to meet modern US safety standards)
Ancap Rating:
N/A (Vehicle not officially tested by ANCAP)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ayc:
Active Yaw Control (AYC) for enhanced cornering stability
Passive Features
Airbags:
Driver's airbag standard (Passenger airbag optional or unavailable depending on market)
Seatbelts:
3-point front seatbelts with pre-tensioners, 3-point rear seatbelts
Chassis Reinforcement:
Reinforced chassis structure for increased rigidity and crash protection
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with cassette player and CD compatibility (optional or market dependent). Aftermarket head units are common upgrades.
Driver Assistance
Electronic Features:
ABS, Active Yaw Control (AYC), performance-oriented AWD system.
Connectivity
Connectivity Options:
N/A (No factory Bluetooth or USB connectivity in this era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first, especially under strenuous driving conditions.
Air Filter Replacement:
Every 15,000 km (9,000 miles) or annually.
Spark Plug Replacement:
Every 30,000 km (18,000 miles).
Timing Belt Replacement:
Every 100,000 km (60,000 miles) or 5 years, whichever comes first.
Brake Fluid Change:
Every 2 years or 30,000 km (18,000 miles).
Coolant Flush:
Every 2 years or 40,000 km (24,000 miles).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron-II or equivalent automatic transmission fluid (ATF)
Known Issues
Engine Reliability:
Robust 4G63T engine, but prone to ring land failure if consistently overheated or run with poor fuel quality. Regular maintenance is critical.
Ayc System Reliability:
AYC pump and sensors can be prone to failure over time, leading to loss of functionality. Proper fluid changes and diagnostics are key.
Turbocharger:
The TD05HR turbo is robust but requires proper warm-up and cool-down procedures to prevent premature wear. Oil starvation can cause significant damage.
Clutch Wear:
Due to the performance nature of the car, clutches can wear faster than average, especially with spirited driving.
Suspension Bushings:
Rubber suspension bushings can degrade over time, affecting handling and ride quality.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi's strong rally heritage, leading to the development of the Lancer Evolution series for WRC homologation.
Model Evolution
Introduction Of Evo Iv:
Introduced in August 1996, featuring a significant redesign over the Evo III, including a longer wheelbase and the introduction of Active Yaw Control (AYC).
Production
Production Years:
1996 - 1998
Production Location:
Japan
Production Volumes:
Limited production, highly sought after by enthusiasts. Exact figures vary, but generally in the tens of thousands.
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Consistently praised in automotive press for its handling, grip, and rally-bred performance. Considered an icon of the 1990s performance car era.
Ratings
Rally Homologation:
Specifically developed to meet World Rally Championship (WRC) homologation requirements.
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