Mitsubishi Lancer Evo 4 and Evo 5 1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution (Evo) Model Variant: Evo IV (CN9A) & Evo V (CP9A) Model Year: 1998 Codes Chassis Code Evo Iv: CN9A Chassis Code...

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Type: Car

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Sku: 495520

Tags: 1998 Car Cars Lancer Evo 4 Lancer Evo 5 Misc Mitsubishi

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Lancer Evolution (Evo)

Model Variant:

Evo IV (CN9A) & Evo V (CP9A)

Model Year:

Codes

Chassis Code Evo Iv:

Chassis Code Evo V:

👋 Introduction

Market Position

Market Position Vehicle:

Iconic homologation special, rally-bred performance sedan, positioned at the pinnacle of affordable performance motoring.

Competitive Analysis

Competitors:

Subaru Impreza WRX STI, Ford Escort RS Cosworth, Audi RS2 Avant (in terms of performance and rally heritage).

Key Features Vehicle

Key Features Vehicle:

Advanced All-Wheel Drive (AWD) system with Active Yaw Control (AYC), potent turbocharged 4G63T engine, aggressive aerodynamic enhancements, close-ratio manual gearbox, performance-tuned suspension and brakes.

Manual Value Proposition

Manual Value Proposition:

Essential resource for owners and technicians to maintain, diagnose, and repair the highly complex and performance-oriented Lancer Evolution models.

📋 Manual Details

Coverage Areas

Covered Systems:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Fuel System, Cooling System, Lubrication System, Emissions Control, Interior, Exterior Trim, Troubleshooting, Specifications

Page Count

Page Count:

Extensive (Specific count not provided, but described as comprehensive)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Likely digital (PDF) based on description, but could be printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for the 4G63T engine.

Engine Performance:

Turbocharger system, intercooler, intake and exhaust manifolds, engine management systems (ECU).

Drivetrain Transmission:

Manual transmission (F5M33/F5M33-1) and Active Yaw Control (AYC) system repair and adjustment.

Drivetrain Differentials:

Front and rear differential servicing and inspection.

Suspension Front:

MacPherson strut, control arms, anti-roll bar, bush replacement, alignment procedures.

Steering System:

Power steering system, steering rack and pinion, tie rod ends, alignment.

Brake System Front:

Ventilated disc brakes, caliper service, pad replacement, rotor inspection, ABS system.

Electrical System General:

Battery, charging system (alternator), starting system (starter motor).

Suspension Rear

Suspension Rear:

Multi-link independent suspension, shock absorbers, springs, bushings, alignment procedures.

Brake System Rear

Brake System Rear:

Solid disc brakes, caliper service, pad replacement, rotor inspection, ABS system.

Electrical System Lighting

Electrical System Lighting:

Headlights, taillights, interior lighting, fog lights.

Electrical System Accessories

Electrical System Accessories:

Wipers, horn, power windows, mirrors, door locks.

Electrical System Ecu

Electrical System ECU:

Engine Control Unit (ECU) diagnostics and basic troubleshooting.

Hvac System

HVAC System:

Air conditioning system servicing, heater core replacement, blower motor troubleshooting.

Fuel System

Fuel System:

Fuel pump, fuel injectors, fuel filter replacement, fuel tank servicing.

Cooling System

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation.

Lubrication System

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure sender.

Emissions Control

Emissions Control:

Catalytic converter, O2 sensors, EVAP system.

Bodywork Exterior

Bodywork Exterior:

Panel removal and installation (fenders, doors, hood, trunk), trim pieces, bumpers.

Bodywork Interior

Bodywork Interior:

Dashboard removal, seat removal, carpet replacement, headliner.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs.

Troubleshooting Diagnostics:

Diagnostic flowcharts for common problems, error code interpretation (OBD-I related for this era).

Component Replacement:

Detailed instructions for replacing major and minor components across all systems.

Engine Rebuild:

Comprehensive steps for engine disassembly, parts inspection, machining recommendations, and reassembly.

Transmission Overhaul:

Steps for transmission removal, disassembly, part inspection, and reassembly.

Suspension Repair:

Replacement of worn suspension components, shock absorber and strut replacement.

Brake Overhaul:

Brake caliper rebuilding, master cylinder replacement, brake line bleeding.

Electrical Troubleshooting:

Wiring diagrams, circuit testing, fuse and relay identification, common electrical faults.

Alignment Procedures:

Front and rear wheel alignment specifications and adjustments.

Technical Depth

Depth Level:

Expert Level: Covers everything from basic preventative maintenance to full engine and transmission rebuilds, including diagnostics and specialized system repair (AYC).

Diagrams Illustrations:

Includes step-by-step instructions with exploded views for clear visual guidance.

📊 Manual Specifications

File Format

File Format:

Likely PDF, optimized for searchability and printing.

Print Quality

Print Quality:

Assumed high quality, suitable for professional use.

Binding Type

Binding Type:

N/A (if digital). If printed, likely spiral-bound or perfect-bound for ease of use in a workshop.

