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Mitsubishi Evolution IV & V 1996-1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution IV / V Product Name: Mitsubishi Evolution IV & V 1996-1999 Service Repair Manual PDF Generation Chassis Code Evo Iv: CN9A...
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Mitsubishi Evolution IV & V 1996-1999 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution IV / V
Product Name:
Mitsubishi Evolution IV & V 1996-1999 Service Repair Manual PDF
Generation
Chassis Code Evo Iv:
CN9A
Chassis Code Evo V:
CP9A
Codes
Production Years Covered:
1996, 1997, 1998, 1999
👋 Introduction
Market Position
Vehicle Class:
Compact Sports Sedan / Rally Homologation Special
Target Audience:
Enthusiasts, owners, mechanics specializing in performance Mitsubishi vehicles.
Competitive Analysis
Key Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Lancia Delta Integrale.
Key Features
Performance Focus:
Designed for the rally-bred performance DNA of the Lancer Evolution line.
Technical Depth Advantage:
Offers in-depth technical information beyond basic owner's manuals, critical for maintenance and repair.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
Over 1500 pages (comprehensive)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (4G63T), fuel injection, ignition, cooling, lubrication, emissions control, turbocharger system, intercooler.
Drivetrain Systems:
Manual transmission (W5M42/W6MG1), transfer case, viscous coupling unit (VCU), active yaw control (AYC) system, rear differential.
Suspension Steering:
Front and rear suspension (McPherson strut front, multi-link rear), steering system, power steering.
Braking System:
Front and rear disc brakes, ABS system, brake fluid specifications.
Electrical Systems:
Wiring diagrams, charging system, starting system, lighting, instrumentation, body electrical, ECUs (Engine Control Unit, AYC Control Unit).
Body Chassis:
Body panels, doors, windows, interior trim, chassis components, corrosion protection.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid flush.
Repair Procedures:
Engine overhaul, transmission rebuild, turbocharger replacement, AYC system diagnostics and repair, brake caliper overhaul, suspension component replacement.
Troubleshooting:
Diagnostic charts for common symptoms, electrical system troubleshooting flowcharts, engine performance issues.
Specifications:
Torque specifications for all fasteners, engine clearances, alignment specifications, fluid capacities.
Technical Depth
Diagnostic Capabilities:
Detailed troubleshooting guides, wiring diagrams for electrical systems, diagnostic trouble codes (DTCs) and their meanings.
Rebuild Instructions:
Comprehensive instructions for engine and transmission disassembly, inspection, repair, and reassembly, including critical component tolerances.
Performance Tuning Info:
While not a dedicated tuning guide, it provides baseline specifications and component information crucial for understanding performance modifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick access to information.
Print Quality
Readability:
High-resolution digital scans ensuring clarity of text and diagrams.
Binding Type
Digital Binding:
N/A (Digital format)
Paper Type
Digital Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Configuration:
Inline 4-cylinder, DOHC, 16-valve, turbocharged and intercooled
Displacement:
1997 cc (2.0 Liters)
Performance
Horsepower Evo Iv:
280 PS (276 hp) @ 6500 rpm (JDM Spec)
Torque Evo Iv:
35.0 kgf⋅m (343 Nm; 253 lb⋅ft) @ 3000 rpm (JDM Spec)
Horsepower Evo V:
280 PS (276 hp) @ 6500 rpm (JDM Spec); slightly higher output for some export markets.
Torque Evo V:
37.5 kgf⋅m (368 Nm; 271 lb⋅ft) @ 3000 rpm (JDM Spec)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, premium octane recommended (98 RON / 93+ AKI)
Turbocharger
Turbo Model:
Mitsubishi TD05H-16G (Evo IV), Mitsubishi TD05HR-16G-8.5cm² (Evo V)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission (W5M42)
Optional
Transmission Type Evo V Gscar:
6-speed manual transmission (W6MG1) for GSR models
Features
Drivetrain:
All-Wheel Drive (AWD) with Active Yaw Control (AYC) system (Evo IV), updated AYC and Super AYC on Evo V.
