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Mitsubishi Lancer Evo 6 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VI Year: 1999 Codes Chassis Code: CP9A Engine Code: 4G63 👋 Introduction Market Position Segment: Performance Rally Homologation Special / Sport...
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Mitsubishi Lancer Evo 6 1999 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Lancer Evolution VI
Year:
1999
Codes
Chassis Code:
CP9A
Engine Code:
4G63
👋 Introduction
Market Position
Segment:
Performance Rally Homologation Special / Sport Compact
Competitive Analysis
Competitors:
Subaru Impreza WRX STI, Ford Escort RS Cosworth, Toyota Celica GT-Four
Key Features
Performance Focus:
Iconic rally-bred performance, advanced all-wheel-drive system (AYC, ACD), powerful turbocharged engine
Manual Value:
Essential for owners and enthusiasts seeking to maintain, repair, or optimize the performance of this specialized vehicle
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive service, maintenance, and repair
Page Count
Estimated Pages:
Varies by specific edition, typically 500-1000+ pages for comprehensive factory service manuals
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF) or Printed
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, turbocharger system, drivetrain, manual transmission, AWD system
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), wheel alignment
Electrical:
Engine control module (ECM), body control module (BCM), lighting, instruments, audio system, power accessories, wiring diagrams
Body:
Exterior body panels, interior trim, HVAC system, safety systems (airbags)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), component testing
Repair:
Component removal and installation, engine rebuilds, transmission overhaul, bodywork repairs, electrical system repairs
Technical Data:
Torque specifications, clearances, wiring schematics, diagnostic flowcharts
Technical Depth
Depth:
Full factory-level detail, including step-by-step instructions, exploded views, and detailed diagrams for complete overhaul and advanced diagnostics
📊 Manual Specifications
File Format
Digital Format:
PDF (typically high-resolution, searchable text)
Print Quality
Quality:
High-quality reproductions with clear diagrams and text for printed versions
Binding Type
Binding:
Digital (no binding), Printed (coil-bound, spiral-bound, or perfect-bound for durability)
Paper Type
Paper:
For printed manuals: Durable, often glossy or semi-gloss paper to withstand workshop environments
⚙️ Engine Specifications
Primary Engine
Engine Type:
4G63T (DOHC, 16-valve, Inline-4, turbocharged)
Performance
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1 (JDM), 8.8:1 (Export)
Horsepower:
276 hp (206 kW) @ 6500 rpm (JDM - 'Gentleman's Agreement'), 280-300 hp for export variants
Torque:
350 Nm (258 lb-ft) @ 3000 rpm (JDM), 350-370 Nm for export variants
Fuel System
Fuel Type:
Unleaded gasoline (premium unleaded recommended, 95-98 RON/91-93 AKI)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI)
Turbocharger:
Mitsubishi TD05HR-16G 8cm² twin-scroll turbocharger
Engine Management
Ignition System:
Electronic ignition with distributor and coil packs
Engine Control:
ECU (Engine Control Unit) with various sensor inputs (MAP, MAF, TPS, O2, Knock)
🔧 Transmission
Standard
Type:
6-speed manual transmission (Type RS, GSR-RS)
Optional
Type:
5-speed manual transmission (GSR)
Features
AWD System:
Full-time 4WD with Active Yaw Control (AYC) and Active Center Differential (ACD)
Clutch:
Hydraulically operated, single-plate, dry-type clutch
Fluid Specs
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (check manual for exact specification)
Transfer Case Fluid:
API GL-5, SAE 75W-90 (check manual for exact specification)
Rear Differential Fluid:
API GL-5, SAE 75W-90 (check manual for exact specification)
📐 Dimensions
Exterior
Length:
4350 mm (171.3 in)
Width:
1770 mm (69.7 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2600 mm (102.4 in)
Track Width Front:
1515 mm (59.6 in)
Track Width Rear:
1505 mm (59.3 in)
Weights
Curb Weight:
Approximately 1350-1400 kg (2976-3086 lbs), depending on trim
Gross Vehicle Weight Rating:
Not commonly specified for performance models, but would be higher than curb weight
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific crash test data available from independent agencies for this era's homologation specials; rely on manufacturer design and safety features
Active Features
Braking System:
Four-wheel disc brakes with ventilated front and rear rotors, ABS (Anti-lock Braking System)
Traction Control:
Standard on many models, integrated with AWD system
AWD System Safety:
AYC and ACD contribute to vehicle stability and grip in various conditions
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners
Chassis Construction:
Reinforced body structure for rigidity and crash protection
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette and CD player (optional), 4-6 speaker system
Instrumentation:
Digital odometer, tachometer, boost gauge (on some models), comprehensive warning lights
Driver Assistance
Traction Control:
Traction control system often integrated with AWD
Connectivity
Original Connectivity:
Limited by era; basic radio and power accessories. No modern Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (synthetic oil recommended)
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on driving conditions
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type
Timing Belt Replacement:
Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years (critical maintenance item)
Fluid Specifications
Engine Oil:
API SJ, ILSAC GF-2, SAE 10W-30 or 10W-40 (check manual for specific viscosity recommendations based on climate)
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water (Mitsubishi Super Long Life Coolant recommended)
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific type and replacement interval)
Power Steering Fluid:
ATF Dexron II or III (check manual for exact specification)
Known Issues
Engine:
Head gasket failure (especially with aggressive tuning), turbocharger wear, piston ring wear
AWD System:
AYC pump failure, ACD issues (can be expensive to repair)
Electrical:
Corrosion in wiring harnesses, starter motor issues
Cooling System:
Radiator leaks, thermostat issues
📚 Vehicle History
Brand Heritage
Rally Legacy:
Mitsubishi's extensive WRC (World Rally Championship) heritage, with the Lancer Evolution series being a direct result of homologation requirements
Model Evolution
Evolution Series:
The Evo VI represented a significant evolution from the Evo V, featuring revised styling, improved cooling, and enhanced AYC/ACD systems
Evo Vi Variants:
Key variants include GSR, RS, RS Sprint (limited edition), Tommi Mäkinen Edition (TME)
Production
Production Years:
1999-2001
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rally Heritage Awards:
Numerous WRC championship titles and victories for the Lancer Evolution series, establishing its performance pedigree
Ratings
Performance Magazine Ratings:
Consistently rated highly by automotive journalists for its handling, acceleration, and rally-inspired driving experience
Certifications
Homologation:
Built to homologate the Lancer for Group A rally racing, demonstrating its purpose-built performance capabilities
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