Paper Type

Paper Type:

N/A (if digital). If printed, would typically be on durable paper stock.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G63T

Engine Type:

Inline-4, DOHC, 16-valve, turbocharged and intercooled

Displacement Cc:

Bore X Stroke Mm:

85.0 x 88.0

Compression Ratio:

8.8:1

Performance

Horsepower Ps Evo Iv:

Horsepower Ps Evo V:

280 (often conservatively rated, actual output higher)

Torque Nm Evo Iv:

Torque Nm Evo V:

Fuel System

Fuel System Type:

Electronic Fuel Injection (EFI) with sequential ignition

Turbocharger Type:

Mitsubishi TD05HR-16G (or similar variants depending on market)

Fuel Type Required:

Unleaded premium gasoline (95 RON or higher)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual

Transmission Code Std:

F5M33 / F5M33-1

Optional

Transmission Type Opt:

None (All Evo IV/V were manual)

Features

Drivetrain Layout:

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

Ayc System:

Electronically controlled torque vectoring differential

📐 Dimensions

Exterior

Length Mm Evo Iv:

Width Mm Evo Iv:

Height Mm Evo Iv:

Wheelbase Mm Evo Iv:

Length Mm Evo V:

Width Mm Evo V:

Height Mm Evo V:

Wheelbase Mm Evo V:

Weights

Curb Weight Kg Evo Iv:

Curb Weight Kg Evo V:

Wheel Bolt Pattern:

5x114.3

Recommended Tire Size Evo Iv:

205/50R16

Recommended Tire Size Evo V:

225/45R17

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Not widely crash-tested by modern standards due to era and limited market, focus was on performance and handling).

Active Features

Active Safety Features:

AYC (Active Yaw Control) for enhanced stability and cornering, ABS (Anti-lock Braking System).

Passive Features

Passive Safety Features:

Driver and front passenger airbags, reinforced chassis, deformable crumple zones.

💡 Technology Features

Infotainment

Infotainment System:

Basic factory stereo system with cassette player and AM/FM radio. Speakers in doors and rear parcel shelf.

Driver Assistance

Driver Assistance Features:

AYC (Active Yaw Control) is the primary advanced driver assistance technology for performance enhancement.

Connectivity

Connectivity Features:

Limited to basic power outlets for accessories; no advanced connectivity like USB or Bluetooth in the original specification.

🔧 Maintenance

Service Intervals

Oil Change Interval Km:

Every 5,000-7,500 km or 6 months (severe use recommended for performance vehicles).

Spark Plug Replacement Km:

Every 30,000-40,000 km (NGK BKR6EGP or equivalent).

Timing Belt Replacement Km:

Every 80,000-100,000 km (critical component).

Fluid Specifications

Engine Oil Spec:

API SG/SH/SJ, ACEA A2/A3. Viscosity: 10W-30, 10W-40, 15W-40 or 5W-30 (depending on climate). Capacity: Approx. 4.5 liters.

Transmission Oil Spec:

API GL-4. Viscosity: 75W-90. Capacity: Approx. 2.5 liters (manual transmission).

Differential Oil Spec Front:

API GL-5. Viscosity: 75W-90. Capacity: Approx. 1.2 liters.

Differential Oil Spec Rear:

API GL-5. Viscosity: 75W-90. Capacity: Approx. 1.3 liters.

Coolant Spec:

Ethylene glycol based coolant, 50/50 mix with distilled water. Capacity: Approx. 7.0 liters.

Brake Fluid Spec:

DOT 3 or DOT 4.

Known Issues

Known Issues Engine:

Connecting rod failure at high mileage or with aggressive tuning, turbocharger wear, valve stem seal degradation.

Known Issues Ayc:

AYC pump failure, sensor issues, actuator problems. Can be complex to diagnose and repair.

Known Issues Suspension:

Wear in control arm bushings, strut top mounts, and wheel bearings due to performance driving.

Known Issues Rust:

Prone to rust in wheel arches, sills, and underbody, especially in regions with salt used on roads.

📚 Vehicle History

Brand Heritage

Brand Heritage Rally:

Mitsubishi has a strong motorsport heritage, particularly in the World Rally Championship (WRC), with the Lancer Evolution being its flagship rally homologation special.

Model Evolution

Evolution Iv Debut:

Introduced in August 1996, featuring a significantly revised chassis and the introduction of AYC.

Evolution V Debut:

Introduced in January 1998, featuring wider track, revised suspension geometry, larger wheels, more powerful engine, and updated styling.

Production

Production Period Evo Iv:

August 1996 - August 1998

Production Period Evo V:

January 1998 - January 1999

Key Production Variations:

RS (Rally Sport) models with stripped interiors and heavier-duty components, GSR (Grand Sport Racing) models with more creature comforts.

🏆 Awards & Recognition

Recognitions

Awards Vehicle:

Consistently praised by automotive media for its performance, handling, and rally-inspired technology. Recognized as an icon in the performance car segment. Many magazine 'best of' lists and performance benchmarks from its era.

Awards Manual:

Not applicable for manual awards, but its comprehensiveness and accuracy are highly valued by owners and mechanics.