Clutch Type:
Hydraulically actuated, single-plate dry clutch
Fluid Specifications
Gearbox Oil Spec:
Refer to manual for specific API GL-4/GL-5 rated gear oil, e.g., Mitsubishi DiaQueen LSD Gear Oil.
📐 Dimensions
Exterior
Length:
Approx. 4350 mm (171.3 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1415 mm (55.7 in)
Weights
Curb Weight:
Approx. 1300-1370 kg (2866-3020 lb)
Wheelbase:
Approx. 2600 mm (102.4 in)
Wheels Tires
Wheel Bolt Pattern:
5x114.3 mm
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
215/40R17
🛡️ Safety Features
Ratings
Safety Standard:
Era-appropriate safety standards. Specific official crash test ratings (e.g., Euro NCAP, NHTSA) are not as readily available for these JDM-homologated models compared to modern vehicles.
Active Features
Ayc System:
Active Yaw Control (AYC) and Super AYC enhance traction and cornering stability by vectoring torque to the rear wheels.
ABS:
Anti-lock Braking System (ABS) standard on most variants.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Head Unit:
Factory fitted AM/FM/Cassette/CD players. Upgradeable to modern aftermarket units.
Driver Assistance
Ayc System Tech:
Advanced electronic control system for torque vectoring, significantly improving handling dynamics and driver confidence.
Connectivity
Diagnostic Ports:
OBD-I or early OBD-II compliant diagnostic port, depending on market and year. The manual details diagnostic procedures and connector pinouts.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, whichever comes first, especially for spirited driving. Consult manual for exact intervals.
Timing Belt Replacement:
Recommended replacement every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5-7 years. Crucial for the 4G63T engine.
Spark Plug Replacement:
Typically every 40,000 - 60,000 km (25,000 - 37,500 miles) depending on type (e.g., iridium plugs have longer life).
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter. Refer to manual for precise capacity.
Engine Oil Type:
API SN or higher, viscosity 5W-30 or 10W-30 synthetic recommended for performance applications. Consult manual.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with deionized water. Refer to manual for specific Mitsubishi coolant.
Brake Fluid Type:
DOT 3 or DOT 4 recommended. High-performance fluid may be beneficial.
Known Issues
Ayc Pump Failure:
The AYC hydraulic pump can be a failure point over time, leading to AYC warning lights and loss of functionality.
Ringland Failure:
A known issue with heavily modified 4G63T engines, especially when subjected to excessive boost or poor tuning. The manual provides baseline specs to help identify issues.
Transfer Case Wear:
The viscous coupling unit in the transfer case can wear out, affecting AWD performance.
📚 Vehicle History
Brand Heritage
Mitsubishi Motorsport:
Mitsubishi's strong heritage in rallying, particularly the World Rally Championship (WRC), heavily influenced the development of the Lancer Evolution series.
Model Evolution
Evolution Iv Introduction:
Launched in August 1996, featuring a significant redesign with improved aerodynamics, chassis rigidity, and the introduction of the AYC system. Larger intercooler and revised turbocharger for increased power.
Evolution V Introduction:
Launched in January 1998, the Evo V received substantial mechanical and styling revisions. Wider track, larger wheels and tires, revised front bumper for better cooling, and a larger rear spoiler. Super AYC introduced on GSR models for even greater traction control.
Production
Production Location:
Mizushima Plant, Kurashiki, Okayama, Japan
Homologation Purpose:
Developed to homologate the Lancer Evolution for Group A regulations in the World Rally Championship.
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Lancer Evolution series, including the IV and V, was highly successful in the World Rally Championship, earning numerous driver and manufacturer titles, cementing its status as a performance icon.
Ratings
Enthusiast Appreciation:
Consistently ranked highly by automotive publications and enthusiasts for its driving dynamics, performance, and rally-bred heritage.
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